Dodge Caravan 2008-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2008-2009 Codes Platform: NS (Chrysler minivan platform) 👋 Introduction Market Position Vehicle Segment: Mid-size Minivan Target Audience: Families, individuals needing versatile...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

2008-2009

Codes

Platform:

NS (Chrysler minivan platform)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size Minivan

Target Audience:

Families, individuals needing versatile passenger and cargo capacity.

Competitive Analysis

Primary Competitors:

Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Uplander.

Key Features

Versatility:

Spacious interior, flexible seating (Stow 'n Go on some trims), significant cargo volume.

Powertrain Options:

Reliable V6 engines, optional All-Wheel Drive.

Value Proposition:

Generally offered competitive features and space at a lower price point than some rivals.

📋 Manual Details

Coverage Areas

Markets Covered:

North America (USA, Canada)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, evaporative emission control (EVAP).

Ignition System:

Spark plugs, ignition coils, crankshaft position sensor, camshaft position sensor.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, oxygen sensors.

Transmission Automatic:

40TES (Chrysler TR40LS) transmission diagnosis, overhaul, torque converter, valve body, solenoids.

Transmission Manual:

Not applicable for typical US models of this generation.

Drivetrain AWD:

All-Wheel Drive system diagnosis, transfer case, rear differential, driveshafts (if applicable).

Brakes System:

Front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid, master cylinder, calipers, rotors, pads.

Steering System:

Power steering system, steering column, steering rack, power steering pump, fluid specifications.

Suspension System:

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

Body Structure:

Chassis, frame components, unibody structure, door mechanisms, hinges, latches.

Exterior Trim:

Bumpers, grilles, fenders, hood, liftgate, doors, exterior moldings, glass replacement.

Interior Trim:

Dashboard, door panels, seats, headliner, carpeting, interior moldings.

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, compressor, evaporator, condenser, refrigerant, blower motor, climate control modules.

Electrical System Overview:

Wiring diagrams, component locations, fuse and relay identification.

Battery Charging System:

Alternator, voltage regulator, battery testing and replacement.

Starting System:

Starter motor, starter solenoid, ignition switch.

Lighting System:

Headlights, taillights, interior lights, fog lights, bulb specifications.

Instrument Panel:

Gauges, warning lights, driver information display, instrument cluster repair.

Audio System:

Radio, speakers, amplifier (if equipped), antenna.

Power Accessories:

Power windows, power locks, power mirrors, power seats, sunroof (if equipped).

Security System:

Anti-theft alarm, immobilizer, key fob programming.

Safety Systems Airbags:

Airbag system diagnosis, SRS module, airbag sensors, airbag modules, seatbelt pre-tensioners.

Safety Systems ABS:

ABS control module, wheel speed sensors, hydraulic unit.

Diagnostic Tools:

OBD-II diagnostic procedures, trouble codes (DTCs), scan tool usage.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations.

Engine Repair:

Head gasket replacement, timing belt/chain service, piston ring replacement, valve adjustments.

Transmission Repair:

Transmission fluid and filter change, solenoid replacement, clutch pack replacement, torque converter replacement.

Brake Service:

Brake pad and rotor replacement, brake caliper overhaul, brake line replacement, ABS system bleeding.

Suspension Component Replacement:

Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement.

Electrical Troubleshooting:

Diagnosing shorts, opens, and intermittent electrical faults using wiring diagrams.

HVAC Repair:

Refrigerant recharge, component replacement (compressor, evaporator), blower motor replacement.

Body Panel Replacement:

Door replacement, fender replacement, liftgate repair.

Interior Component Repair:

Dashboard disassembly, seat repair, trim panel replacement.

Diagnostic Troubleshooting:

Step-by-step diagnostic flowcharts for various symptoms and DTCs.

Specifications And Tolerances:

Torque specifications, engine clearances, wheel alignment specifications.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission overhauls and advanced electrical diagnostics).

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution (suitable for printing key sections).

Binding Type

Binding:

Not applicable (digital format).

Paper Type

Paper Quality:

Not applicable (digital format).

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EDV (3.3L V6)

Displacement 1:

3.3 Liters (3301 cc)

Configuration 1:

SOHC V6 (Single Overhead Camshaft)

Horsepower 1:

Approximately 180 hp @ 5000 rpm

Torque 1:

Approximately 230 lb-ft @ 3600 rpm

Fuel Induction 1:

Sequential Multi-Port Fuel Injection (MPI)

Bore X Stroke 1:

93.0 mm x 81.0 mm

Compression Ratio 1:

9.5:1

Optional Engine

Engine Code 2:

EGA (3.8L V6)

Displacement 2:

3.8 Liters (3778 cc)

Configuration 2:

OHV V6 (Overhead Valve)

Horsepower 2:

Approximately 190-200 hp @ 5000 rpm

Torque 2:

Approximately 235-245 lb-ft @ 3600 rpm

Fuel Induction 2:

Sequential Multi-Port Fuel Injection (MPI)

Bore X Stroke 2:

96.0 mm x 87.0 mm

Compression Ratio 2:

9.6:1

Engine Code 3:

SXT (4.0L V6 - for 2008, some specific later models might have it)

Displacement 3:

4.0 Liters (3952 cc)

Configuration 3:

SOHC V6 (Single Overhead Camshaft)

Horsepower 3:

Approximately 251 hp @ 6000 rpm

Torque 3:

Approximately 259 lb-ft @ 4000 rpm

Fuel Induction 3:

Sequential Multi-Port Fuel Injection (MPI)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

87 Octane Minimum (89 or higher recommended for optimal performance)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic

Transmission Model:

40TES / Chrysler TR40LS

Optional

Transmission Type AWD:

4-speed Automatic (with All-Wheel Drive)

Transmission Model AWD:

40TES-FWD / Chrysler TR40LS (with AWD transfer case)

Features

Overdrive:

Yes (4th gear)

Torque Converter Lockup:

Fluid Type:

ATF+4 (Mopar)

Fluid Capacity

Transmission Fluid Capacity:

Approx. 4.6 Quarts (4.4 Liters) - Dry fill. Check manual for specific fill procedure.

📐 Dimensions

Exterior

Length:

Approx. 190-201 inches (4826-5105 mm), varies by configuration.

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 68.0-69.0 inches (1727-1753 mm)

Wheelbase:

Approx. 119.2 inches (3028 mm)

Interior

Seating Capacity:

5 or 7 passengers (depending on configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 30-40 cu ft (varies by model/seating)

Cargo Volume Behind 2Nd Row:

Approx. 70-80 cu ft (varies by model/seating)

Cargo Volume Max:

Approx. 140-160 cu ft (with 2nd/3rd rows folded/removed)

Weights

Curb Weight:

Approx. 3900-4500 lbs (1769-2041 kg), varies by engine and AWD.

Gross Vehicle Weight Rating:

Approx. 5700-6000 lbs (2585-2722 kg)

Towing Capacity:

Up to 3,800 lbs (1724 kg) with optional towing package.

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

5 Stars (for 2008 model year)

NHTSA Frontal Passenger:

5 Stars (for 2008 model year)

NHTSA Side Driver:

5 Stars (for 2008 model year)

NHTSA Side Rear Passenger:

5 Stars (for 2008 model year)

NHTSA Rollover:

4 Stars (for 2008 model year, for 2WD and AWD)

Active Features

Standard Anti-lock Braking System

Traction Control:

Available Traction Control System (TCS)

Electronic Stability Control:

Available Electronic Stability Control (ESC) or Electronic Stability Program (ESP).

Passive Features

Airbags Front:

Standard front driver and passenger airbags.

Airbags Side:

Available front and second-row side curtain airbags.

Seatbelts:

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

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with CD player, optional satellite radio, optional rear-seat entertainment system (DVD player).

Navigation System:

Optional factory navigation system available on higher trims.

Driver Assistance

Parking Sensors:

Optional rear parking assist sensors available.

Backup Camera:

Not commonly available for this generation; typically limited to aftermarket solutions.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack for portable media players.

Remote Start:

Optional remote start system available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type (consult manual for synthetic oil recommendations).

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually.

Spark Plug Replacement 3.3L/3.8L:

Every 100,000 miles (160,000 km) for long-life spark plugs (e.g., iridium).

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km) or as per severe service recommendations.

Coolant Flush:

Every 60,000-100,000 miles (96,000-160,000 km) or 5 years for long-life coolant.

Fluid Specifications

Engine Oil Viscosity:

0W-20 (preferred for fuel economy), 5W-20, or 5W-30 (check owner's manual for exact recommendation based on temperature and engine).

Engine Oil Specification:

API SN or newer, ILSAC GF-5 or newer.

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, HOAT (Hybrid OAT) in some instances. Typically a purple or orange color. Consult manual for specific color/type.

Brake Fluid Type:

DOT 3 or DOT 4 (check cap or manual, DOT 3 is common).

Power Steering Fluid:

ATF+4 or specific Mopar Power Steering Fluid (verify with manual).

Known Issues

Transmission Hard Shifts:

Common issue with the 40TES transmission, often related to internal solenoid issues or valve body wear. Can be exacerbated by fluid degradation.

Power Sliding Doors:

Can experience issues with motors, tracks, or switches becoming inoperative or slow.

Stow N Go Seating Mechanisms:

The complex folding mechanisms can sometimes bind or fail due to debris or wear.

Alternator Failure:

Alternators can be a wear item, particularly in high-mileage vehicles.

Rear Suspension Sag:

Over time, rear springs can sag, especially when loaded, impacting ride height and handling.

Ignition Coil Failure:

Individual ignition coils can fail, leading to misfires and check engine lights.

📚 Vehicle History

Brand Heritage

Dodge Heritage:

Dodge, a division of Chrysler, has a long history in American automotive manufacturing, known for performance and utility vehicles.

Model Evolution

Caravan History:

The Dodge Caravan (and its Plymouth/Chrysler Voyager/Town & Country siblings) pioneered the minivan segment in the 1980s, becoming a dominant force.

Generation 2008-2009:

These model years represent the latter part of the fourth generation (RS) of the Dodge Caravan, which debuted for the 2001 model year. Key updates for this period often focused on features and refinement.

Production

Manufacturing Locations:

Primarily Windsor, Ontario, Canada (Chrysler Canada assembly plants).

Production Years:

The fourth generation (RS) ran from 2001-2007, with the later models (2008-2009) often considered a continuation or minor refresh before the introduction of the fifth generation (RT) Grand Caravan.

🏆 Awards & Recognition

Recognitions

Common Recognition:

While not always winning major awards, the Caravan was consistently recognized for its value, practicality, and family-friendly features, often appearing on 'most affordable' or 'best family vehicle' lists.

Ratings

IIHS Ratings:

Good ratings in front and side impact tests for many configurations, contributing to its strong safety scores.