🏷️ Basic Information

Make:

Dodge

Model:

Grand Caravan

Years Covered:

2002, 2003, 2004

Chassis Code:

RS

Platform:

Chrysler NS

👋 Introduction

Segment:

Minivan

Target Audience:

Families, fleet operators, DIY mechanics, automotive enthusiasts.

Key Competitors:

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

Strengths Of Grand Caravan:

Spacious interior, versatile seating (Stow 'n Go introduced later, but flexibility present), comfortable ride, relatively affordable pricing, robust powertrain options.

Model Generation:

Third generation of the Dodge Grand Caravan (1996-2007), with significant updates for 2001 including a redesigned interior and exterior.

Body Styles:

Long-wheelbase minivan.

Seating Capacity:

Typically 7-8 passengers depending on configuration.

📋 Manual Details

Overall Coverage:

Comprehensive repair and service information for all systems.

Mechanical Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes.

Electrical Systems:

Ignition, Charging, Lighting, Instrument Cluster, HVAC Controls, Power Accessories, Body Electronics, Powertrain Control Module (PCM) diagnostics.

Body And Interior:

Body panels, doors, interior trim, seating, glass, HVAC (heating, ventilation, and air conditioning) system, body control module (BCM) diagnostics.

Estimated Pages:

Over 1500 pages (typical for comprehensive service manuals of this era).

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Engine Overview:

Detailed breakdown of 3.3L and 3.8L V6 engines, including disassembly, assembly, inspection, and repair procedures.

Engine Management:

Ignition timing, fuel injection system operation, emissions control systems (EGR, PCV), sensor diagnostics (MAP, TPS, O2, Crankshaft Position).

Transmission Systems:

Coverage of the 4-speed automatic transmissions (e.g., 41TE, 42LE), including hydraulic controls, valve body, torque converter, and electronic control module (TCM) diagnostics.

Drivetrain And Axles:

Front-wheel drive axle shafts, CV joints, differential inspection, and repair.

Suspension And Steering:

Front and rear suspension components (struts, control arms, ball joints, bushings), power steering system (pump, rack and pinion, hoses), wheel alignment specifications.

Braking System:

Front and rear brake systems (disc and drum), ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications, bleeding procedures.

Electrical And Diagnostics:

Wiring diagrams, fuse and relay locations, diagnostic trouble codes (DTCs) for various modules (PCM, TCM, BCM, ABS module), component testing procedures.

HVAC System:

Air conditioning system operation, refrigerant charging, climate control module diagnostics, blower motor, evaporator, and condenser service.

Body And Chassis:

Body panel removal and installation, door hinge adjustment, glass replacement, liftgate operation, chassis component torque specifications.

Maintenance Procedures:

Oil changes, filter replacements (oil, air, fuel, cabin), coolant flushes, spark plug replacement, belt inspection and replacement.

Troubleshooting Guides:

Systematic diagnostic flowcharts and symptom-based troubleshooting for common drivability issues, electrical faults, and mechanical failures.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Diagnostic Procedures:

Detailed instructions on using diagnostic scan tools, interpreting live data, and performing actuator tests.

Torque Specifications:

Comprehensive list of torque values for critical fasteners across all major components.

Electrical Troubleshooting:

Utilizing wiring diagrams for pinpoint testing of circuits, voltage drop tests, and continuity checks.

Depth Level:

Factory-level detail suitable for professional technicians and advanced DIYers.

Diagnostic Capability:

Enables in-depth diagnosis of powertrain, chassis, and body control systems.

Rebuild Information:

Includes procedures for major component overhauls (e.g., engine, transmission).

📊 Manual Specifications

File Type:

PDF

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Printability:

Printable pages, allowing for hard copies of specific sections or the entire manual.

Quality Description:

High-resolution digital reproduction of original factory documentation, ensuring clarity of diagrams and text.

Binding Description:

N/A (Digital PDF format)

Paper Description:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Option 1:

3.3L V6 OHV 12-valve (EGA)

Displacement 1:

3.3 liters (201.8 cubic inches)

Horsepower 1:

Approx. 170-180 hp @ 4800-5000 rpm

Torque 1:

Approx. 225-230 lb-ft @ 3200-3400 rpm

Engine Option 2:

3.8L V6 OHV 12-valve (EGH)

Displacement 2:

3.8 liters (230.5 cubic inches)

Horsepower 2:

Approx. 200-205 hp @ 5000-5200 rpm

Torque 2:

Approx. 240-245 lb-ft @ 3800-4000 rpm

Fuel Type:

Unleaded gasoline

Induction Type:

Sequential Multi-Port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-near-Plug technology.

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle (e.g., 41TE/42LE)

Optional Transmission:

N/A (All models equipped with automatic)

Transmission Control:

Electronic control with limp-in mode capability.

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approx. 10.7 quarts (10.1 liters) with torque converter.

📐 Dimensions

Wheelbase:

120.0 inches (3048 mm)

Length:

198.5 inches (5042 mm)

Width:

77.0 inches (1956 mm)

Height:

67.5 inches (1715 mm)

Passenger Volume:

Approx. 145-155 cubic feet (varies by configuration)

Cargo Volume Behind 1St Row:

Approx. 140-150 cubic feet (with seats removed/folded)

Cargo Volume Behind 2Nd Row:

Approx. 80-90 cubic feet

Curb Weight:

Approx. 4300-4500 lbs (1950-2041 kg)

Gross Vehicle Weight Rating Gvw:

Approx. 5900-6000 lbs (2676-2722 kg)

🛡️ Safety Features

NHTSA Frontal Driver:

5-Star (for 2002-2004 models generally, check specific tests)

NHTSA Front Passenger:

5-Star (for 2002-2004 models generally, check specific tests)

IIHS Front Small Overlap:

Not tested/applicable in this format for early 2000s vehicles.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models.

Airbags Front:

Standard front driver and passenger airbags.

Airbags Side:

Optional front side airbags available on some trims.

Seatbelts:

Three-point seatbelts for all occupants, with pretensioners for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Audio System:

Optional AM/FM stereo with CD player, cassette tape player, and optional rear entertainment system (DVD player with screens in later models of this generation, less common for 2002-2004 base models).

Navigation:

Rarely available, if at all, during these specific years.

Cruise Control:

Standard cruise control.

Power Accessories:

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

Remote Keyless Entry:

Available on most trims.

🔧 Maintenance

Oil Change Interval:

Every 3,000 to 7,500 miles (depending on oil type and driving conditions, consult manual for specifics).

Air Filter Replacement:

Every 15,000 to 30,000 miles, or as needed based on inspection.

Spark Plug Replacement:

Typically around 100,000 miles for iridium/platinum plugs, shorter for older types. Consult manual.

Coolant Flush:

Every 30,000 to 50,000 miles or every 2-3 years.

Transmission Fluid Service:

Every 30,000 to 60,000 miles, recommended for longevity.

Engine Oil Viscosity:

0W-30 or 5W-30 (check manual for specific engine and temperature recommendations).

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) for 3.3L, 5.0 quarts (4.7 liters) for 3.8L (with filter change).

Coolant Type:

Mopar Antifreeze/Coolant (Green) or equivalent HOAT (Hybrid Organic Acid Technology) coolant.

Power Steering Fluid:

ATF+4 (Mopar) or equivalent.

Common Concern 1:

Transmission solenoid pack failures or valve body issues leading to shifting problems.

Common Concern 2:

Evaporator core leaks in the HVAC system, causing AC failure and potential water ingress into the cabin.

Common Concern 3:

Power sliding door mechanism issues (if equipped).

Common Concern 4:

Oil filter housing leaks or gasket failures.

Common Concern 5:

Dashboard instrument cluster failures or flickering gauges.

📚 Vehicle History

Dodge Brand:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler, now Stellantis), has a long history of producing trucks, performance cars, and family vehicles.

Caravan Lineage:

The Grand Caravan is the long-wheelbase version of the original Dodge Caravan minivan, first introduced in 1984. It has been a consistent leader in the minivan segment for decades.

Third Generation Updates:

The 2001 redesign brought a more aerodynamic exterior, significantly improved interior comfort and ergonomics, and enhanced safety features. Engine options remained largely the same but were refined.

Manufacturing Plant:

Primarily produced at the Windsor Assembly Plant in Windsor, Ontario, Canada.

Production Years For This Generation:

2001-2007

🏆 Awards & Recognition

Automotive Press Awards:

While specific awards for the 2002-2004 models are not as widely publicized as later generations, the Grand Caravan consistently ranked well in consumer satisfaction surveys for its class and utility.

Consumer Reports Ratings:

Consumer Reports often rated the Grand Caravan's reliability in the 'Average' to 'Below Average' range for this generation, with particular attention to transmission and electrical system issues. This manual is crucial for addressing these potential problems.

Safety Certifications:

Met all US Federal Motor Vehicle Safety Standards (FMVSS) for the respective model years.