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Chrysler

Chrysler Caravan 2003-2007 Workshop Service Repair Manual

Chrysler Caravan 2003-2007 Workshop Service Repair Manual

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$16.99
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Vehicle data plateRef 74148
Brand
Chrysler
Vehicle
Marine
Models covered
Caravan, Misc, Outboard Engines
Years
2003, 2004, 2005, 2006, 2007
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Generation:
Fourth Generation (RS)
Production Years:
2003-2007
Vehicle Type:
Minivan
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, fleet operators, and DIY vehicle owners seeking comprehensive repair and maintenance guidance.
Competitive Analysis
Competitors:
Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Vans.
Key Features
Vehicle Highlights:
Spacious interior, flexible seating, practical cargo hauling, multiple engine options, comfortable ride.
Manual Value Proposition
Benefits For Owner:
Enables DIY repairs, reduces reliance on dealerships, aids in understanding vehicle systems, helps maintain resale value.
📋 Manual Details
Coverage Areas
Covered Years:
2003, 2004, 2005, 2006, 2007
Trim Levels:
All (SE, SXT, etc.)
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as 'complete')
Manual Type
Type:
Workshop Service Repair Manual (Full Factory)
Completeness:
Complete Official Factory Service Repair Manual.
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed diagnostics, repair, overhaul, timing, lubrication, cooling, fuel, emission controls for all specified engines.
Engine Electrical:
Ignition system, starter system, charging system, sensors, actuators, ECU, wiring diagrams.
Transmission:
Automatic transmission (e.g., 40TE/41TE) repair, overhaul, diagnostics, fluid specifications, torque converter.
Drivetrain:
Front-wheel drive axles, CV joints, differential, drive shafts.
Suspension:
Front and rear suspension components, struts, shock absorbers, control arms, ball joints, wheel bearings, alignment specifications.
Steering:
Power steering system, steering gear, tie rods, steering column, alignment specifications.
Brakes:
Front and rear brake systems (disc/drum), ABS, parking brake, hydraulic components, bleeding procedures, specifications.
Body And Chassis:
Body construction, doors, windows, interior trim, exterior trim, bumpers, frame components, corrosion protection.
HVAC:
Heating, ventilation, air conditioning system, refrigerant, compressor, evaporator, condenser, climate control.
Electrical Systems:
Complete wiring diagrams, lighting, power windows, locks, mirrors, interior electronics, fuses, relays.
Safety Systems:
Airbag system, seat belts, child restraint systems, ABS diagnostics.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, belt inspection/replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon faults across all systems, using diagnostic trouble codes (DTCs).
Component Replacement:
Step-by-step instructions for replacing major and minor components (e.g., water pump, alternator, starter, fuel pump, master cylinder).
Rebuilds And Overhauls:
Detailed procedures for engine and transmission rebuilds, including specifications and clearances.
Diagnostics:
Fault finding charts, symptom-to-cause analysis, on-board diagnostics (OBD-II) information.
Wiring Diagrams:
Comprehensive, high-quality electrical schematics for all vehicle circuits.
Specifications And Tolerances:
Precise measurements, torque values, and clearances for all adjustable and replaceable parts.
Technical Depth
Depth:
Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Information on using specific diagnostic tools and procedures for the vehicle.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High resolution, printable pages with clear text and diagrams.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Paper:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
2.4L Inline-4 (e.g., EDZ)
Displacement 1:
2429 cc (148 cu in)
Horsepower 1:
Approx. 150 hp @ 5800 rpm
Torque 1:
Approx. 160 lb-ft @ 4000 rpm
Optional Engine
Engine Code 2:
3.3L V6 (e.g., EGW)
Displacement 2:
3301 cc (201 cu in)
Horsepower 2:
Approx. 180 hp @ 5000 rpm
Torque 2:
Approx. 205 lb-ft @ 3200 rpm
Engine Code 3:
3.8L V6 (e.g., EGH, EZH - Supercharged available later)
Displacement 3:
3778 cc (231 cu in)
Horsepower 3:
Approx. 205 hp @ 5000 rpm (non-supercharged)
Torque 3:
Approx. 230 lb-ft @ 3200 rpm (non-supercharged)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Emission Control
System:
Catalytic converter, EGR (Exhaust Gas Recirculation), On-Board Diagnostics (OBD-II).
🔧 Transmission
Standard
Type:
4-Speed Automatic (e.g., 40TE/41TE)
Optional
Type:
N/A (All models equipped with automatic)
Features
Electronic Control:
Electronically controlled transmission for optimal shift points and fuel economy.
Fluid Type
Fluid Specification:
Chrysler ATF+4 (Automatic Transmission Fluid Type 9602)
📐 Dimensions
Exterior
Length:
Approx. 193.7 inches (Standard Wheelbase), 201.5 inches (Long Wheelbase)
Width:
Approx. 72.5 inches
Height:
Approx. 68.5 inches
Interior
Seating Capacity:
7 Passengers (2-2-3 configuration typically)
Cargo
Cargo Volume Behind First Row:
Approx. 150.7 cu ft (Long Wheelbase)
Cargo Volume Behind Second Row:
Approx. 90.3 cu ft (Long Wheelbase)
Weights
Curb Weight:
Approx. 3700 - 4300 lbs (depending on engine and configuration)
Towing Capacity:
Up to 3,500 lbs (with optional towing package and V6 engine)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
5-Star (2003-2007 models generally rated highly)
NHTSA Frontal Impact Passenger:
5-Star (2003-2007 models generally rated highly)
IIHS Side Impact:
Good (for most years, depending on equipment)
Active Features
ABS:
Standard Anti-lock Braking System.
Traction Control:
Optional Traction Control System (TCS) on some models.
Passive Features
Airbags:
Frontal airbags (driver and passenger), optional side-impact airbags.
Seat Belts:
Three-point seat belts for all seating positions, pretensioners, load limiters.
💡 Technology Features
Infotainment
Audio System:
AM/FM radio with CD player, optional cassette player, SiriusXM Satellite Radio ready on some trims.
Rear Entertainment:
Optional rear-seat video entertainment system (RSES) with DVD player and wireless headphones.
Driver Assistance
Parking Sensors:
Optional rear parking assist sensors.
Connectivity
Auxiliary Input:
N/A (Not typically equipped with factory auxiliary input ports).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (consult manual for specifics).
Air Filter Replacement:
Every 12,000-15,000 miles or as needed based on inspection.
Spark Plug Replacement:
Approx. 60,000-100,000 miles (depending on plug type, e.g., Platinum or Iridium).
Transmission Fluid Change:
Every 30,000-60,000 miles or as per severe service schedule.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 (API certified for gasoline engines), consult manual for specific viscosity based on temperature.
Coolant Specification:
Chrysler OAT (Organic Additive Technology) Antifreeze/Coolant, P/N 68048553AA (or equivalent Mopar specification, often pink or orange).
Brake Fluid Specification:
DOT 3
Known Issues
Common Problem 1:
Transmission issues: Harsh shifting, delayed engagement, failure to engage (especially on higher mileage units).
Common Problem 2:
Water pump leaks, especially with the V6 engines.
Common Problem 3:
Power steering pump or line leaks.
Common Problem 4:
Wheel bearing failures.
Common Problem 5:
HVAC blower motor resistor failure.
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler has a long history of innovation in the minivan segment, having introduced the first minivan in 1984.
Model Evolution
Rs Generation Introduction:
The fourth generation (RS) debuted for the 2001 model year, with styling updates and mechanical refinements continuing through 2007.
Updates During Generation:
Minor styling tweaks, powertrain enhancements (e.g., introduction of the 3.8L V6 across more trims), and safety feature updates occurred throughout its production run.
Production
Manufacturing Location:
Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)
Market Success:
Consistently a strong seller in the highly competitive minivan market during its lifespan.
🏆 Awards & Recognition
Recognitions
Kbb Consumer Ratings:
Generally received favorable consumer reviews for space, versatility, and value for money.
Edmunds Reviews:
Consistently recognized for its practicality and family-friendly features.
Certifications
Epa Fuel Economy:
Variable by engine and year; typically in the range of 16-20 MPG city and 22-28 MPG highway.

Delivery & file format

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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