Dodge Caravan 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2003 Type: Minivan Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Full-size Minivan Description: The Dodge Caravan was a...

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Type: Car

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Sku: 319561

Tags: 2003 Car Caravan Cars Chrysler Dodge

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Type:

Minivan

Codes

Platform:

NS (Third Generation)

👋 Introduction

Market Position

Segment:

Full-size Minivan

Description:

The Dodge Caravan was a highly popular and practical family vehicle, known for its spacious interior, flexible seating, and versatile cargo capacity. It was a segment leader for many years.

Competitive Analysis

Key Competitors:

Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana.

Key Features

Features:

Multiple seating configurations (Stow 'n Go was introduced in later generations, but flexibility was a hallmark), optional all-wheel drive, a range of V6 engines, and user-friendly sliding doors.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Compatibility:

Windows and MAC

Distribution Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Systems:

All engine systems, including fuel, ignition, cooling, lubrication, starting, charging, and emissions control.

Transmission:

Manual and automatic transmission systems, including service, repair, and overhaul procedures.

Driveline And Differential:

Front-wheel drive axle shafts, CV joints, differential, and related components.

Suspension And Steering:

Front and rear suspension components (struts, springs, control arms, shocks), steering system (rack and pinion, power steering).

Brakes:

Hydraulic brake system, including disc and drum components, ABS, parking brake, and fluid specifications.

Body And Frame:

Body panels, doors, windows, interior trim, bumpers, and structural frame components.

Heating And Air Conditioning:

HVAC system components, refrigerant handling, diagnostics, and repair.

Electrical Systems:

Wiring diagrams, lighting, power distribution, instrument cluster, audio systems, horns, chimes, and security systems.

Restraints Systems:

Airbag system, seat belts, and related components.

Emissions Control:

Emissions control systems, including catalytic converters, O2 sensors, EGR, and evaporative emissions.

Procedures Included

Maintenance Schedules:

Recommended maintenance schedules for fluids, filters, belts, and spark plugs.

Troubleshooting Guides:

Diagnostic procedures and troubleshooting flowcharts for various systems.

Repair Procedures:

Step-by-step repair instructions for all major vehicle components and systems.

Component Removal And Installation:

Detailed procedures for removing and installing engines, transmissions, suspension parts, body panels, etc.

Diagnostics And Testing:

Procedures for testing electrical circuits, sensors, actuators, and mechanical components.

Specifications And Tolerances:

Torque specifications, clearances, and other critical technical data.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

Technical Depth

Level Of Detail:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls.

Target Audience:

Professional technicians and knowledgeable DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within the PDF document.

Print Quality

Printability:

Yes, designed to be printed.

Resolution:

High resolution, suitable for clear viewing and printing.

Binding Type

Binding Format:

Digital (PDF Download)

Paper Type

Paper Quality:

N/A (Digital File)

Requirements

Software Requirements:

Adobe PDF Reader or compatible.

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.4L DOHC I4 (GEMA engine family)

Engine 1 Displacement:

2429 cc

Engine 1 Power:

Approx. 150 hp @ 5800 rpm

Engine 1 Torque:

Approx. 167 lb-ft @ 4400 rpm

Optional Engine

Engine 2:

3.3L OHV V6 (EGA engine family)

Engine 2 Displacement:

3301 cc

Engine 2 Power:

Approx. 180 hp @ 5000 rpm

Engine 2 Torque:

Approx. 205 lb-ft @ 3500 rpm

Engine 3:

3.8L OHV V6 (EGH engine family)

Engine 3 Displacement:

3778 cc

Engine 3 Power:

Approx. 205 hp @ 5000 rpm

Engine 3 Torque:

Approx. 230 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Turbo Diesel

Diesel Engine Option:

Yes, a 2.5L Turbo Diesel was an option, though less common in North America.

Diesel Engine Coverage:

Manual explicitly covers the 2.5L Turbo Diesel engine and its associated systems.

🔧 Transmission

Standard

Transmission Option 1:

4-speed Automatic (41TE/42LE)

Optional

Transmission Option 2:

5-speed Manual (Limited availability, typically on base models or specific markets)

Features

Transmission Features:

Electronically controlled, adaptive shift logic for automatic transmissions. Torque converter lock-up.

Fluid Specifications

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602) or equivalent.

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approximately 4.5-5.0 quarts (4.3-4.7 liters) for fluid change, 8.5-9.0 quarts (8.0-8.5 liters) for overhaul.

📐 Dimensions

Exterior

Wheelbase:

Approx. 112.1 inches (2847 mm)

Length:

Approx. 179.4 inches (4557 mm) for standard wheelbase, 190.7 inches (4844 mm) for long wheelbase.

Interior

Passenger Capacity:

5 to 7 passengers, depending on configuration.

Cargo

Cargo Volume:

Significantly large cargo volume, adjustable with seat configurations. Up to approx. 140-150 cu ft behind front seats in long-wheelbase models.

Weights

Curb Weight:

Ranges from approx. 3,600 lbs to 4,200 lbs (1633 kg to 1905 kg) depending on engine and configuration.

Gross Vehicle Weight Rating:

Typically in the range of 5,300 lbs to 5,800 lbs (2404 kg to 2631 kg).

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Generally performed well for its class, though specific ratings may vary by test date and methodology.

IIHS Offset Crash Test:

Performed adequately but highlighted typical minivan safety challenges of the era.

Active Features

Active Safety:

Optional Anti-lock Braking System (ABS), Traction Control System (TCS) available on some models.

Passive Features

Passive Safety:

Driver and front passenger airbags, side-impact airbags (optional on some trims), three-point seat belts for all occupants, child seat anchors (LATCH).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette and/or CD player. Optional premium sound systems with more speakers and amplifiers were available.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Connectivity

Power Features:

Power windows, power door locks, and power mirrors were widely available, often standard on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-7,500 miles (5,000-12,000 km) or 3-6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Transmission Fluid Change:

Recommended every 30,000-60,000 miles (48,000-96,000 km), or more frequently under severe service conditions.

Spark Plug Replacement:

Depending on plug type: platinum-tipped plugs (common for V6) up to 100,000 miles; standard plugs typically 30,000 miles.

Fluid Specifications

Engine Oil Specification:

SAE 5W-30 or 10W-30 (depending on ambient temperature) meeting Chrysler MS-6395 specification.

Coolant Specification:

Chrysler Long Life Antifreeze/Coolant (HOAT) or equivalent meeting MS-9769, typically a 50/50 mix with distilled water.

Brake Fluid Specification:

DOT 3 brake fluid.

Known Issues

Common Wear Items:

Wheel bearings, ball joints, tie rod ends, and CV joints are common wear items, especially in higher-mileage vehicles. Heater core leaks can also occur.

Transmission Issues:

Some transmissions, particularly the 4-speed automatics, could experience issues with solenoid packs, valve bodies, or torque converter clutches if not properly maintained.

Engine Issues:

The 2.4L engine can be prone to head gasket issues if overheated. The 3.3L and 3.8L V6 engines are generally robust but can develop intake manifold gasket leaks or oil filter housing leaks.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge, alongside Chrysler, is credited with inventing the modern minivan segment with the original Caravan/Voyager in the early 1980s. The 2003 model is part of the highly successful third generation.

Model Evolution

Generation:

Third Generation (NS) - 1996-2000, with a facelift for 2001-2007. The 2003 model falls within this facelifted period.

Facelift Updates:

Updated exterior styling (grille, headlights, taillights), revised interior, and powertrain enhancements for the 2001 model year which carried through 2003.

Production

Manufacturing Locations:

Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Recognitions

Segment Leadership:

The Dodge Caravan (and its Chrysler sibling) was consistently a top seller and often recognized for its practicality and value within the minivan segment throughout its production run.