🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2004

Chassis Code:

RS (Third Generation)

👋 Introduction

Market Position:

The 2004 Dodge Caravan was a leading player in the minivan segment, known for its practicality, spacious interior, and flexible seating configurations. This manual targets DIY mechanics and professional technicians needing detailed repair information for this popular family vehicle.

Competitive Analysis:

Competed directly with vehicles like the Honda Odyssey, Toyota Sienna, and Ford Windstar. The Caravan's strength lay in its affordability and extensive dealer network, making a comprehensive repair manual essential for its upkeep.

Key Features:

Official licensing ensures accuracy and completeness. Digital format allows for quick searches, zoom capabilities, and easy navigation through complex procedures and diagrams.

📋 Manual Details

Coverage Areas:

All U.S., Canadian, and Mexican Market Models

Page Count:

Extensive (Specific count not provided, but typical for full service manuals)

Manual Type:

Service and Repair Manual Software

Language:

English

Format:

Digital Software (Likely PDF or proprietary application)

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, lubrication, cooling system, fuel system, ignition system, emission controls, engine mechanical specifications, diagnosis, and repair.

Transmission Drivetrain:

Automatic Transmission (40TE/41TE) overhaul, fluid specifications, diagnosis, and repair; clutch, drive axles, and related components.

Brakes:

Front and rear brake systems (disc/drum), Anti-lock Brake System (ABS) diagnosis and repair, hydraulic components, parking brake.

Suspension Steering:

Front and rear suspension systems, steering system components, power steering, alignment specifications, diagnosis, and repair.

Electrical:

Battery, charging system, starting system, lighting system, instrument cluster, power windows, power locks, wipers, horn, fuses, relays, wiring diagrams, body control module (BCM).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, repair, refrigerant handling, components.

Body Interior:

Body panel repair, doors, hood, liftgate, interior trim, seats, dashboard, glass replacement, sealants.

Diagnostics Troubleshooting:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, diagnostic procedures.

Maintenance:

Scheduled maintenance services, fluid changes, filter replacements, belt inspections and replacements, spark plug replacement, tire rotation.

Repair Overhaul:

Complete engine overhaul, transmission rebuilding, brake caliper replacement, suspension component replacement, starter motor replacement, alternator replacement.

Diagnostics:

Step-by-step diagnostic routines for various systems, electrical circuit tracing using wiring diagrams, fuel pressure testing, compression testing.

Troubleshooting:

Troubleshooting tables for common symptoms like starting issues, poor performance, strange noises, electrical faults.

Specifications:

Torque specifications for critical fasteners, engine timing specifications, alignment angles, fluid capacities, electrical resistance values.

Technical Depth:

Comprehensive from basic maintenance and fluid checks to advanced engine and transmission diagnostics and complete component overhauls. Includes detailed wiring diagrams and diagnostic flowcharts.

📊 Manual Specifications

File Format Details:

Likely a search-enabled digital format for quick access to information. May include interactive diagrams and troubleshooting tools.

Print Quality Aspect:

Digital format ensures consistent clarity and detail, unlike older printed manuals which can degrade over time.

Binding Type:

N/A (Software)

Paper Type:

N/A (Software)

⚙️ Engine Specifications

Engine Options:

2.4L (2429cc) DOHC 16-valve I4 (DOHC) - GEMA engine (Emergency Vehicle/Police/Taxi variant also common, less so for general market)

Engine Options 2:

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

Engine Options 3:

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

3.3L V6 Horsepower:

Approx. 180 hp @ 5000 rpm

3.3L V6 Torque:

Approx. 205 lb-ft @ 3200 rpm

3.8L V6 Horsepower:

Approx. 205 hp @ 5000 rpm

3.8L V6 Torque:

Approx. 230 lb-ft @ 4000 rpm

Fuel System Type:

Multi-port Fuel Injection (MPI)

Fuel Type Recommendation:

Unleaded gasoline (87 octane or higher recommended for V6 engines)

🔧 Transmission

Standard Transmission:

4-Speed Automatic Transaxle (40TE/41TE)

Optional Transmission:

N/A (4-speed automatic was standard across most configurations)

Transmission Fluid Spec:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approx. 3.5 - 4.0 quarts (dry fill); 1.5 quarts (drain and fill)

📐 Dimensions

Wheelbase:

112.1 inches (Standard Wheelbase), 119.3 inches (Long Wheelbase)

Length:

187.0 inches (Standard), 199.7 inches (Long)

Seating Capacity:

Up to 7 or 8 passengers depending on configuration.

Cargo Volume Behind 3Rd Row:

Approx. 24.1 cu ft (Standard), 34.5 cu ft (Long)

Curb Weight Range:

Approx. 3,900 - 4,300 lbs

🛡️ Safety Features

NHTSA Frontal Crash Rating Driver:

4 Stars

NHTSA Frontal Crash Rating Passenger:

4 Stars

NHTSA Side Impact Rating Front Passenger:

4 Stars

IIHS Moderate Overlap Frontal Offset:

Good (Vehicle was redesigned in 1996, this rating applies to the generation it belongs to)

Active Safety Features:

Optional Anti-lock Brake System (ABS), Traction Control (on some models).

Passive Safety Features:

Driver and front passenger airbags, optional side airbags, three-point seatbelts for all occupants, LATCH child seat anchors.

💡 Technology Features

Infotainment Options:

Optional AM/FM stereo with CD player, cassette player, and optional rear-seat entertainment system (DVD player).

Driver Assistance Features:

Cruise control, optional rear parking assist sensors.

Connectivity Options:

N/A (No Bluetooth or advanced connectivity features in this era).

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 6,000 miles or 3-6 months, depending on oil type and driving conditions (check owner's manual for specifics).

Air Filter Replacement Interval:

Every 15,000 - 30,000 miles or as needed based on driving conditions.

Spark Plug Replacement Interval V6:

Approx. 100,000 miles with iridium-tipped plugs; check specific plug type.

Transmission Fluid Change Interval:

Every 30,000 - 60,000 miles or as recommended by the manual for severe usage.

Engine Oil Specification:

SAE 5W-30 (most common for V6 engines), SAE 5W-20 or 10W-30 may be specified for the 4-cylinder. Always consult manual for precise specification and viscosity.

Coolant Specification:

Mopar Antifreeze/Coolant (OAT - Organic Acid Technology) or equivalent HOAT coolant.

Brake Fluid Specification:

DOT 3

Common Issues:

Transmission solenoid failure (especially in earlier models of this generation), water pump leaks, rear evaporator core leaks (in vehicles with rear A/C), power window motor failures, suspension component wear (ball joints, tie rod ends).

Engine Performance Issues:

Carbon buildup on intake valves (especially 3.3L V6), occasional misfires due to coil pack or spark plug issues.

Electrical Issues:

Intermittent power lock or window issues, flickering dashboard lights, issues with the Body Control Module (BCM).

📚 Vehicle History

Brand Heritage Context:

Dodge, as a division of Chrysler, has a long history of producing reliable and practical vehicles, including a strong legacy in the minivan segment.

Model Evolution Context:

The 2004 Caravan is part of the third generation (RS) of the Dodge Caravan, introduced in 1996. This generation saw significant updates in styling, safety, and powertrain options, including the introduction of the long-wheelbase Grand Caravan.

Production Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA.

🏆 Awards & Recognition

Recognitions:

The Dodge Caravan (and Grand Caravan) has consistently been a best-seller in the minivan segment and has received various accolades over its production life for utility and value, though specific awards for the 2004 model year are best verified through automotive review archives.