2003 Chrysler Town & Country, Dodge Caravan, Chrysler Voyager Service Manual (P/N 81-370-03062, 81-370-03038)

• Covers 2003 RS Chrysler Town & Country, Dodge Caravan/Grand Caravan, and Chrysler Voyager/Grand Voyager in front-wheel-drive and all-wheel-drive form, with short- and long-wheelbase identification data. The PDF also carries a 2003 RG 2.5L turbo-diesel engine supplement designed for use with the Voyager service manual.
• Separates the EDZ 2.4L DOHC gasoline, EGA 3.3L gasoline, EGH 3.8L gasoline, EGM 3.3L E-85 flexible-fuel, and ENJ 2.5L turbo-diesel engines, together with the 31TH three-speed automatic, 41AE/41TE four-speed electronic automatic, and T850 five-speed manual transaxles.
• Documents engine removal and internal repair, cylinder-head and valve service, timing-belt and timing-chain work, oil-pressure testing, automatic-transaxle overhaul, manual-transaxle disassembly and assembly, and AWD power-transfer and rear-driveline service.
• Addresses MacPherson-strut and leaf-spring suspension repair, FWD and AWD rear layouts, wheel alignment and curb-height checks, hydraulic and mechanical brake service, Teves Mark 20e ABS/traction-control diagnosis, and power-steering flow and pressure testing.
• Adds dedicated DRB III diagnostic material for powertrain, body, chassis, transmission, and diesel systems, with DTC test trees, verification tests, component locations, connector pinouts, system schematics, and lab-scope charts.
• Supplies the Front Suspension exploded view, FWD/AWD Rear Suspension layouts, Unequal Length Half Shaft System, Teves Mark 20e ABS schematic, power sliding door and power liftgate schematics, and KDB/PCI-bus lab-scope patterns.

4,732 PDF pages total — main service manual: 2,179 pages; RS powertrain diagnostics: 556 pages; body diagnostics: 1,160 pages; chassis diagnostics: 58 pages; transmission diagnostics: 344 pages; RG 2.5L diesel service supplement: 153 pages; diesel powertrain diagnostics: 282 pages. The RS service manual corresponds to DaimlerChrysler Publication No. 81-370-03062, and the RS Powertrain Diagnostic Procedures volume to Publication No. 81-370-03038.

Vehicle Identification and Configuration Coverage

The identification chapters are useful before any repair begins. VIN and body-code tables distinguish FWD and AWD car lines, short- and long-wheelbase bodies, Low Line, High Line, Premium, Sport, Special, and Luxury series or price classes, engine codes, transaxle codes, assembly plants, and market codes. That lets the technician check the vehicle build against the correct drivetrain, suspension, electrical, and body procedure instead of relying only on the badge on the liftgate.

Mechanical coverage runs from scheduled service through major teardown work. The engine groups address removal and installation, cylinder heads, camshafts and valvetrain, crankshaft and piston service, lubrication-system diagnosis, oil pumps, intake and exhaust components, and the correct timing system for each engine family. Transmission chapters cover the 31TH, 41AE/41TE, and T850 units. AWD repair material follows the power transfer unit, propeller shaft, rear half-shafts, rear driveline module, bi-directional overrunning clutch, carrier, seals, and related fluid service.

Diagnostics, Electrical Systems, and Body Repair

The diagnostic books are organized around the factory six-step troubleshooting method and DRB III scan-tool workflows. They cover communication faults, hard and intermittent codes, controller programming or initialization where specified, transmission Quick Learn and clutch-volume data, ABS initialization, TPMS training, compass calibration, and post-repair verification tests. Body diagnostics reach into the Body Control Module, Front Control Module, airbag and side-impact systems, automatic and manual HVAC, instrument cluster, EVIC, remote keyless entry, theft security, power sliding doors, power liftgate, exterior lighting, and wiper operation.

Wiring support is more than a group of generic circuit drawings. The set provides system-specific schematics, connector, ground, and splice-location illustrations, cavity-by-cavity pinouts, component-location views, and selected bus lab-scope patterns. Mechanical sections add exploded assembly views, section drawings, torque tables, fluid-capacity data, electrical test values, wear limits, alignment specifications, and special-tool callouts. Examples include Puller C-3894A, Ball Joint Press C-4212F, suspension bushing tools 8459 and 8460, Strut Rod Nut Wrench 6864, DRB III equipment, and the Miller 8333 transmission simulator with its FWD adapter.

The manual flags repair traps that are easy to miss when parts are assembled by appearance alone. High Line, Premium, and Sport lower-control-arm hydro-bushings are side-specific and must not be lubricated on the mounting stem; incorrect indexing or lubricant can reduce their grip on the arm. Rear leaf-spring pivot-bolt direction and hanger tightening order also matter, because the wrong setup can cause structural damage or bend the hanger.

The diagnostic volumes concentrate on fault isolation and then direct the technician back to the service manual for mechanical removal and repair procedures. Owner-manual operating instructions are outside this publication’s scope. For shop use, support the vehicle only at the specified hoist points, isolate the battery before restraint or high-current electrical work, and follow the manual’s precautions for pressurized cooling and fuel systems, spring-loaded suspension parts, brakes, and refrigerant service.