🏷️ Basic Information

Make:

Dodge

Model:

Grand Caravan

Years Covered:

2002, 2003, 2004

Platform:

NS (Minivan Platform)

👋 Introduction

Market Segment:

Full-size Minivan

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana

Versatility:

Renowned for its flexible seating arrangements (Stow 'n Go not yet available in this generation), ample cargo space, and family-friendly features.

Reliability Perception:

Generally considered a reliable family vehicle, with common issues often related to aging components rather than inherent design flaws.

Diy Support:

Empowers DIY mechanics and owners to perform repairs and maintenance, saving on labor costs and extending vehicle lifespan.

📋 Manual Details

General Coverage:

Comprehensive workshop and repair service for the specified Dodge Grand Caravan models.

Estimated Page Count:

1500-2500+ (typical for comprehensive workshop manuals of this era, specific PDF count may vary)

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Powertrain:

Engine (3.3L, 3.8L V6), Transmission (4-speed Automatic - 41TE/42LE), Drivetrain (FWD)

Chassis:

Suspension (Front/Rear), Steering, Brakes (ABS, conventional), Wheels and Tires

Electrical:

Starting and Charging System, Ignition System, Lighting, Instrumentation, Wiper/Washer System, Power Accessories (windows, locks, doors), Audio System, HVAC Controls, Body Control Module (BCM)

Body And Frame:

Body panels, Doors, Glass, Upholstery, Exterior trim, Interior trim, Seats, Body sealing

HVAC:

Heating, Ventilation, Air Conditioning (System components, refrigerant, diagnosis)

Safety Systems:

Airbags, Seat Belts, ABS System

Maintenance:

Fluid changes (oil, coolant, brake, transmission), Filter replacements, Spark plug service, Belt inspection/replacement, Tire rotation/pressure checks

Diagnostics:

Troubleshooting guides for common symptoms, Diagnostic Trouble Codes (DTCs), Wiring diagrams, Component testing

Repair:

Engine repair (head gasket, timing components), Transmission overhaul, Brake caliper replacement, Suspension component replacement, Electrical component repair/replacement, Body panel repair

Disassembly Reassembly:

Step-by-step instructions for component removal and installation, torque specifications, special tool requirements

Depth Of Coverage:

Intermediate to Expert: Covers routine maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures and wiring schematics.

📊 Manual Specifications

File Quality:

High-resolution scan, readable text, often searchable

Printability:

Designed for printing, allowing users to print specific sections or the entire manual.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Option 1:

3.3L (3301cc) OHV V6

Engine Option 2:

3.8L (3778cc) OHV V6

3.3L Horsepower:

Approx. 180 hp @ 5000 rpm

3.3L Torque:

Approx. 205 lb-ft @ 3600 rpm

3.8L Horsepower:

Approx. 200 hp @ 5000 rpm

3.8L Torque:

Approx. 232 lb-ft @ 4000 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Coolant Type:

Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) coolant, typically orange or pink. Refer to manual for specific Mopar part numbers (e.g., 05013457AA or equivalent).

Spark Plugs 3.3L:

Champion Copper Plus (e.g., RC12MCC) or equivalent, gap 0.045 inches

Spark Plugs 3.8L:

Champion Copper Plus (e.g., RC12LYCC) or equivalent, gap 0.045 inches

🔧 Transmission

Transmission Type:

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

Optional Transmission:

N/A (All models for these years featured the 4-speed automatic)

Drive Wheels:

Front Wheel Drive (FWD)

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 4, Mopar P/N 05013457GA or equivalent). Avoid ATF+3 or Dexron/Mercon.

Transmission Fluid Capacity:

Approx. 4.7 Quarts (4.4 Liters) for dry fill, less for a simple drain and fill (approx. 3.5-4 Quarts).

📐 Dimensions

Wheelbase:

Approx. 120.0 inches

Length:

Approx. 197.7 inches

Width:

Approx. 76.7 inches

Height:

Approx. 67.5 inches

Max Cargo Volume:

Approx. 145.4 cu ft (with second and third rows folded/removed)

Curb Weight:

Approx. 4200-4500 lbs (depending on engine and trim)

Gross Vehicle Weight Rating Gvwr:

Approx. 5700-5800 lbs

Standard Wheel Size:

15-inch or 16-inch steel or alloy wheels

Standard Tire Size:

215/65R16 or 225/60R16 (check specific trim)

Bolt Pattern:

5x114.3 mm (5x4.5 inches)

🛡️ Safety Features

NHTSA Frontal Impact Driver:

4/5 Stars (2002-2004 models, specific year ratings may vary slightly)

NHTSA Frontal Impact Passenger:

4/5 Stars (2002-2004 models)

NHTSA Side Impact Driver:

4/5 Stars (2002-2004 models)

NHTSA Side Impact Rear Passenger:

4/5 Stars (2002-2004 models)

ABS:

Standard Anti-lock Braking System

Traction Control:

Available on some models/trims

Airbags:

Driver and front passenger airbags. Available side curtain airbags on later production models.

Seat Belts:

3-point seat belts for all seating positions, front seat belt pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM stereo with cassette and CD player. Optional Infinity premium sound system available. Manual covers basic operation, fuse locations, and speaker replacement.

Cruise Control:

Standard cruise control system. Manual details operation and troubleshooting.

Remote Keyless Entry:

Available on most trims. Manual covers reprogramming procedures.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Consult manual for severe vs. normal service. Use synthetic blend or full synthetic for longer intervals.

Transmission Fluid Change Interval:

Every 30,000-60,000 miles, or as recommended by manual, especially with towing or heavy use. ATF+4 is designed for longer life but regular checks are advised.

Coolant Change Interval:

Initial change at 100,000 miles or 5 years, then every 60,000 miles or 3-5 years thereafter. Use HOAT coolant.

Air Filter Replacement:

Every 15,000-30,000 miles or when visually dirty.

Engine Oil Specification:

SAE 5W-30, meeting Chrysler MS-6395 specification. Capacity approximately 4.5 quarts (4.25 Liters) for 3.3L, 5.0 quarts (4.7 Liters) for 3.8L.

Brake Fluid Specification:

DOT 3 (or DOT 4 if specified by manual). Mopar Brake Fluid (P/N 04549686AB or equivalent).

Power Steering Fluid Specification:

Mopar Power Steering Fluid (P/N 04549688AB or equivalent) or generic ATF+3/ATF+4 compatible fluid.

Common Issue 1:

Transmission solenoids (especially for harsh shifting or failure to engage gears), often related to ATF+4 maintenance. Manual provides diagnostic steps.

Common Issue 2:

Rear heat core leaks, causing coolant loss and cabin moisture/fogging. Manual details system diagnostics and repair.

Common Issue 3:

EGR (Exhaust Gas Recirculation) valve issues leading to rough idling or stalling. Manual covers cleaning and replacement procedures.

Common Issue 4:

Fuel pump failures. Manual provides replacement procedures.

Common Issue 5:

Power window motor failures. Manual details diagnosis and replacement of regulators and motors.

📚 Vehicle History

Dodge Legacy:

Dodge has a long history of producing robust and practical vehicles, with the Caravan line representing a significant contribution to the minivan segment.

Generation Nickname:

Third Generation (GS/NS), 1996-2007. This specific manual covers the facelifted phase of this generation.

Facelift Updates:

The 2001-2007 models received significant styling updates over the original 1996 design, including revised front and rear fascias, updated interiors, and improved powertrains.

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

🏆 Awards & Recognition

Historical Recognition:

The Grand Caravan, as part of the Caravan family, has historically been a segment leader and award winner for utility and practicality. Specific awards for 2002-2004 models would be found in automotive reviews of those years.