🏷️ Basic Information

Make:

Chrysler

Model:

Caravan

Year:

2004

Platform:

RS (Third Generation)

👋 Introduction

Vehicle Segment:

Minivan / Passenger Van

Target Audience:

Families, fleet operators, tradespeople seeking versatile and practical transportation.

Key Competitors:

Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture.

Market Differentiation:

Known for its practicality, spacious interior, comfortable ride, and often competitive pricing. The Caravan platform offered a good balance of features and functionality for its class.

Body Styles:

Long-wheelbase (ES) and short-wheelbase (SE, SXT) variants available.

Seating Configurations:

Flexible seating options, including Stow 'n Go (introduced later, but the platform was designed for evolving configurations) allowing for multiple passenger and cargo arrangements.

Powertrain Options:

V6 engine options were prevalent, offering a good balance of power and refinement for a vehicle of its size.

📋 Manual Details

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Hundreds of Pages (estimated 1000-1500+ for full factory documentation)

File Format:

PDF

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Searchability:

Searchable text within the PDF for quick information retrieval.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Complete diagnosis, repair, overhaul, and specifications for all engine variants. Includes cylinder head, block, pistons, crankshaft, camshafts, valvetrain, timing systems, lubrication, cooling.

Engine Performance:

Fuel injection system diagnosis and repair (MPI), ignition system, emissions control systems (catalytic converter, EGR, EVAP), engine control module (ECM) diagnosis.

Transmission Automatic:

Diagnosis, repair, overhaul, and specifications for the automatic transmission. Includes torque converter, valve body, planetary gear sets, clutch packs, seals, and fluid.

Transmission Manual:

Diagnosis, repair, and specifications for manual transmission variants if applicable.

Drivetrain:

Front-wheel drive axle shafts, CV joints, differential, rear axle service (if applicable).

Suspension:

Front and rear suspension components, struts, shock absorbers, springs, control arms, ball joints, bushings, wheel alignment specifications.

Steering:

Power steering system diagnosis and repair, steering gear, tie rods, power steering pump, fluid specifications.

Brakes:

Front and rear disc brake systems, caliper, rotor, pad replacement, brake fluid specifications, ABS system diagnosis and repair, parking brake.

Electrical System:

Complete wiring diagrams, charging system (alternator, battery, starter), lighting system, horn, wipers, power windows, door locks, interior and exterior electrical components.

Body And Frame:

Body panel repair, door mechanisms, tailgate/liftgate, bumpers, interior trim, chassis lubrication, corrosion protection.

Heating Ventilation Air Conditioning HVAC:

HVAC system diagnosis, refrigerant handling, compressor, condenser, evaporator, heater core, climate control panel, blower motor, airflow controls.

Routine Maintenance:

Oil changes, filter replacements, fluid level checks and top-offs, tire rotation and pressure checks, spark plug replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon faults across all systems, including symptom-based troubleshooting charts and fault code interpretation.

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake system overhauls, steering system repairs.

Component Replacement:

Step-by-step instructions for replacing virtually all serviceable components, from sensors and actuators to major assemblies.

Electrical Diagnostics:

Pinpoint testing, circuit continuity checks, voltage drop testing, diagnostic connector usage, relay and fuse testing.

Diagnostic Charts:

Extensive diagnostic flowcharts and symptom-to-cause tables.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Alignment Specifications:

Detailed wheel alignment angles (camber, caster, toe) for front and rear axles.

Schematics:

Comprehensive electrical wiring diagrams for all circuits and options.

Rebuild Procedures:

Detailed instructions for disassembling, inspecting, cleaning, and reassembling major components like engines and transmissions.

⚙️ Engine Specifications

Engine Code:

EER (3.3L V6)

Engine Displacement:

3.3 Liters (3301 cc)

Engine Type:

Overhead Valve (OHV) V6

Horsepower:

Approx. 180 hp @ 5000 RPM

Torque:

Approx. 205 lb-ft @ 3200 RPM

Engine Code:

LXT (3.8L V6)

Engine Displacement:

3.8 Liters (3778 cc)

Engine Type:

Overhead Valve (OHV) V6

Horsepower:

Approx. 200 hp @ 5000 RPM

Torque:

Approx. 230 lb-ft @ 3200 RPM

Fuel Type:

Unleaded Gasoline

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Pump Pressure:

Specific pressure values detailed in manual.

🔧 Transmission

Transmission Type:

4-Speed Automatic Transaxle (41TE/42LE)

Transmission Type:

5-Speed Manual Transaxle (less common on this model year, but possible)

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 4) - Official Chrysler specification.

Transmission Fluid Capacity:

Approx. 4.0-4.5 quarts (dry fill), 2.0-2.5 quarts (drain and fill). Exact capacity in manual.

Overdrive:

Yes, with electronically controlled torque converter clutch (TCC).

📐 Dimensions

Wheelbase Short:

112.1 inches (2847 mm)

Wheelbase Long:

119.3 inches (3030 mm)

Overall Length Short:

178.5 inches (4534 mm)

Overall Length Long:

185.7 inches (4717 mm)

Overall Width:

72.0 inches (1829 mm)

Overall Height:

67.7 inches (1720 mm)

Max Cargo Volume Short:

Approx. 120.9 cubic feet

Max Cargo Volume Long:

Approx. 145.8 cubic feet

Curb Weight Min:

Approx. 4000 lbs (1814 kg)

Gross Vehicle Weight Rating Gvwr:

Varies by configuration, typically around 5800-6000 lbs.

Towing Capacity:

Up to 3800 lbs (with optional towing package).

🛡️ Safety Features

NHTSA Frontal Impact Driver:

4-star (2004 model year specific rating may vary slightly)

NHTSA Frontal Impact Passenger:

4-star (2004 model year specific rating may vary slightly)

NHTSA Side Impact Front Seat:

5-star (2004 model year specific rating may vary slightly)

NHTSA Side Impact Rear Seat:

4-star (2004 model year specific rating may vary slightly)

ABS:

Standard Anti-lock Braking System (ABS) on all four wheels.

Traction Control:

Available Traction Control System (TCS) on some models.

Airbags Front:

Dual front airbags (driver and passenger).

Airbags Side:

Optional side-curtain airbags or side-impact airbags (availability varies by trim).

Seatbelts:

Three-point seatbelts for all seating positions, pretensioners for front seats.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player, optional cassette tape player, and premium Infinity sound system. Multiple speaker configurations available.

Rear Entertainment:

Optional rear-seat entertainment system with overhead video monitor and wireless headphones.

Cruise Control:

Standard cruise control.

Keyless Entry:

Optional keyless entry system with remote key fob.

Power Outlets:

12V accessory power outlets for charging devices.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months if using conventional oil; 6,000 miles or 6 months if using synthetic oil and severe driving conditions are not met. Refer to manual for exact intervals based on driving habits.

Engine Air Filter Replacement:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Spark Plug Replacement:

Approx. 60,000 - 100,000 miles depending on plug type (e.g., platinum or iridium). Manual will specify exact type and interval.

Transmission Fluid Change:

Inspect every 30,000 miles, recommended change every 60,000 miles, or sooner under severe service. ATF+4 is designed for longer intervals but regular inspection is key.

Coolant Flush:

Initial change at 100,000 miles, then every 50,000 miles thereafter. Mopar OAT (Olds Antifreeze Type) or equivalent is typically required.

Engine Oil Viscosity 3.3L:

SAE 5W-30 (API Certified)

Engine Oil Viscosity 3.8L:

SAE 5W-30 (API Certified)

Engine Coolant:

Mopar OAT (Orange Antifreeze) or equivalent 50/50 mix.

Brake Fluid:

DOT 3 (or DOT 4, consult manual for specific application)

Power Steering Fluid:

ATF+3 or ATF+4 (check manual for confirmation on 2004 models).

Transmission Hard Shifting:

Can be caused by worn solenoids, fluid degradation, or internal wear in the 41TE/42LE transmission. Manual provides diagnostic steps.

Power Steering Pump Noise:

Whining or groaning noise from the power steering pump can indicate low fluid, air in the system, or a failing pump.

Cv Joint Failure:

Clicking noise when turning can indicate worn front CV joints. Manual covers replacement procedure.

Rear Hatch Strut Failure:

Common wear item, struts may lose pressure and fail to hold the liftgate open.

Blower Motor Failure:

HVAC blower motor can fail, resulting in no airflow from vents. The blower resistor can also fail, causing fan speed issues.

📚 Vehicle History

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983. The Chrysler Caravan is a direct descendant of this groundbreaking vehicle.

Third Generation Start:

The third generation (RS body style) was introduced for the 1996 model year, representing a significant redesign with improved aerodynamics, interior space, and available all-wheel drive.

2004 Updates:

The 2004 model year is part of the latter half of the third generation's lifecycle. Minor updates may have included feature packaging changes, new exterior/interior color options, and potential refinement of existing systems.

Production Location:

Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

Production Years Third Gen:

1996-2007

🏆 Awards & Recognition

Car And Driver 10 Best:

Chrysler/Dodge minivans have historically appeared on Car and Driver's '10 Best' lists in various years of their production, often for their practicality and value.

Consumer Reports Reliability:

Reliability ratings for the 2004 model year can vary; it's advisable to consult specific consumer reports data for this year. The third generation generally saw improvements over earlier models, but certain powertrain components were known to have issues.

Manual Certification:

Official Factory Service Manual, produced by or for Chrysler Corporation.