Dodge Grand Caravan 2008-2009 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Dodge Model: Grand Caravan Years Covered: 2008, 2009 Codes Platform Code: Dodge Caravan (RT) 👋 Introduction Market Position Segment: Full-size minivan Target Audience: Families, fleet...

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Type: Car

Vendor:

Sku: 475441

Tags: 2008 2009 Car Cars Dodge Grand Caravan Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Grand Caravan

Years Covered:

2008, 2009

Codes

Platform Code:

Dodge Caravan (RT)

👋 Introduction

Market Position

Segment:

Full-size minivan

Target Audience:

Families, fleet operators, DIY mechanics, professional technicians.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Strengths:

Spacious interior, versatile seating (Stow 'n Go), comfortable ride, practical for families and cargo.

Manual Value

Benefit To Owner:

Enables owners to perform routine maintenance, diagnose issues, and undertake repairs, saving time and money.

Benefit To Technician:

Provides factory-level diagnostic procedures, specifications, and repair techniques essential for efficient and accurate service.

📋 Manual Details

Coverage Areas

Major Systems:

Engine, Transmission, Brakes, Steering, Suspension, Electrical, HVAC, Body, Interior, Diagnostics

Powertrain Control Module (PCM):

Detailed diagnostics, component testing, and replacement procedures for the PCM and related sensors.

Page Count

Estimated Pages:

2500+

Manual Type

Type:

Factory Service Repair Workshop Manual

Origin:

Factory Original Equipment Manufacturer (OEM) equivalent.

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for engine disassembly, assembly, inspection, and overhaul for all gasoline engines offered.

Engine Performance:

Fuel system, ignition system, emission control systems, cooling system, lubrication system diagnostics and repair.

Transmission Automatic:

Comprehensive repair and overhaul procedures for the 4-speed and 6-speed automatic transmissions (e.g., 41TE, 42RLE, 62TE).

Transmission Manual:

Details for any manual transmission variants if applicable (less common for Grand Caravan).

Brakes:

Front and rear brake system diagnostics, repair, including ABS, traction control, and electronic stability control (ESC) components.

Steering:

Power steering system, steering column, steering linkage components diagnosis and repair.

Suspension:

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

Electrical System:

Complete wiring diagrams, fuse and relay locations, power distribution, charging system, starting system, lighting systems, and accessory circuits.

HVAC:

Air conditioning and heating system diagnostics, component replacement, refrigerant handling, climate control module.

Body Exterior:

Body panel removal and installation, doors, liftgate, bumpers, glass, exterior trim, and convertible top (if applicable).

Body Interior:

Interior trim panels, seats, dashboard, center console, interior lighting, and accessory components.

Diagnostics And Troubleshooting:

Extensive troubleshooting guides, diagnostic trouble codes (DTCs), fault finding procedures, and repair strategies.

Procedures Included

Scheduled Maintenance:

Detailed instructions for routine maintenance tasks such as oil changes, filter replacements, fluid checks, and belt inspections.

Component Replacement:

Step-by-step guides for replacing major components like alternators, starters, fuel pumps, water pumps, and more.

Repair And Overhaul:

In-depth procedures for repairing and rebuilding major vehicle systems, including engine and transmission overhauls.

Diagnostic Testing:

Procedures for using diagnostic tools, interpreting scan tool data, and performing specific circuit tests.

Alignment And Balancing:

Wheel alignment specifications and procedures, tire balancing instructions.

Reprogramming And Calibration:

Procedures for programming electronic modules, calibrating sensors, and key fobs.

Body Repair:

Detailed sections on frame straightening, collision repair guidelines, and body panel alignment.

Wheel And Tire:

Tire pressure monitoring system (TPMS) diagnosis and reset procedures, wheel bearing replacement, tire rotation.

Diagnostic Tools Usage:

Guidance on using OBD-II scanners, MUT-II (Chrysler's proprietary diagnostic tool) functionality, and specific diagnostic procedures.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine/transmission rebuilds and advanced diagnostics).

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

High-resolution, searchable text and clear diagrams for easy printing.

Binding Type

Binding:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Primary Engine

Engine 3.3L V6:

3.3L (3301cc) OHV V6, 180 hp @ 5000 rpm, 205 lb-ft @ 4000 rpm. Engine Code: EGY.

Engine 3.8L V6:

3.8L (3778cc) OHV V6, 197 hp @ 5200 rpm, 230 lb-ft @ 3200 rpm. Engine Code: EGN.

Engine 4.0L V6:

4.0L (3952cc) SOHC V6, 251 hp @ 5800 rpm, 259 lb-ft @ 4000 rpm. Engine Code: ENH (High Output).

Performance

Fuel Type:

Unleaded gasoline (87 octane recommended for 3.3L and 3.8L; 89 octane recommended for 4.0L).

Fuel System

Injection System:

Sequential Electronic Fuel Injection (SEFI).

Cooling System

Coolant Type:

Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (typically purple).

Lubrication System

Oil Type:

SAE 5W-20, API Certified. (Consult specific engine for variations).

Oil Capacity:

3.3L: 4.5 US qts (4.3L) with filter. 3.8L: 4.5 US qts (4.3L) with filter. 4.0L: 5.0 US qts (4.7L) with filter. (Always verify dipstick).

🔧 Transmission

Standard

Transmission Type Base:

4-speed automatic transmission (e.g., 41TE or 42RLE) on most models.

Optional

Transmission Type Optional:

6-speed automatic transmission (62TE) available on higher trims or with the 4.0L engine.

Features

Transmission Fluid Type:

ATF+4 (Mopar Automatic Transmission Fluid, Type 9602).

Transmission Fluid Capacity:

4-speed: Approx. 4.0 US qts (3.8L) dry, 8.0 US qts (7.6L) with torque converter. 6-speed: Approx. 4.5 US qts (4.3L) dry, 9.5 US qts (9.0L) with torque converter. (Always verify capacity).

📐 Dimensions

Exterior

Wheelbase:

121.1 inches (3076 mm)

Length:

199.5 inches (5067 mm)

Width:

78.5 inches (1994 mm)

Height:

68.9 inches (1750 mm)

Interior

Seating Capacity:

7 or 8 passengers depending on configuration.

Cargo

Cargo Volume Behind 3Rd Row:

Approximately 39.6 cubic feet (1121 liters).

Cargo Volume Behind 2Nd Row:

Approximately 79.5 cubic feet (2251 liters).

Cargo Volume Max:

Approximately 140.5 cubic feet (3978 liters) with 2nd and 3rd rows folded.

Weights

Curb Weight Range:

Approx. 4400 - 4700 lbs (2000 - 2130 kg) depending on engine and equipment.

Gross Vehicle Weight Rating Gvwr:

Approx. 6050 - 6350 lbs (2744 - 2880 kg).

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars (2008 model year).

NHTSA Front Impact Passenger:

5 Stars (2008 model year).

NHTSA Side Impact Front Seat:

5 Stars (2008 model year).

NHTSA Side Impact Rear Seat:

5 Stars (2008 model year).

IIHS Roof Strength:

Good (for models tested).

Active Features

Electronic Stability Control:

Standard on most trims (often referred to as ESP or Electronic Stability Program).

Traction Control:

Standard, often integrated with ESC.

Passive Features

Airbags Front:

Advanced multi-stage front airbags.

Airbags Side:

Optional or standard side curtain airbags for all rows.

Seatbelts:

Three-point seatbelts in all seating positions, pretensioners and load limiters for front seats.

💡 Technology Features

Infotainment

Audio System Options:

Available SiriusXM Satellite Radio, aftermarket head units, CD/MP3 players.

Rear Seat Entertainment:

Optional rear-seat video screens and DVD player.

Driver Assistance

Parking Assist:

Optional rear park assist sensors.

Cruise Control:

Standard on most models.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack for portable music players.

Power Outlets:

Multiple 12V power outlets throughout the cabin.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (severe service) or 6,000-7,500 miles (normal service) or as indicated by the Oil Change Indicator System.

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed or at 30,000-45,000 miles depending on driving conditions.

Engine Coolant Flush:

Initial flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter.

Transmission Fluid Change:

Every 30,000-60,000 miles depending on service conditions (severe duty recommended for frequent towing or stop-and-go).

Fluid Specifications

Power Steering Fluid:

ATF+4 or equivalent specified fluid. Consult manual for precise type.

Brake Fluid Type:

DOT 3

Wiper Blade Size:

Driver: 20 inches, Passenger: 18 inches, Rear: 14 inches (typical sizes, verify).

Known Issues

Common Problems Powertrain:

Transmission solenoid issues, torque converter shudder (especially on 42RLE), occasional oil leaks from valve covers or oil pan.

Common Problems Electrical:

Power window motor failures, interior light malfunctions, CAN bus communication errors, instrument cluster issues.

Common Problems Suspension Steering:

Worn ball joints and tie rod ends, sway bar links, strut mount bearings.

Common Problems HVAC:

Blend door actuator failure, refrigerant leaks, blower motor resistor issues.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan in the 1980s, setting a benchmark for family vehicles.

Model Evolution

Rt Generation Introduction:

The RT generation (2008-2016) was a significant redesign, moving to a unibody platform with improved styling and features.

Key Innovations For Era:

Introduction of the Stow 'n Go seating system, entertainment systems, and improved powertrain options.

Production

Manufacturing Location:

Windsor Assembly Plant, Windsor, Ontario, Canada.

🏆 Awards & Recognition

Recognitions

Family Car Awards:

The Grand Caravan has historically received accolades from automotive publications for its family-friendly features and value.

Ratings

Consumer Reports Reliability:

Reliability ratings vary by year and specific components; the manual helps address common wear items.