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Chrysler Caravan 2002-2004 Service Repair Workshop Manual

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The Chrysler Caravan, part of the Third Generation (RG) platform, represents a significant entry in the minivan segment, produced for the 2002, 2003, and 2004 model years. Known for its...
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Chrysler Caravan 2002-2004 Service Repair Workshop Manual
The Chrysler Caravan, part of the Third Generation (RG) platform, represents a significant entry in the minivan segment, produced for the 2002, 2003, and 2004 model years. Known for its versatility and spacious interior, this vehicle was engineered to meet the demands of family transportation, offering flexible seating arrangements and ample cargo capacity. With a focus on providing a balance of features, space, and affordability, the Caravan competes effectively in its market. Its design prioritizes practicality and passenger comfort, making it a reliable choice for daily commuting and longer journeys. This comprehensive Service Repair Workshop Manual, written in English, covers the Chrysler Caravan across its 2002-2004 production years. It details essential maintenance procedures, including oil changes, fluid checks, and component replacements for engines (3.3L V6 EGA and 3.8L V6 L32), the 4-speed automatic transaxle (41TE, 42LE), brakes, suspension, steering, HVAC, and electrical systems. The manual also includes in-depth diagnostic information, troubleshooting flowcharts, repair instructions for major components, and technical specifications, equipping owners and technicians with the knowledge to maintain and repair the vehicle effectively.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Model Generation:
Third Generation (RG)
Codes
Platform:
NS/GS Platform
👋 Introduction
Market Position
Segment:
Minivan / MPV
Target Audience:
DIY Mechanics, Independent Repair Shops, Fleet Maintenance
Competitive Analysis
Key Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture
Key Features
Versatility:
Known for its spacious interior, flexible seating arrangements, and family-hauling capabilities.
Powertrain Options:
Reliable V6 engine options provide adequate power for daily driving and hauling.
Value Proposition:
Offered a strong balance of features, space, and affordability in its segment.
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003, 2004
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
3.3L V6 (EGA), 3.8L V6 (L32)
Transmission:
4-Speed Automatic Transaxle (41TE, 42LE)
Brakes:
Front Disc / Rear Drum, Optional ABS
Suspension:
Independent Front (MacPherson Strut), Rear Beam Axle with Track Bar
Steering:
Power Rack and Pinion
Electrical:
Complete System Diagnosis, Wiring Diagrams, Fuses, Relays, Lighting, Power Accessories
HVAC:
Air Conditioning, Heating, Ventilation System Operation and Repair
Body:
Interior and Exterior Trim, Doors, Glass, Body Panels, Chassis
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks, Lubrication, Belt and Hose Inspection/Replacement
Diagnostics:
On-Board Diagnostics (OBD-II), Diagnostic Trouble Codes (DTCs), Troubleshooting Flowcharts
Repair:
Engine Overhaul, Transmission Rebuild, Brake Component Replacement, Suspension Component Replacement, Electrical Component Repair
Installation:
Component Replacement Procedures (e.g., Alternator, Starter, Water Pump)
Specifications:
Torque Specifications, Clearance Measurements, Component Data
Technical Depth
Depth:
Comprehensive: From basic maintenance to complete engine and transmission overhaul, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Clarity:
High Resolution Diagrams and Illustrations
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Displacement 1:
3.3 Liters (201.6 cu. in.)
Configuration 1:
SOHC V6
Horsepower 1:
180 hp @ 5000 rpm (approx.)
Torque 1:
205 lb-ft @ 3600 rpm (approx.)
Optional Engine
Engine Code 2:
L32
Displacement 2:
3.8 Liters (230.5 cu. in.)
Configuration 2:
OHV V6
Horsepower 2:
193 hp @ 4600 rpm (approx.)
Torque 2:
230 lb-ft @ 3200 rpm (approx.)
Fuel System
Induction:
Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
20 gallons (75.7 Liters)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic Transaxle
Transmission Model 1:
41TE
Transmission Model 2:
42LE (with optional AWD)
Features
Drive Type:
Front-Wheel Drive (FWD), Optional All-Wheel Drive (AWD)
Fluid Type:
ATF+4 (Chrysler Material Number 05010057GA or equivalent)
📐 Dimensions
Exterior
Length:
187.7 - 194.5 inches (4768 - 4940 mm) depending on configuration
Width:
72.0 inches (1829 mm)
Height:
67.0 - 69.2 inches (1702 - 1758 mm) depending on configuration
Interior
Seating Capacity:
7 Passengers (2-2-3 or 2-3-3 configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.7 - 30.0 cu. ft. (depending on model)
Cargo Volume Behind 2Nd Row:
Approx. 86.0 - 97.6 cu. ft. (depending on model)
Cargo Volume Max:
Approx. 143.7 - 165.8 cu. ft. (depending on model)
Weights
Curb Weight:
Approx. 4000 - 4300 lbs (1814 - 1950 kg)
Gross Vehicle Weight Rating:
Approx. 5700 - 6000 lbs (2585 - 2722 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (2002 Model Year)
NHTSA Frontal Impact Passenger:
4 Stars (2002 Model Year)
NHTSA Side Impact Front Seat:
4 Stars (2002 Model Year)
NHTSA Side Impact Rear Seat:
4 Stars (2002 Model Year)
Active Features
ABS:
Standard on most trims, optional on lower trims
Traction Control:
Optional on some models
Passive Features
Airbags Front:
Driver and Front Passenger Airbags
Airbags Side:
Optional Side Curtain Airbags (later years/higher trims)
Seatbelts:
Three-point seatbelts for all seating positions
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, optional premium audio systems, and rear-seat entertainment options.
Navigation:
Optional factory navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims
Parking Sensors:
Optional rear parking assist sensors
Connectivity
Power Outlets:
Multiple 12V power outlets for device charging.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (check owner's manual for specific conditions).
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), or as per severe duty recommendations.
Coolant Change:
Every 30,000 - 100,000 miles (48,000 - 160,000 km), depending on coolant type.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Certified)
Engine Oil Capacity:
4.5 quarts (4.2 liters) for 3.3L; 4.5 quarts (4.2 liters) for 3.8L
Coolant Type:
Chrysler OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) compatible coolant (e.g., Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula).
Brake Fluid Type:
DOT 3
Known Issues
Transmission Reliability:
Some models may experience issues with the automatic transmission, particularly with solenoid packs or torque converters. Regular fluid changes are crucial.
Power Sliding Doors:
Electric motor or cable issues can affect power sliding door operation. Manual lubrication and adjustment are often key.
Suspension Wear:
Worn tie rod ends, ball joints, and struts are common due to the vehicle's weight and family usage.
Ignition System:
Spark plug and ignition coil failures can occur, leading to misfires and reduced performance.
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler has a long history of innovation in the minivan segment, pioneering many features.
Model Evolution
Third Generation:
The 2001-2007 generation introduced a sleeker design, improved safety, and more powerful engine options compared to its predecessor.
Facelift Timing:
Mid-cycle refresh occurred for the 2005 model year, with minor updates for 2002-2004.
Production
Manufacturing Location:
Windsor, Ontario, Canada; Saint Louis, Missouri, USA
Production Years:
2001-2007 (RG Platform)
🏆 Awards & Recognition
Recognitions
Car And Driver:
Often ranked among the best family vehicles and praised for practicality and value by publications like Car and Driver.
Jd Power Initial Quality:
Received mixed to average ratings in initial quality studies during this period, reflecting common automotive industry challenges of the era.
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