Dodge Caravan 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2003 👋 Introduction Market Position Segment: Minivan Target Audience: Families, commercial use Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford...

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标签: 2003 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, commercial use

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture

Key Features

Versatility:

Known for its flexible seating arrangements and cargo space.

Practicality:

Designed for everyday family needs and hauling capabilities.

Affordability:

Often positioned as a more budget-friendly option in its class.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Brakes:

Suspension:

Steering:

Electrical System:

Body And Frame:

HVAC:

Interior Trim:

Diagnostics And Troubleshooting:

Maintenance Procedures:

Component Replacement:

Wiring Diagrams:

Page Count

Approximate Pages:

2000+

Manual Type

Type:

Factory Service Manual

Purpose:

Repair and Maintenance

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing, and lubrication systems.

Engine Performance:

Detailed diagnostics for fuel delivery, ignition system, emissions control, cooling system, and starting/charging systems.

Transmission Automatic:

Diagnosis, overhaul, and adjustment procedures for the automatic transmission (e.g., 41TE/42LE).

Transmission Manual:

Diagnosis and repair procedures for any manual transmission options if available.

Brake System:

Disc brake overhaul (front and rear), drum brake maintenance (rear), hydraulic system diagnostics, parking brake adjustments.

Suspension System:

Front and rear suspension component diagnosis and replacement (struts, shocks, ball joints, control arms, bushings), wheel alignment specifications.

Steering System:

Power steering system diagnosis and repair, steering gear/rack and pinion overhaul, steering column components.

Electrical System Power Distribution:

Battery, charging system, starter motor, fuses, relays, and power distribution modules.

Electrical System Lighting:

Headlights, taillights, interior lighting, hazard lights, and related circuits.

Electrical System Instrumentation:

Instrument cluster diagnosis and repair, gauge functionality.

Body Exterior:

Door mechanisms, latches, hinges, glass replacement, exterior trim, bumpers.

Body Interior:

Seat removal and repair, interior trim panel removal, dashboard disassembly, headliner.

HVAC System:

Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser, heater core replacement, blower motor.

Safety Systems:

Airbag system diagnosis and component replacement, seat belt mechanisms.

Procedures Included

Preventive Maintenance:

Scheduled maintenance intervals for oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement, belt inspections.

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting trees.

Component Repair And Rebuild:

Detailed instructions for disassembling, inspecting, repairing, and reassembling major components like engines, transmissions, brakes, and steering racks.

Electrical Diagnostics:

Wiring diagrams, circuit testing procedures, component testing methods, and diagnostic trouble code (DTC) interpretation.

Body Repair:

Panel replacement, dent repair, door and glass repair procedures.

Lubrication And Capacities:

Specific fluid types, capacities, and lubrication points for all vehicle systems.

Technical Depth

Depth:

Comprehensive from basic fluid changes to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Printable:

Print Quality

Quality:

High-resolution scans, clear diagrams and text.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

ECL (2.4L GEMA I4)

Displacement 1:

2.4 Liters

Horsepower 1:

150 hp @ 5600 rpm

Torque 1:

170 lb-ft @ 4000 rpm

Secondary Engine

Engine Code 2:

ESR (3.3L EER V6)

Displacement 2:

3.3 Liters

Horsepower 2:

180 hp @ 5000 rpm

Torque 2:

205 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Emission Control:

California Emissions System (Optional on some models)

🔧 Transmission

Standard

Transmission Type 1:

4-Speed Automatic (41TE/42LE)

Optional

Transmission Type 2:

5-Speed Manual (Rare, if available for specific configurations)

Features

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approximately 10.4 quarts (9.8 liters) for initial fill

📐 Dimensions

Exterior

Wheelbase:

112.1 inches (2847 mm)

Length:

187.4 inches (4760 mm)

Width:

72.4 inches (1839 mm)

Height:

67.2 inches (1707 mm)

Cargo

Cargo Volume Max:

143.7 cubic feet (4069 liters)

Weights

Curb Weight Min:

Approximately 3800 lbs (1724 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 5600 lbs (2540 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★☆ (4/5 Stars)

NHTSA Front Impact Passenger:

★★★★☆ (4/5 Stars)

NHTSA Side Impact Front Driver:

★★★★☆ (4/5 Stars)

NHTSA Side Impact Rear Passenger:

★★★★☆ (4/5 Stars)

Active Features

Standard on all models

Traction Control:

Optional on some models

Passive Features

Airbags Front:

Driver and Passenger Frontal Airbags

Airbags Side:

Optional Side Curtain Airbags (availability varies by trim)

Seatbelts:

Three-point seat belts for all seating positions

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette and/or CD player, optional CD changer.

Display:

Basic digital or analog displays for radio and climate controls.

Driver Assistance

Cruise Control:

Standard on most trims

Rear Parking Sensors:

Optional availability

Connectivity

Auxiliary Input:

Not typically standard, may be aftermarket modification

Bluetooth:

Not available from factory

🔧 Maintenance

Service Intervals

Oil Change Interval Severe:

3,000 miles (4,800 km) or 3 months

Oil Change Interval Normal:

7,500 miles (12,000 km) or 6 months (synthetic oil recommended)

Engine Air Filter Replacement:

15,000-30,000 miles (24,000-48,000 km), or as needed based on inspection

Spark Plug Replacement I4:

100,000 miles (160,000 km) with platinum-tipped plugs

Spark Plug Replacement V6:

100,000 miles (160,000 km) with platinum-tipped plugs

Transmission Fluid Service:

60,000-100,000 miles (96,000-160,000 km) or every 4-5 years

Coolant Flush:

Every 100,000 miles (160,000 km) or 5 years

Fluid Specifications

Engine Oil I4:

SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395)

Engine Oil V6:

SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395)

Coolant:

Ethylene Glycol Antifreeze (Mopar OAT or HOAT)

Brake Fluid:

DOT 3

Known Issues

Common Problem 1:

Transmission issues (shifting problems, solenoid failures, especially in early models).

Common Problem 2:

Power steering pump leaks or failure.

Common Problem 3:

CV axle wear and boot tears.

Common Problem 4:

Heater core leaks leading to interior steam or coolant smell.

Common Problem 5:

Door lock actuator failures.

📚 Vehicle History

Brand Heritage

Brand:

Dodge (Chrysler Corporation/DaimlerChrysler)

Model Evolution

Generation:

Third Generation (RS/RG Platform)

Design Era:

Rounded, aerodynamic styling

Production

Production Start Year:

1996 (for this generation)

Production End Year:

2007 (for this generation)

Manufacturing Location:

Windsor, Ontario, Canada; Saltillo, Mexico

🏆 Awards & Recognition

Recognitions

Kbb Ratings:

Often cited for practicality and value by Kelley Blue Book in its segment during its production years.