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Dodge Caravan 2003-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2003, 2004, 2005, 2006, 2007 Codes Platform Code: RS (Third Generation) 👋 Introduction Market Position Segment: Mid-size minivan Target Audience:...
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Type: Car
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Sku: 495595
Dodge Caravan 2003-2007 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
2003, 2004, 2005, 2006, 2007
Codes
Platform Code:
RS (Third Generation)
👋 Introduction
Market Position
Segment:
Mid-size minivan
Target Audience:
Families, individuals seeking versatile transportation, DIY mechanics
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana
Key Features
Versatility:
Flexible seating arrangements, ample cargo space, available Stow 'n Go seating (later in the generation)
Powertrain Options:
Reliable V6 engines, popular for towing and everyday driving
Value Proposition:
Affordable and practical transportation solution
📋 Manual Details
Coverage Areas
Main Focus:
Service, Maintenance, Repair
Page Count
Estimated Pages:
Approximately 1500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine performance, fuel system, exhaust system, transmission (automatic), driveline
Chassis:
Suspension (front and rear), steering system, brake system (hydraulic and ABS), wheels and tires
Electrical:
Battery, starting system, charging system, ignition system, lighting, instrument cluster, body control modules, HVAC controls, power windows, power locks, power sliding doors, power liftgate
Body And Interior:
Exterior body panels, interior trim, seating, safety restraints (airbags, seatbelts), HVAC system operation and components, doors, windows, liftgate
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt inspection/replacement
Repair:
Engine component replacement (e.g., head gaskets, water pump, starter), transmission service and repair, brake caliper/rotor replacement, suspension component replacement (shocks, struts, ball joints), steering rack replacement, electrical component diagnosis and replacement
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble code (DTC) interpretation and diagnostic procedures, component testing procedures
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhaul, including detailed electrical schematics and diagnostic routines
📊 Manual Specifications
File Format
Searchability:
Searchable text content for quick information retrieval
Print Quality
Quality:
High-resolution diagrams and text for clarity
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1 Type:
3.3L V6 (EGA)
Engine 1 Displacement:
3301 cc
Engine 1 Horsepower:
Approx. 180 hp @ 5000 rpm
Engine 1 Torque:
Approx. 210 lb-ft @ 3300 rpm
Optional Engine
Engine 2 Type:
3.8L V6 (L32)
Engine 2 Displacement:
3778 cc
Engine 2 Horsepower:
Approx. 200 hp @ 5000 rpm
Engine 2 Torque:
Approx. 235 lb-ft @ 3200 rpm
Engine 3 Type:
3.8L V6 Supercharged (L67 variant)
Engine 3 Displacement:
3778 cc
Engine 3 Horsepower:
Approx. 215 hp @ 5000 rpm
Engine 3 Torque:
Approx. 245 lb-ft @ 3600 rpm
Performance
Timing System:
Timing belt (3.3L) / Timing chain (3.8L)
Fuel System
Induction:
Multi-port fuel injection (MPI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (41TE, 42LE)
Optional
Transmission Type Optional:
N/A (All models used automatic transmission)
Features
Overdrive:
Yes
Transmission Fluid Type:
ATF+4 (Chrysler Specification MS-9602)
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.3 inches
Length:
Approx. 189.5 - 201.0 inches (depending on wheelbase)
Width:
Approx. 72.0 inches
Height:
Approx. 68.4 inches
Interior
Seating Capacity:
7 passengers (typically 2-2-3 configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15-20 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 60-70 cu ft
Cargo Volume Max:
Approx. 150-160 cu ft
Weights
Curb Weight:
Approx. 3900 - 4200 lbs
Gross Vehicle Weight Rating Gvwr:
Approx. 5600 - 5700 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (for 2003-2007 models in general, though specific test results may vary slightly by year)
NHTSA Frontal Impact Passenger:
Good (for 2003-2007 models in general)
NHTSA Side Impact Front Seat:
Good (for 2003-2007 models in general)
NHTSA Side Impact Rear Seat:
Good (for 2003-2007 models in general)
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Optional (on some models/trims)
Passive Features
Airbags:
Driver and front passenger airbags (standard), optional side curtain airbags (later years)
Seat Belts:
All seating positions, front seat pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium audio systems, rear seat entertainment (DVD player) available on higher trims
Driver Assistance
Cruise Control:
Standard
Rear Parking Sensors:
Optional
Connectivity
Aux Input:
Rarely standard, often aftermarket installation
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type (refer to manual for specific recommendations)
Engine Coolant Flush:
Every 30,000-50,000 miles or 2-3 years
Transmission Fluid Change:
Every 30,000-60,000 miles (dependent on usage, refer to manual)
Spark Plug Replacement:
100,000 miles for platinum/iridium plugs
Timing Belt Replacement:
Recommended every 70,000-100,000 miles for the 3.3L engine (critical maintenance item)
Fluid Specifications
Engine Oil Type:
API SN or SP, SAE 5W-30 (check owner's manual for precise grade)
Engine Oil Capacity:
Approx. 3.8 - 4.5 quarts (with filter, depending on engine)
Transmission Fluid Type Spec:
ATF+4 (MS-9602)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) / Mopar Antifreeze/Coolant (MS-9769)
Brake Fluid Type:
DOT 3
Known Issues
Common Issues Engine:
Oil leaks from valve cover gaskets or oil pan, occasional coolant leaks from water pump or hoses, timing belt failure on 3.3L if not replaced on schedule (can cause catastrophic engine damage)
Common Issues Transmission:
Slipping in gears, rough shifting, transmission fluid leaks (especially around cooler lines or seals)
Common Issues Suspension Steering:
Worn ball joints, tie rod ends, control arm bushings, premature front strut/shock absorber wear
Common Issues Electrical:
Faulty power window regulators, issues with power sliding doors or liftgate mechanisms, intermittent HVAC blower motor issues, instrument cluster problems (e.g., dead gauges), PCM (Powertrain Control Module) failures
Common Issues Brakes:
Premature wear of brake pads and rotors, caliper seizing
📚 Vehicle History
Brand Heritage
Brand:
Dodge (a division of Chrysler)
Model Evolution
Generation:
Third Generation (RS Body Style)
Redesign Year:
2001 (for the RS platform)
Facelift:
Minor styling updates and feature additions throughout the generation
Production
Production Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years For Gen:
2001-2007
🏆 Awards & Recognition
Recognitions
Type:
Recognized for value and family utility
Examples:
Often listed as a top pick for affordable minivans by consumer guides and automotive publications during its production years.
Ratings
Consumer Satisfaction:
Generally good for its segment, though specific reliability ratings can vary by year and engine.
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