🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation:

RG

Years Covered:

2003, 2004, 2005, 2006, 2007

Platform Code:

NS (primarily, with updates)

👋 Introduction

Segment:

Minivan

Target Audience:

DIY mechanics, professional technicians, fleet owners, Dodge Caravan owners seeking to understand and maintain their vehicle

Key Competitors Era:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Buick Terraza (later)

Vehicle Appeal:

Spacious interior, versatile seating (Stow 'n Go on later models), comfortable ride, practical for families and cargo transport

Benefit:

Empowers owners and technicians with detailed, accurate procedures to perform maintenance, diagnostics, and repairs, saving time and money while ensuring vehicle longevity and safety.

📋 Manual Details

Engine:

3.3L V6, 3.8L V6

Transmission:

4-speed Automatic (41TE/42LE)

Drivetrain:

Front-Wheel Drive (FWD)

Chassis Systems:

Suspension (front & rear), Steering, Brakes (front disc, rear drum/disc), Wheels & Tires

Electrical Systems:

Power distribution, Lighting, Ignition, Starting, Charging, Instrumentation, HVAC Controls, Power Accessories (windows, locks, mirrors), Audio System, Wiper/Washer System, SRS (Airbag) System

Body And Interior:

Body panels, Doors, Windows, Seats, Trim, HVAC components, Safety restraints

Maintenance:

Scheduled maintenance, Fluid changes, Filter replacements, Tune-ups

Diagnostics And Troubleshooting:

Component testing, Symptom-based diagnostics, Diagnostic Trouble Codes (DTCs)

Estimated Pages:

1500+

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Powertrain:

Engine mechanical (3.3L EGD, 3.8L EGH), Fuel & Emissions, Cooling, Lubrication, Ignition, Exhaust, Transmission (41TE/42LE) operation and overhaul

Chassis:

Front & Rear Suspension, Steering System (Power Steering), Brake System (ABS included), Wheel Alignment specifications

Electrical:

Wiring diagrams, Lighting systems, Horn, Wiper/Washer, Power windows/locks/mirrors, Climate control, Instrument cluster, Audio, Remote Keyless Entry (RKE), Trailer Towing Wiring

Body:

Exterior body panels, Doors, Hood, Liftgate, Bumpers, Glass replacement, Interior trim, Seats, Stow 'n Go system details (where applicable)

Safety Systems:

Supplemental Restraint System (SRS) - Airbag system component identification, testing, and replacement procedures

Routine Maintenance:

Oil change, Filter replacements (oil, air, cabin), Spark plug replacement, Fluid level checks and top-offs, Belt inspection and replacement

Component Repair:

Engine repair (head gasket, valve seals, timing belt/chain on earlier models if applicable, piston rings), Transmission overhaul, Brake caliper/rotor/pad replacement, Suspension component replacement (shocks, struts, ball joints, tie rods), Steering rack replacement, Alternator/starter replacement, Radiator/water pump replacement

Diagnostics:

Troubleshooting common drivability issues, electrical faults, HVAC problems, using diagnostic scan tools, interpreting DTCs

Wiring Diagrams:

Detailed, color-coded wiring diagrams for all major electrical systems, allowing for precise troubleshooting of circuits

Specifications And Tolerances:

Torque specifications for all fasteners, valve clearances, bore and stroke dimensions, etc.

Depth:

Comprehensive from basic fluid checks to full engine and transmission rebuilds, including electrical system diagnostics and body panel repair

📊 Manual Specifications

Format:

PDF

Searchability:

Fully searchable text content for quick access to information

Quality:

High resolution, suitable for printing individual sections or the entire manual

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code 1:

EGD

Engine Description 1:

3.3L (3301cc) OHV V6, 12-valve

Horsepower 1:

180 hp @ 4800 rpm (approx.)

Torque 1:

200 lb-ft @ 3200 rpm (approx.)

Engine Code 2:

EGH

Engine Description 2:

3.8L (3778cc) OHV V6, 12-valve

Horsepower 2:

200 hp @ 4800 rpm (approx.)

Torque 2:

235 lb-ft @ 3200 rpm (approx.)

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

ECU Type:

Chrysler SBEC/JTEC based systems (specific variants apply)

🔧 Transmission

Type:

4-speed Automatic Transaxle

Model Code 1:

41TE

Model Code 2:

42LE (for some 3.8L applications)

Overdrive:

Yes, 4th gear is overdrive

Torque Converter Lockup:

Electronically controlled lockup clutch

Transmission Fluid:

ATF+4 (Mopar)

Capacity Approx:

8.0 US quarts (7.6 Liters) for a dry fill; 4-5 US quarts for a fluid change

📐 Dimensions

Wheelbase:

119.3 inches (3030 mm)

Length:

195.5 inches (4966 mm)

Width:

72.0 inches (1829 mm)

Height:

67.9 inches (1725 mm)

Cargo Volume Behind 3Rd Row:

Approx. 15.6 cubic feet (442 Liters)

Cargo Volume Behind 2Nd Row:

Approx. 79.2 cubic feet (2242 Liters)

Cargo Volume Max:

Approx. 145.2 cubic feet (4111 Liters)

Curb Weight Approx:

4,000 - 4,200 lbs (1814 - 1905 kg)

Gross Vehicle Weight Rating Gvwr:

5,700 lbs (2585 kg)

🛡️ Safety Features

NHTSA Front Impact Driver:

4/5 Stars (2003 model)

NHTSA Front Impact Passenger:

4/5 Stars (2003 model)

NHTSA Side Impact Front Seat:

5/5 Stars (2003 model)

NHTSA Side Impact Rear Seat:

4/5 Stars (2003 model)

IIHS Front Offset Driver:

Acceptable (2003 model)

ABS:

Standard (Anti-lock Braking System)

Traction Control:

Optional (TCS)

Airbags Front:

Standard front driver and passenger airbags

Airbags Side:

Optional front side-impact airbags

Seat Belts:

Three-point seat belts with pretensioners for front occupants, LATCH child seat anchors

💡 Technology Features

Audio Options:

Base AM/FM stereo with CD player, optional premium Infinity sound system, optional rear-seat entertainment (DVD player).

Navigation:

Optional factory navigation system available on higher trim levels.

Parking Assist:

Optional rear parking assist sensors on select models.

Remote Keyless Entry:

Standard or optional on most trims.

Power Features:

Power windows, power door locks, power mirrors standard or optional depending on trim.

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic or synthetic blend oil)

Air Filter Replacement Interval:

Every 30,000 miles (48,000 km) or as needed based on inspection

Spark Plug Replacement Interval:

3.3L V6: 100,000 miles (160,000 km) with platinum-tipped plugs. 3.8L V6: Similar interval. Consult manual for exact type.

Transmission Fluid Change Interval:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on driving conditions. 'Severe' service recommends more frequent changes.

Engine Oil:

SAE 5W-30 (preferred for most conditions); SAE 10W-30 can be used in warmer climates. Consult owner's manual for specific API service classification (e.g., API SN or equivalent).

Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, or equivalent HOAT coolant meeting Chrysler MS-9769 specifications. Color is typically orange.

Brake Fluid:

DOT 3

Transmission Slipping:

Common issue with the 41TE/42LE transmission, often related to solenoid packs, fluid leaks, or internal wear. Regular fluid changes and filter service are critical.

Front Suspension Wear:

Ball joints, tie rod ends, and struts can wear prematurely due to the vehicle's weight and typical use, leading to clunking noises and alignment issues.

Power Sliding Doors:

Can develop issues with motors, tracks, or wiring, leading to slow operation or failure to open/close.

Heater Core Leaks:

Can leak coolant into the cabin, often indicated by a sweet smell or fogged windows.

Oil Filter Housing Leaks:

The plastic oil filter housing can degrade over time and leak oil.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan/Voyager in 1983, establishing a dominant market presence for decades.

Generation Period:

The 2001-2007 models represent the fourth generation of the Dodge Caravan, featuring significant styling and packaging updates.

Key Updates 2003-2007:

Introduction of the Stow 'n Go seating system in 2005 significantly enhanced interior versatility; powertrain refinements and styling tweaks throughout the generation.

Assembly Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA (depending on specific year/configuration)

Production Start Year Generation:

2001

Production End Year Generation:

2007

🏆 Awards & Recognition

Previous Generation Awards:

While specific awards for the 2003-2007 generation are less documented, earlier Caravans were consistently top sellers and received recognition for practicality and value.

Consumer Reports Reliability:

Reliability ratings varied by year and specific components; the manual provides the knowledge to address common issues proactively.