Chrysler Grand Caravan 2002-2004 Factory Service Repair Manual

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Type: Car

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Sku: 104539

Tags: 2002 2003 2004 Car Cars Chrysler Featured Grand Caravan

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Description

This manual covers the Chrysler Grand Caravan, Fourth Generation (RS), produced for the 2002, 2003, and 2004 model years. Known for its practicality and family-oriented design, the Grand Caravan has been a staple in the minivan segment, building on Chrysler's pioneering legacy in this vehicle class. It offers versatile cargo space, with up to approximately 140.5 cubic feet behind the first row, and is powered by either a 3.3L V6 engine producing around 180 horsepower or a 3.8L V6 engine delivering approximately 200 horsepower, both featuring Multi-point Fuel Injection. Standard safety features include Anti-lock Braking System (ABS) and driver and front passenger airbags, with four-star NHTSA frontal crash ratings for the driver and passenger. This comprehensive factory service repair manual provides in-depth information for all styles of the Grand Caravan. It details everything from general maintenance, including oil and transmission fluid changes, to complex engine service, transmission repair, and brake system maintenance. The manual also covers electrical systems with detailed wiring diagrams, suspension, steering, cooling, fuel injection, emission control, HVAC, and restraint systems. With hundreds of illustrations, step-by-step instructions, and troubleshooting guides, this resource is designed to assist vehicle owners and professional technicians in performing accurate diagnostics, repairs, and maintenance to ensure the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Grand Caravan

Model Years Covered:

2002, 2003, 2004

Generation

Generation:

Fourth Generation (RS)

Codes

Chassis Code:

👋 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:

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:

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

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).