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Chrysler Grand Caravan 2002-2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Grand Caravan Model Years Covered: 2002, 2003, 2004 Generation Generation: Fourth Generation (RS) Codes Chassis Code: RS 👋 Introduction Market Position Target Audience:...
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Type: Car
Vendor:
Sku: 104539
Chrysler Grand Caravan 2002-2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Grand Caravan
Model Years Covered:
2002, 2003, 2004
Generation
Generation:
Fourth Generation (RS)
Codes
Chassis Code:
RS
👋 Introduction
Market Position
Target Audience:
Vehicle owners and DIY mechanics seeking comprehensive factory-level repair information.
Competitive Analysis
Authenticity:
Actual Genuine Repair Service Factory Manuals, not third-party publications.
Key Features
Cost Savings Potential:
Enables owners to save $50-$60 per hour on shop labor costs by performing servicing themselves.
Search Functionality:
Searchable PDF format allows for quick location of specific information.
Portability Flexibility:
Print only needed pages or the entire manual, eliminating wear and tear on physical copies.
📋 Manual Details
Coverage Areas
All Styles Covered:
True
Page Count
Estimated Page Count:
Hundreds of pages (exact count not specified but implied to be extensive for factory service)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Service Repair:
Comprehensive engine diagnostics, repair, and overhaul procedures.
Transmission Service Repair:
Detailed procedures for automatic transmission maintenance and repair.
Brake System:
Front and rear brake system service, including disc and drum components, hydraulic system, and ABS.
Electrical System:
Complete coverage of all electrical components, circuits, and systems.
Wiring Diagram:
Detailed wiring diagrams for all vehicle systems, crucial for electrical troubleshooting.
Suspension:
Front and rear suspension component service, alignment specifications, and diagnostics.
Steering:
Power steering system maintenance, repair, and component replacement.
Cooling System:
Radiator, water pump, thermostat, hoses, and coolant specifications.
Fuel Injection Fuel System:
Fuel pump, injectors, fuel pressure, and evaporative emissions control system (EVAP).
Emission System:
Exhaust system, catalytic converter, oxygen sensors, and emission control strategies.
Heater Air Conditional:
HVAC system components, refrigerant handling, and climate control diagnostics.
Engine Control System:
Powertrain Control Module (PCM) diagnostics, sensor operations, and actuator testing.
Chassis Body:
Body panel repair, structural components, and chassis adjustments.
Restraint System:
Airbag system diagnostics, seatbelt service, and occupant protection components.
Interior:
Interior trim, seating mechanisms, and accessory components.
Differential Drive:
Front-wheel drive axle and differential service.
Axle:
Front drive axle and CV joint service.
Procedures Included
General Maintenance:
Routine maintenance tasks, fluid checks, filter replacements, and lubrication.
Troubleshooting:
Advanced diagnostic procedures for identifying and resolving vehicle issues.
Periodic Lubrication:
Specific lubrication points and recommended lubricants for various components.
Technical Depth
Technical Depth:
Complete factory-level repair, maintenance, rebuilding, refurbishing, and restoration.
Diagnostic Capabilities:
Advanced troubleshooting guides and diagnostic procedures for all systems.
Instructional Format
Step By Step Instructions:
Detailed, numbered instructions for all repair procedures.
Illustrations Diagrams Photos:
Hundreds of illustrations, drawings, and photos to guide technicians.
Critical Information Notes:
Includes notes, cautions, and warnings throughout each chapter.
Electrical Diagnostics Wiring:
Combined troubleshooting and electrical service with detailed wiring diagrams.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution, fully printable (individual pages or entire manual).
Binding Type
Binding Type:
N/A (Digital Download - user printable)
Paper Type
Paper Type:
N/A (Digital Download - user printable)
Software Requirements
Software Requirements:
Adobe PDF Reader
Compatibility
Operating System Compatibility:
All PC based Windows operating systems and Mac.
Delivery Method
Delivery Method:
Instant download link on checkout page after payment.
⚙️ Engine Specifications
Primary Engine
Engine Options:
3.3L V6 (EGA), 3.8L V6 (L32)
Performance
3.3L V6 Horsepower:
Approximately 180 hp @ 4800 rpm (EGA)
3.3L V6 Torque:
Approximately 210 lb-ft @ 3600 rpm (EGA)
3.8L V6 Horsepower:
Approximately 200 hp @ 5000 rpm (L32)
3.8L V6 Torque:
Approximately 240 lb-ft @ 3200 rpm (L32)
Fuel System
Fuel System Type:
Multi-point Fuel Injection (MPI)
Engine Components
Engine Type:
Overhead Valve (OHV) V6
🔧 Transmission
Standard
Standard Transmission:
4-Speed Automatic (41TE)
Optional
Optional Transmission:
None specified for this generation/year range.
Features
Transmission Control:
Electronic Control
📐 Dimensions
Exterior
Wheelbase:
Approximately 119.2 inches
Length:
Approximately 193.5 inches
Cargo
Cargo Volume Behind First Row:
Approximately 140.5 cu ft
Weights
Curb Weight:
Approximately 4,100 - 4,300 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating Driver:
Four out of five stars (for 2002 model year, may vary slightly for 2003-2004)
NHTSA Frontal Crash Rating Passenger:
Four out of five stars (for 2002 model year, may vary slightly for 2003-2004)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags.
💡 Technology Features
Infotainment
Available Audio Systems:
Various audio system options, including AM/FM cassette/CD players, with available premium sound systems.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Available Entertainment:
Optional rear-seat entertainment systems (e.g., DVD players) were available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals based on driving conditions (typically 3,000-7,500 miles or 6-12 months).
Transmission Fluid Change:
Recommended every 30,000 - 60,000 miles, refer to manual for specific fluid type and procedure.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Certified)
Coolant Type:
Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, G-05 spec
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid)
Known Issues
Transmission Issues:
Some models may experience issues with the 41TE transmission, particularly regarding solenoid packs and torque converters. Early detection and proper fluid maintenance are crucial.
Power Window Regulator:
Common wear item, often requiring replacement of the regulator mechanism.
Rear Wiper Motor:
Occasional failures of the rear wiper motor.
Climate Control Blend Door Actuators:
Actuators can fail, leading to improper temperature control or air direction.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager, evolving into the Grand Caravan nameplate.
Model Evolution
Fourth Generation Introduction:
The fourth generation (RS) debuted for the 2001 model year, introducing a more modern design and improved features compared to its predecessors.
Production
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
While specific year ratings vary, the Grand Caravan was generally a popular choice in its segment for practicality and family hauling. (Refer to specific Consumer Reports archives for detailed ratings).
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