Chrysler Caravan 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Year: 2003 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Market Segment: Minivan Positioning: Family-oriented, practical, versatile people mover Competitive...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Caravan

Year:

Product Type:

Factory Service Repair Manual

👋 Introduction

Market Position

Market Segment:

Minivan

Positioning:

Family-oriented, practical, versatile people mover

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Venture

Key Features

Selling Points:

Spacious interior, flexible seating, V6 engine option, available AWD (depending on trim/market)

Manual Value Proposition

Utility:

Essential for DIY maintenance, repairs, and understanding vehicle systems

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair and adjustment procedures

Target Audience:

Mechanics and DIY persons

Page Count

Page Count:

Estimated 2000+ pages (typical for a complete FSM)

Manual Type

Manual Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Printed Book (typically)

📖 Manual Coverage

Systems Covered

Engine:

All major engine components, diagnostics, repair, removal/installation

Transmission:

Automatic transmission (e.g., 41TE/42LE), diagnostics, repair, removal/installation

Drivetrain:

Front-wheel drive, axles, CV joints, differential

Suspension:

Front and rear suspension, steering linkage, components

Brakes:

Disc brakes (front and rear), ABS, parking brake system

Electrical System:

Battery, charging system, starting system, ignition system, lighting, accessories, wiring diagrams

Body And Frame:

Body panel removal/installation, interior trim, exterior trim, chassis

HVAC:

Heating, ventilation, air conditioning system diagnosis and repair

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines

Cooling System:

Radiator, water pump, thermostat, hoses, fan

Exhaust System:

Muffler, catalytic converter, pipes

Safety Systems:

Airbags, seat belts, restraint systems

Procedures Included

Maintenance:

Oil changes, fluid checks, filter replacements, tune-ups

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting charts

Repair:

Detailed step-by-step repair instructions for all major components

Disassembly Assembly:

Complete instructions for dismantling and reassembling vehicle components

Installation:

Guidance for installing new or replacement parts

Checks Inspections:

Pre-purchase inspections, routine checks

Technical Depth

Depth:

Comprehensive, from basic checks to major component overhaul

Diagnostics:

Includes diagnostic trouble codes (DTCs) and diagnostic flowcharts

Specifications:

Torque specifications, clearances, fluid capacities, and electrical parameters

📊 Manual Specifications

File Format

File Format:

Typically PDF for digital versions, printed for physical

Print Quality

Print Quality:

High-resolution text and diagrams (for printed/high-quality digital)

Binding Type

Binding Type:

Perfect bound or spiral bound (for printed)

Paper Type

Paper Type:

Durable, coated paper for workshop use (for printed)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EGA (3.3L V6)

Engine Displacement:

3.3 Liters (201.7 cu. in.)

Engine Configuration:

3.3L V6 SOHC

Horsepower:

180 hp @ 5000 rpm (approx.)

Torque:

205 lb-ft @ 3200 rpm (approx.)

Fuel System

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Unleaded Gasoline

Engine Components

Engine Block Material:

Aluminum Alloy

Cylinder Head Material:

Aluminum Alloy

Timing Mechanism:

Timing Belt (3.3L V6)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transaxle

Transmission Code:

41TE (Commonly)

Optional

Optional Transmission:

None typically offered for 2003 models

Features

Drive System:

Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) available on some trims/markets

Fluid Specifications

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602)

📐 Dimensions

Exterior

Length:

Approx. 189.4 inches

Width:

Approx. 72.1 inches

Height:

Approx. 67.5 inches

Interior

Passenger Capacity:

7 Passengers (typically with 2-2-3 or 2-3-3 seating)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 20.6 cu. ft.

Cargo Volume Behind 2Nd Row:

Approx. 75.1 cu. ft.

Cargo Volume Max:

Approx. 147.1 cu. ft. (with seats removed)

Weights

Curb Weight:

Approx. 4,000 - 4,500 lbs (depending on configuration)

Gross Vehicle Weight Rating:

Approx. 5,700 - 5,900 lbs

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

4 Stars (2003 model year typical)

NHTSA Passenger Front Impact:

4 Stars (2003 model year typical)

IIHS Side Impact:

Acceptable (depending on specific configuration and testing year)

Active Features

Anti-lock Braking System (Standard on most trims)

Traction Control:

Available on some models/trims

Passive Features

Airbags:

Driver and front passenger airbags; available side airbags

Seat Belts:

3-point seat belts for all occupants, LATCH child seat anchors

💡 Technology Features

Infotainment

Audio Options:

AM/FM stereo, CD player, cassette player (optional), premium audio systems available

Rear Seat Entertainment:

Available rear seat video system (RSVS) on some trims

Driver Assistance

Cruise Control:

Standard on most trims

Parking Assist:

Rear park assist sensors available on some models

Connectivity

Power Outlets:

12V auxiliary power outlets

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions)

Transmission Fluid Change:

Typically every 30,000-60,000 miles (refer to manual for specific recommendation)

Engine Air Filter:

Inspect every 15,000 miles, replace as needed

Cabin Air Filter:

Replace every 15,000-30,000 miles (if equipped)

Spark Plugs:

Platinum plugs typically last 100,000 miles (refer to manual for specific type and interval)

Timing Belt Replacement:

Crucial interval, often around 90,000-105,000 miles for the 3.3L V6. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified, meets MS-6395)

Engine Oil Capacity:

Approx. 4.5 quarts (with filter)

Coolant Type:

HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Mopar OAT (MS-9769) or equivalent

Power Steering Fluid:

Chrysler Power Steering Fluid (MS-5901)

Brake Fluid Type:

DOT 3

Known Issues

Common Problems:

Transmission issues (slipping, harsh shifting), heater core leaks, power window motor failures, starter failures, exhaust manifold cracks, PCM failures

Timing Belt Risk:

Critical to adhere to timing belt replacement intervals to avoid severe engine damage.

📚 Vehicle History

Brand Heritage

Brand Focus:

Chrysler's long history of innovation in the minivan segment

Model Evolution

Generation:

Third Generation (RS) - Launched in 1996, facelifted in 2001

Facelift Impact:

The 2003 model year falls under the refreshed RS generation, featuring updated styling and features compared to earlier models.

Production

Production Location:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Production Years

Model Run:

1996-2007 (for the RS platform)

🏆 Awards & Recognition

Recognitions

Previous Awards Association:

Caravan has a history of being a segment leader and has received numerous accolades over its production run, often cited for practicality and value.

Ratings

Consumer Ratings General:

Generally favorable for its segment during its production years, particularly for its utility and family-friendly features.