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Chrysler Grand Caravan 2003-2007 Factory Service Manual
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Basic Information Identification Make: Chrysler Model: Grand Caravan Generation: Fourth Generation (RS) Model Years Covered: 2003, 2004, 2005, 2006, 2007 Codes Chassis Code: RS Introduction Market Position Positioning: The Chrysler...
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| Basic Information | |
| Identification | |
| Make: | Chrysler |
| Model: | Grand Caravan |
| Generation: | Fourth Generation (RS) |
| Model Years Covered: | 2003, 2004, 2005, 2006, 2007 |
| Codes | |
| Chassis Code: | RS |
| Introduction | |
| Market Position | |
| Positioning: | The Chrysler Grand Caravan served as a cornerstone of the minivan segment, offering practicality, versatility, and comfort for families. |
| Competitive Analysis | |
| Competitors: | Competed directly with other popular minivans such as the Honda Odyssey, Toyota Sienna, Ford Windstar/Freestar, and Chevrolet Venture/Uplander. |
| Key Features | |
| Features Highlight: | Known for its spacious interior, flexible seating arrangements (like Stow 'n Go), and family-oriented features. |
| Manual Value Proposition | |
| Owner Benefit: | Empowers owners to perform maintenance and repairs themselves, saving significant labor costs and ensuring proper vehicle upkeep. |
| Manual Details | |
| Coverage Areas | |
| Manual Content: | General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle |
| Page Count | |
| Estimated Pages: | Hundreds (specific number not provided, but indicative of comprehensive coverage) |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Authenticity | |
| Source: | Genuine Factory Service Manuals, not third-party content. |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Detailed service and repair procedures for all engine variants, including diagnostics, component replacement, and tuning. |
| Transmission: | Comprehensive coverage for both automatic and manual transmissions (if applicable), including diagnosis, repair, and fluid service. |
| Brakes: | Detailed information on ABS, hydraulic systems, disc and drum brake components, service procedures, and bleeding. |
| Electrical: | Extensive coverage of the entire electrical system, including starter, charging system, lighting, power accessories, and advanced diagnostics with full wiring diagrams. |
| Suspension: | Covers front and rear suspension components, alignment, shock absorbers, struts, and associated systems. |
| Steering: | Detailed procedures for power steering systems, steering columns, and linkage components. |
| Cooling System: | Service and repair of radiators, water pumps, thermostats, cooling fans, and coolant specifications. |
| Fuel System: | In-depth coverage of fuel pumps, injectors, fuel filters, evaporative emission control (EVAP) systems, and fuel pressure testing. |
| HVAC: | Repair and maintenance of the heating, ventilation, and air conditioning systems, including refrigerant handling and component replacement. |
| Body Chassis: | Information on body panels, structural components, doors, liftgates, and associated hardware. |
| Restraint System: | Details on airbags, seatbelts, and associated safety systems. |
| Chassis Body Work: | Covers repairs and adjustments for exterior body panels, doors, latches, hinges, glass, and interior trim components. |
| Differential Drive Axle: | Details on front-wheel drive components, including CV axles, differential assembly, and related bearings and seals. |
| Procedures Included | |
| Maintenance: | Routine maintenance tasks, fluid changes, filter replacements, and scheduled servicing. |
| Troubleshooting: | Advanced diagnostic procedures, symptom-based troubleshooting guides, and fault code interpretation. |
| Repair: | Step-by-step repair instructions for virtually all components and systems, including engine rebuilds, transmission overhauls, and bodywork. |
| Diagnostics: | Detailed diagnostic routines and procedures for all electronic control modules (ECMs), sensors, and actuators. |
| Lubrication: | Specifics on periodic lubrication points, types of lubricants, and intervals as per factory recommendations. |
| Technical Depth | |
| Depth: | Comprehensive, covering basic to advanced repair, overhaul, and diagnostic procedures, mirroring factory technician knowledge. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Print Quality | |
| Printability: | Fully printable, allowing users to print specific pages or the entire manual without restriction. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Requirements | |
| Software: | Adobe PDF Reader |
| Delivery | |
| Method: | Instant download link provided upon completion of payment. |
| File Integrity | |
| Text Searchability: | The PDF format allows for text searching, enabling users to quickly locate specific information, procedures, or keywords. |
| Digital Features | |
| Navigation: | Numbered table of contents for easy navigation within the digital document. |
| Engine Specifications | |
| Primary Engine | |
| Engine Options: | Primarily offered with V6 engines. Likely includes the 3.3L (EGA) and 3.8L (L27/GPM) OHV V6 engines. A 2.4L (EDZ) DOHC I4 may have been available in some base models or markets, but less common for the Grand Caravan. |
| Performance | |
| Horsepower Torque Typical: | 3.3L V6: Approx. 180-185 hp, 210-220 lb-ft torque. 3.8L V6: Approx. 200-215 hp, 240-250 lb-ft torque. (Specifics vary by year and tuning). |
| Fuel System | |
| Injection Type: | Sequential Multi-Port Fuel Injection (MPI) |
| Engine Management | |
| ECM Type: | Chrysler's proprietary Powertrain Control Module (PCM) system, often referred to by its diagnostic trouble codes (DTCs). |
| Diagnosis Tools: | The manual will guide users on utilizing diagnostic scan tools to retrieve fault codes and monitor live data from the PCM. |
| Emissions | |
| Emission Standards: | Meets relevant EPA emission standards for the model years covered. May include OBD-II (On-Board Diagnostics II) compliance. |
| Transmission | |
| Standard | |
| Transmission Type: | Primarily automatic transmissions. Likely the 4-speed 41TE/42LE family (e.g., 42LE). |
| Optional | |
| Optional Transmissions: | While not typical for this generation, some earlier or specific market variants might have offered other options. The focus here is on the automatic. |
| Features | |
| Transmission Features: | Features like Electronic Range Select (ERS) or AutoStick (manual shifting mode) may be present depending on trim level and year. |
| Fluid Specifications | |
| Transmission Fluid Type: | Typically Chrysler ATF+4 (Mopar Part Number 05013457AA or equivalent). |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approximately 121.1 inches (long wheelbase configuration typical for Grand Caravan). |
| Length: | Approximately 200.5 inches. |
| Width: | Approximately 72.2 inches (excluding mirrors). |
| Height: | Approximately 68.9 inches. |
| Interior | |
| Passenger Capacity: | Typically seats 7 passengers (2-2-3 configuration). |
| Cargo | |
| Cargo Volume Max: | Significant cargo space, often exceeding 140 cubic feet with rear seats removed/folded. |
| Weights | |
| Curb Weight Typical: | Around 4,000 - 4,500 lbs, depending on engine and configuration. |
| Safety Features | |
| Ratings | |
| NHTSA Ratings Typical: | Generally received good ratings in NHTSA crash tests for its era, often 4 or 5 stars in frontal and side impacts, but can vary by year and specific test. |
| Active Features | |
| Active Safety: | Anti-lock Braking System (ABS), Traction Control System (TCS) often available, especially on higher trims or later years. |
| Passive Features | |
| Passive Safety: | Driver and front passenger airbags, side curtain airbags may be optional or standard depending on year and trim. Seatbelt pretensioners. |
| Technology Features | |
| Infotainment | |
| Infotainment Systems: | Available with CD players, cassette decks (early models), AM/FM radios, and optional premium audio systems. Later models or higher trims might have offered DVD entertainment systems and basic navigation. |
| Driver Assistance | |
| Driver Assistance Features: | Available features could include rear parking assist sensors, cruise control. Advanced driver-assistance systems (ADAS) as known today were not common in this period. |
| Connectivity | |
| Connectivity Options: | Early models may have lacked modern connectivity. Later models might have had AUX input jacks or, rarely, early forms of Bluetooth integration (e.g., Uconnect hands-free, depending on exact year and options). |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically every 3,000 miles (severe service) or 6,000-7,500 miles (normal service) depending on oil type and driving conditions. Refer to manual for precise intervals and oil specifications. |
| Transmission Fluid Interval: | Recommended every 30,000-60,000 miles, or as per severe service conditions, with fluid and filter change. |
| Fluid Specifications | |
| Engine Oil Specification: | Typically SAE 5W-30 synthetic or synthetic blend oil, meeting Chrysler MS-6395 specification. (Verify with manual for exact engine). |
| Coolant Specification: | Mopar Antifreeze/Coolant (AF) or equivalent HOAT (Hybrid Organic Additive Technology) coolant, typically a 50/50 mix with distilled water. |
| Known Issues | |
| Common Wear Items: | Front suspension components (ball joints, control arm bushings), water pumps, power steering pumps, and transmission issues (e.g., solenoid packs, torque converter shudder) are common on higher-mileage vehicles of this era. EGR valve issues can also occur. |
| Tune Up Components | |
| Spark Plugs Type: | Often platinum or iridium tipped spark plugs. For 3.3L and 3.8L V6, expect approximately 6 spark plugs. Specific part numbers and torque specs are in the manual. |
| Vehicle History | |
| Brand Heritage | |
| Chrysler Minivan Legacy: | Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in the mid-1980s. The Grand Caravan is an evolution of this successful platform. |
| Model Evolution | |
| Fourth Gen Highlights: | The RS generation introduced significant updates over its predecessor, focusing on improved aerodynamics, interior refinement, and the introduction of the revolutionary Stow 'n Go seating system (introduced for 2005 model year). |
| Production | |
| Manufacturing Locations: | Primarily manufactured in Windsor, Ontario, Canada. |
| Awards & Recognition | |
| Recognitions | |
| Automotive Journalism Awards: | While specific awards for the 2003-2007 Grand Caravan are not prominently highlighted in general, the model lineage has consistently been recognized for its practicality and value in the minivan segment by various automotive publications over the years. |