🏷️ Basic Information

Make:

Dodge

Model:

Caravan, Grand Caravan, Voyager, RS, RG

Model Years Covered:

2003, 2004, 2005, 2006, 2007

Platform Code:

NS (for Caravan/Grand Caravan), RS/RG (for Voyager/Town & Country)

👋 Introduction

Market Position:

This generation of Dodge Caravan/Grand Caravan and Chrysler Voyager/Town & Country was a highly popular segment of the minivan market, known for its practicality, seating capacity, and family-oriented features. This manual targets DIY mechanics and professional technicians aiming to maintain or repair these vehicles.

Competitive Analysis:

Competed directly with vehicles like the Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, and Chevrolet Venture/Vans. The availability of a comprehensive workshop manual is crucial for owners and independent repair shops servicing these vehicles, which often reach an age where specialized repair information is needed.

Key Features:

Comprehensive coverage from A-Z, high-quality visuals, instant download availability, 100% complete and non-corrupt file, detailed diagnostic and repair procedures mirroring factory information.

📋 Manual Details

Coverage Scope:

Comprehensive workshop service and repair for all major systems and components.

Vehicle Variants Covered:

Dodge Caravan, Dodge Grand Caravan, Dodge Voyager, Chrysler Town & Country (RS/RG).

Estimated Page Count:

Varies by specific model and year, but typically 1500+ pages for a full workshop manual.

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for engine disassembly, inspection, assembly, and overhaul of all internal components (pistons, rings, bearings, crankshaft, camshaft, valves, etc.).

Engine Lubrication System:

Oil pump, oil filter, oil cooler, oil passages, oil pressure testing, maintenance.

Engine Cooling System:

Radiator, water pump, thermostat, coolant passages, hoses, fan, cooling fan clutch, pressure testing, flush and fill procedures.

Engine Control System:

ECU, sensors (crankshaft position, camshaft position, oxygen, MAP, TPS, coolant temp), actuators, ignition system (spark plugs, coils, wires), emission controls, diagnostic trouble codes (DTCs).

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, pressure regulator, EVAP system, fuel quality checks.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, emissions components, diagnosis of exhaust leaks.

Clutch:

Clutch disc, pressure plate, release bearing, slave cylinder, master cylinder, hydraulic system, adjustment procedures (for manual transmission).

Manual Transaxle:

Disassembly, inspection, reassembly of manual gearboxes, gear ratios, shift forks, synchronizers, maintenance, fluid specifications.

Automatic Transaxle:

Detailed overhaul procedures for automatic transmissions, torque converter, valve body, transmission control module (TCM), fluid types, filter replacement, diagnostic procedures, shift solenoid testing.

Front Axle:

CV joints, axleshafts, wheel bearings, hub assemblies, differential (if applicable), maintenance.

Rear Axle:

Axleshafts, wheel bearings, differential (if applicable), maintenance.

Front Suspension:

MacPherson struts, control arms, ball joints, sway bar, bushings, springs, shock absorbers, alignment specifications.

Rear Suspension:

Trailing arms, multi-link suspension (depending on model), springs, shock absorbers, alignment specifications.

Road Wheels And Tyres:

Tire pressure, rotation, balancing, wheel alignment, wheel bolt torque specifications, recommended tire sizes.

Brake System:

Brake pads, rotors, calipers, brake lines, brake fluid, bleeding procedures, master cylinder, power booster, inspection and replacement.

Parking Brake System:

Parking brake cables, mechanism, adjustment, inspection.

Brake Control System:

ABS (Anti-lock Braking System) components (sensors, modulator), ESP (Electronic Stability Program), diagnostic procedures for ABS/ESP faults.

Power Steering System:

Power steering pump, reservoir, hoses, steering rack/gearbox, fluid specifications, bleeding procedures, diagnosis.

Steering System:

Steering column, tie rods, steering knuckle, steering wheel, alignment specifications.

Seat Belts:

Operation, inspection, replacement of seat belt assemblies, pre-tensioners.

Supplemental Restraint System Srs:

Airbag modules (driver, passenger, side), SRS control module, crash sensors, wiring, diagnostic procedures, safety precautions for working with airbags.

Body Lock And Security System:

Door locks, latches, handles, power locks, remote keyless entry, immobilizer system, central locking, anti-theft alarm.

Glasses Window System And Mirrors:

Power windows, manual windows, window regulators, seals, mirrors (power, heated), windshield wiper system.

Roof:

Sunroof, moonroof operation and maintenance, seals, headliner.

Exterior And Interior:

Bumpers, fenders, doors, hood, liftgate, trim panels, interior panels, seating, carpeting, sound deadening.

Instrumental Panel:

Instrument cluster, gauges, warning lights, dashboard trim, climate control panel, radio/audio system.

Seat:

Seat adjustment mechanisms, power seats, seat heaters, seat trim replacement.

Air Conditioner System:

Compressor, condenser, evaporator, expansion valve, receiver/drier, refrigerant, operation, maintenance, leak detection, charging procedures, climate control module.

Wiring Diagrams:

Complete, detailed electrical wiring schematics for all vehicle systems, including component locations and wire colors.

Starting And Charging System:

Battery, alternator, starter motor, ignition switch, charging system diagnostics, testing procedures.

Lighting System:

Headlights, taillights, turn signals, interior lighting, fog lights, bulb replacement, aiming procedures.

Driver Information System:

Trip computer, fuel economy display, warning messages, basic diagnostic information displayed to the driver.

Wiper Washer And Horn:

Wiper motor, blades, linkage, washer pump, reservoir, nozzles, horn operation and replacement.

Body Control System:

BCM (Body Control Module) functions, integration of various body electronic systems (lighting, wipers, locks, windows, etc.).

Lan System:

CAN (Controller Area Network) communication bus, diagnostic access to modules on the network.

Audio Visual Navigation And Telephone System:

Radio, CD player, speakers, optional navigation system, Bluetooth/phone integration components and troubleshooting.

Auto Cruise Control System:

Cruise control module, switches, actuators, sensors, operation and troubleshooting.

Power Supply Ground And Circuit Elements:

Fuse box locations, fuse types and ratings, relay locations, power distribution, ground points, circuit protection.

Maintenance:

Scheduled maintenance tasks, fluid changes (oil, coolant, brake, transmission), filter replacements, inspections, lubrication.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon faults, including symptom-based troubleshooting trees.

Repair Rebuild Refurbish Restore:

Detailed instructions for disassembling, repairing, rebuilding, and reassembling all major vehicle components and systems.

Diagnostic Procedures:

Step-by-step guidance for diagnosing electrical and mechanical issues, including use of diagnostic tools and interpretation of sensor data.

Technical Depth:

Professional-level detail covering everything from basic fluid checks and filter replacements to complete engine and transmission overhauls, complex electrical system diagnostics, and body repair.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual. Includes high-quality photos, illustrations, and diagrams.

Binding Type:

Not applicable (Digital Download)

Paper Type:

Not applicable (Digital Download)

Compatibility:

Compatible with all versions of Windows, Mac, and Linux operating systems, requiring only a PDF reader.

⚙️ Engine Specifications

Engine Options:

3.3L V6 (EGA), 3.8L V6 (L32), 4.0L V6 (N/A - introduced later in some markets, check specific vehicle VIN).

3.3L V6 (Ega):

Approx. 180-185 hp @ 5000-5200 rpm, 200-210 lb-ft torque @ 3400-3600 rpm.

3.8L V6 (L32):

Approx. 200-205 hp @ 5000-5200 rpm, 240-250 lb-ft torque @ 3800-4000 rpm.

Fuel System Type:

Sequential Multi-Port Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline (87 octane recommended).

🔧 Transmission

Standard Transmission:

4-speed automatic transaxle (41TE/AE) on most models.

Optional Transmission:

5-speed manual transaxle (M500) was very rare on these models, primarily found on earlier generations or specific export markets. Automatic transmission is the overwhelming standard.

Transmission Features:

Electronic controls, torque converter lock-up clutch for improved fuel economy, selectable gear ranges (e.g., 1, 2, D, OD).

📐 Dimensions

Wheelbase:

Approximately 119.2 inches (standard wheelbase) or 136.0 inches (long wheelbase for Grand Caravan/Town & Country).

Length:

Varies based on wheelbase: approx. 190-200 inches (standard) or 205-215 inches (long).

Curb Weight:

Typically ranges from 4,000 to 4,500 lbs depending on configuration and engine.

🛡️ Safety Features

NHTSA Ratings:

Varies by model year and specific configuration. Generally achieved good frontal and side impact ratings for its era, but specific NHTSA reports should be consulted for precise details.

Active Safety Features:

Anti-lock Braking System (ABS), Traction Control System (TCS) often standard or available, Electronic Stability Program (ESP) introduced in later years for some trims.

Passive Safety Features:

Multi-stage front airbags, available side-impact airbags, three-point seat belts for all occupants, LATCH child seat anchors, crumple zones.

💡 Technology Features

Infotainment Options:

Various audio systems including AM/FM/CD players, optional Sirius satellite radio, and rear-seat entertainment systems on higher trims. Navigation systems were also optional.

Driver Assistance Features:

Cruise control, available rear parking sensors, and basic trip computer functions. Advanced driver-assistance systems (ADAS) were not prevalent in this era.

Connectivity Features:

Available Bluetooth hands-free calling (Uconnect system in later model years within this range), auxiliary audio inputs on some systems.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 to 7,500 miles (depending on oil type used and driving conditions). Refer to owner's manual or specific manual section for precise intervals.

Transmission Fluid Change:

Recommended every 30,000 to 60,000 miles for automatic transmissions, or as indicated by the manual. Fluid should be ATFDEXRON-III or equivalent.

Engine Oil Specification:

SAE 5W-30 synthetic blend or full synthetic oil is generally recommended for these engines. Check specific engine's oil capacity (approx. 4.5-5 quarts).

Coolant Specification:

Mopar HOAT (Hybrid Organic Acid Technology) coolant or equivalent. Typically a 50/50 mix of antifreeze and distilled water. Capacity around 12-14 quarts.

Brake Fluid Specification:

DOT 3 brake fluid.

Common Issues:

Common issues can include: automatic transmission solenoid failure (leading to shifting problems), rear liftgate actuator failure, power sliding door motor failure, blend door actuator failure in HVAC system, timing belt wear (on some engine variants if equipped, though most were OHC engines with chains or belts requiring replacement at intervals), suspension component wear (ball joints, control arm bushings), and potential oil leaks from valve cover gaskets or oil filter housings.

📚 Vehicle History

Brand Heritage:

Dodge, as part of Chrysler (later DaimlerChrysler), has a long history in the minivan segment, essentially pioneering the modern minivan with the original Dodge Caravan in the early 1980s.

Model Evolution:

This generation (NS platform) represented a significant styling and engineering update from the previous generation. It offered improved aerodynamics, updated powertrains, and enhanced safety features, continuing the legacy of the Caravan and its siblings.

Production Location:

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

🏆 Awards & Recognition

Recognitions:

While specific awards for these model years are not widely publicized as groundbreaking, the Dodge Caravan and Chrysler Town & Country consistently ranked as popular choices in the minivan segment, often praised for their practicality, interior space, and value for money by consumer publications and automotive critics of the time.