Dodge Grand Caravan 2003 2004 2005 2006 2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Grand Caravan Model Years Covered: 2003, 2004, 2005, 2006, 2007 Generation Generation Code: RS Generation Description: The fourth generation Grand Caravan, representing significant...

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Type: Car

Vendor:

Sku: 427514

Tags: 2003 2004 2005 2006 2007 Car Cars Dodge Grand Caravan

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Grand Caravan

Model Years Covered:

2003, 2004, 2005, 2006, 2007

Generation

Generation Code:

Generation Description:

The fourth generation Grand Caravan, representing significant styling and technological updates from the previous generation.

👋 Introduction

Market Position

Vehicle Segment:

Minivan

Target Audience:

Families, fleet operators, DIY mechanics, professional technicians.

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana SV6.

Key Features

Versatility:

Known for its flexible seating configurations (Stow 'n Go available in later models, but the foundation for this generation). Optimized cargo and passenger capacity.

Powertrain Options:

Offered with robust V6 engine options focused on torque and hauling capacity.

Value Proposition:

Often positioned as a value-oriented choice in the minivan segment, offering substantial utility for the price.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Workshop Service & Repair

Page Count

Page Count:

Over 2000 pages

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery Method:

Instant Download

Compatibility:

Windows, Mac, Linux OS

Accessibility Requirement:

Adobe Reader

Print Quality

Printability:

Yes, all pages printable

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for engine assembly, disassembly, component testing, and overhaul.

Engine Management:

Diagnostic procedures, sensor testing, fuel injection system diagnosis and repair.

Transmission Automatic:

Diagnosis, repair, overhaul, and fluid service for automatic transmissions.

Transmission Manual:

Diagnosis, repair, overhaul, and fluid service for manual transmissions (if applicable).

Drivetrain:

Front-wheel drive systems, axles, CV joints, and differentials.

Suspension:

Front and rear suspension components, steering linkage, wheel alignment specifications.

Brakes:

Hydraulic brake system diagnosis, ABS system, brake pad/rotor replacement, caliper service.

Steering:

Power steering system diagnosis, pump and rack repair, steering column service.

Electrical System:

Complete wiring diagrams, component testing, charging system, starting system, ignition system.

HVAC:

Air conditioning system diagnosis, refrigerant handling, heater core and evaporator service.

Body And Frame:

Body panel repair, door and liftgate mechanisms, interior trim removal and installation.

Safety Systems:

Airbag system diagnosis and replacement, seatbelt mechanisms.

Body Controls:

Power windows, power locks, remote keyless entry system, power sliding doors (if equipped).

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements.

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues.

Repair:

Detailed instructions for component repair and replacement.

Removal Installation:

Comprehensive guides for removing and installing all major and minor components.

Disassembly Assembly:

Detailed breakdowns and reassembly procedures for various systems.

Adjustments:

Procedures for various adjustments, including wheel alignment, brake adjustments, and door alignment.

Specifications:

Torque specifications, fluid capacities, wear limits, and performance data.

Technical Depth

Depth:

Bumper-to-bumper coverage, from basic maintenance to complete engine and transmission overhauls.

Illustrations:

Detailed illustrations, exploded diagrams, drawings, and photographs for clear guidance.

Special Tools:

Reference to and illustration of required special service tools.

📊 Manual Specifications

File Format

File Type:

Digital PDF

Print Quality

Print Resolution:

High-resolution for clear viewing and printing of text and diagrams.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code And Type:

3.3L OHV V6 (EGA)

Displacement Liters:

Displacement Cubic Inches:

Horsepower Peak:

~180-185 hp @ 5000 rpm (varies by year and specific tune)

Torque Peak:

~230-235 lb-ft @ 3200 rpm (varies by year and specific tune)

Performance

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum

Fuel System

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Required Octane:

87 Octane (minimum)

Additional Engines

Optional Engine 38L V6:

3.8L OHV V6 (L32) - Introduced for later models in this generation, offering more power.

38L V6 Hp:

~200-205 hp

38L V6 Torque:

~235-240 lb-ft

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Model:

41TE / 42LE (depending on engine and specific application)

Optional

Optional Transmission Type:

N/A for this generation covered by the manual.

Features

Drive Layout:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Length:

~199.5 inches (depending on configuration)

Width:

~72.0 inches

Height:

~68.0 - 69.0 inches (depending on roof rack options)

Interior

Passenger Capacity:

7-8 Passengers

Cargo

Max Cargo Volume:

~140-160 cubic feet (behind front seats, varies by configuration)

Weights

Curb Weight:

~4,000 - 4,300 lbs (depending on engine and equipment)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4-Star (for most configurations in this generation)

NHTSA Frontal Impact Passenger:

4-Star (for most configurations in this generation)

NHTSA Side Impact Front Seat:

4-Star (for most configurations in this generation)

NHTSA Side Impact Rear Seat:

4-Star (for most configurations in this generation)

IIHS Side Impact Rating:

Good (for models equipped with side airbags)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags Front:

Standard front driver and passenger airbags.

Airbags Side:

Optional side curtain airbags for all three rows.

Seatbelts:

All seating positions equipped with three-point seatbelts. Second and third-row seats feature integrated child seat anchors (LATCH).

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, cassette player, and optional premium sound systems. Rear-seat entertainment systems available on higher trims.

Navigation:

Optional factory-installed GPS navigation system available on select models.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assist:

Available rear park assist sensors on some trims.

Connectivity

Keyless Entry:

Standard remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 miles or 6 months, whichever comes first, using synthetic oil. Consult manual for specific recommendations.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Cabin Air Filter:

Inspect every 15,000 miles, replace as needed or every 20,000 miles.

Transmission Fluid Change:

Recommended at 60,000-100,000 miles depending on driving conditions. Refer to manual for specific type and procedure.

Coolant Flush:

Typically every 60,000 miles or 5 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (API Certified)

Engine Oil Capacity:

~3.5 - 4.0 quarts (3.3L V6), ~4.0 - 4.5 quarts (3.8L V6) - Consult manual for exact capacity.

Automatic Transmission Fluid Type:

ATF+4 (Mopar)

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent (MS-5901)

Coolant:

Mopar HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant (50/50 mix with distilled water)

Known Issues

Transmission Issues:

Some models may experience issues with the transmission solenoid pack or torque converter clutch (TCC) slippage.

Engine Mounts:

Worn engine mounts can lead to excessive vibration and noise.

Power Sliding Doors:

The mechanism for power sliding doors can require lubrication or adjustment, and occasional motor failures.

Rear Wiper Motor:

The rear wiper motor is a common point of failure.

Sway Bar Links:

Wear in the sway bar links and bushings can cause clunking noises over bumps.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge, a division of Chrysler, has a long history of producing practical and robust vehicles, particularly trucks and vans.

Model Evolution

Grand Caravan Introduction:

The Grand Caravan nameplate debuted in 1991 as a longer-wheelbase version of the original Dodge Caravan, establishing the minivan as a popular family vehicle.

Fourth Generation Launch:

The RS generation (2001-2007) brought substantial updates in styling, interior packaging, and available technology, solidifying its position in the market.

Production

Manufacturing Locations:

Primarily manufactured at Chrysler's Windsor Assembly Plant in Windsor, Ontario, Canada.

Production Period:

2003-2007 model years fall within the RS generation of the Grand Caravan.