Target Audience:
Families, fleet operators, and automotive service professionals.
Competitors:
Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Vans.
Vehicle Attributes:
Spacious interior, versatile seating configurations, available all-wheel drive, comfortable ride, a wide array of powertrain options.
Manual Value Proposition:
Provides comprehensive factory-level repair information, empowering owners and technicians to perform maintenance and repairs accurately and efficiently, saving on labor costs.
Models Covered:
Chrysler Town & Country (FWD, AWD), Dodge Caravan/Grand Caravan (FWD, FWD C/V, AWD, AWD C/V), Chrysler Voyager/Grand Voyager (FWD, AWD, FWD LHD, AWD LHD, FWD RHD, AWD RHD)
Engine Variants Covered:
2.4L 4-Cyl 16-Valve DOHC (MPI), 3.3L 6-Cyl SMPI, 3.8L 6-Cyl SMPI, 2.5L 4-Cyl 16-Valve Turbo Diesel (RS 2.5L Diesel Supplement)
Chassis Types:
Both Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations are covered.
Estimated Pages:
Detailed, extensive coverage implies 1500+ pages (typical for a complete factory service manual of this era).
Content Density:
Hundreds of photos and illustrations accompany step-by-step instructions, providing visual clarity for complex procedures.
Type:
Factory Service Repair Workshop Manual
Powertrain:
Engine Mechanical, Engine Fuel System, Engine Lubrication, Engine Cooling, Engine Electrical, Ignition Control, Exhaust System, Fuel System, Transmission/Transaxle (including differentials and driveline), Clutch (for manual transmission applications if applicable).
Chassis:
Suspension (Front and Rear), Steering, Brakes (Front and Rear, including ABS), Wheels and Tires, Frame and Bumpers.
Body And Electrical:
Body (Structure, Doors, Glass, Interior Trim), Heating and Air Conditioning (HVAC), Electrical Systems (Power Distribution, Lighting, Instruments, Audio, Message Systems, Horn, Wipers/Washers, Restraints/Airbags, Speed Control, Vehicle Theft Security), Wiring Diagrams.
Emissions Control:
Covers emission control systems, components, and diagnostic procedures to meet regulatory standards.
Body Repair:
Includes procedures for body panel repair, door adjustments, glass replacement, and interior trim removal/installation.
Maintenance:
Lubrication and Maintenance schedules, fluid specifications, filter replacements, tune-ups, inspections.
Repair And Rebuild:
Step-by-step instructions for component disassembly, repair, reassembly, and installation. Includes major overhauls and rebuilds.
Diagnostics And Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation (OBD-II), troubleshooting flowcharts, electrical circuit analysis.
Electrical Diagnostics:
Detailed wiring diagrams, component locations, pin-out charts, and diagnostic procedures for all electrical systems, including power windows, locks, climate control, and instrument cluster.
Depth:
Comprehensive factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Covers everything from basic fluid changes to complex powertrain and electrical system diagnostics and repairs.
Torque Specifications:
Precise torque values for all fasteners (engine, suspension, brakes, body, etc.) are provided, crucial for correct assembly and preventing damage.
2.4L DOHc (Mpi):
Engine Code: EDZ. Displacement: 2378 cc. Bore x Stroke: 87.5 x 98.0 mm. Compression Ratio: 9.8:1. Horsepower: 150 hp @ 5800 rpm. Torque: 160 lb-ft @ 4400 rpm. Fuel System: Multi-point Fuel Injection (MPI).
3.3L Smpi:
Engine Code: EDB. Displacement: 3301 cc. Bore x Stroke: 96.0 x 76.0 mm. Compression Ratio: 9.1:1. Horsepower: 180 hp @ 5000 rpm. Torque: 205 lb-ft @ 4000 rpm. Fuel System: Sequential Multi-Point Fuel Injection (SMPI).
3.8L Smpi:
Engine Code: EGS. Displacement: 3778 cc. Bore x Stroke: 96.0 x 86.0 mm. Compression Ratio: 8.5:1. Horsepower: 200 hp @ 5000 rpm. Torque: 240 lb-ft @ 3200 rpm. Fuel System: Sequential Multi-Point Fuel Injection (SMPI).
2.5L Turbo Diesel:
Engine Code: RSE. Displacement: 2499 cc. Configuration: 4-cylinder, turbocharged, intercooled. Fuel System: Indirect Injection (IDI) with Turbocharging. Horsepower/Torque: Specific figures vary, but typically around 100-115 hp and 200-230 lb-ft torque for this era of diesel in this application.
Fuel Type:
Unleaded gasoline (91 AKI or higher recommended for optimal performance, but 87 AKI acceptable for 3.3L and 3.8L). Diesel fuel for diesel variant.
Automatic:
4-speed automatic transaxle (e.g., 41TE, 42LE variants) standard on gasoline engines.
Manual:
5-speed manual transaxle might have been available on some base models or specific markets for the 2.4L engine, though less common in North America for this generation.
AWD Integration:
Integrated with AWD systems for models equipped with all-wheel drive, featuring a transfer case and rear differential.
Wheelbase:
Standard: ~113.0 inches. Grand: ~119.0 inches. Voyager/Grand Voyager dimensions may vary slightly by region.
Length:
Varies by model (Caravan/Voyager shorter than Grand Caravan/Grand Voyager). Approx. 188-195 inches for standard wheelbase, 199-205 inches for long wheelbase.
Cargo Volume:
Highly configurable with Stow 'n Go seating (introduced in later generations, but removable/fold-flat seating was a feature). Typical cargo volume behind the first row exceeding 100 cubic feet.
Curb Weight:
Approx. 3800-4500 lbs depending on configuration (engine, drivetrain, trim).
NHTSA Front Crash:
Generally good for the era, often receiving 4 or 5 stars (manual would detail specific test results if available).
IIHS Side Impact:
Good to Acceptable for the era (manual would detail specific test results if available).
ABS:
Anti-lock Braking System (ABS) standard or available on most models.
Traction Control:
Traction control system (TCS) available on some models, particularly those with AWD.
Airbags:
Front airbags standard. Side curtain airbags and/or front-seat side airbags available on higher trims or as options.
Seatbelts:
3-point seatbelts for all seating positions, often with pretensioners and load limiters.
Audio System:
Factory AM/FM/CD players, optional cassette, CD/MP3 changers, and rear-seat entertainment systems (RSE) were available. Manual covers audio system diagnostics and component replacement.
Cruise Control:
Standard or available cruise control system, detailed in the manual under 'Speed Control'.
Vehicle Theft Security:
Factory immobilizer system and optional alarm systems. Manual covers key fob programming and security system diagnostics.
Oil Change:
Typically every 7,500 miles or 6 months (or as per owner's manual/oil life monitor) using appropriate viscosity oil.
Air Filter:
Inspect every 15,000-20,000 miles, replace as needed or every 30,000 miles.
Spark Plugs:
2.4L DOHC: approximately 60,000-100,000 miles (depending on plug type, e.g., platinum/iridium). 3.3L/3.8L V6: approximately 60,000-100,000 miles (depending on plug type).
Engine Oil 3.3L/3.8L:
SAE 3.5W-30 (API certified, meeting Chrysler MS-6395 specification). Diesel engines typically require specific diesel engine oil, e.g., 5W-40 or 15W-40 API CG-4 or CH-4 rated.
Transmission Fluid 4Spd Auto:
ATF+4® (Chrysler Material Standard MS-9602). Check level and condition regularly, replace fluid and filter per maintenance schedule (e.g., every 30,000-60,000 miles).
Coolant:
Mopar® OAT (Organic Additive Technology) Antifreeze/Coolant (Chrysler Material Standard MS-9769) or equivalent HOAT (Hybrid Organic Additive Technology) coolant. Mix 50/50 with deionized water. Capacity varies by engine, approx. 10-14 quarts.
Transmission Issues:
Early 4-speed automatics (especially 41TE/42LE) can be prone to solenoid issues, torque converter shudder, or failure if fluid maintenance is neglected. Manuals cover troubleshooting and repair.
Engine Issues:
3.3L/3.8L V6s are generally robust but can develop oil leaks (valve cover gaskets, oil pan gaskets). Crankshaft position sensors can fail. 2.4L can have issues with timing belt tensioners or head gaskets if overheated.
Suspension Components:
Wear on control arm bushings, ball joints, tie rod ends, and struts/shocks is common due to vehicle weight and use. Manual provides replacement procedures.
HVAC System:
Blend door actuator failures, AC compressor clutch issues, and refrigerant leaks are common on many vehicles of this era.
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment in the US with the original Dodge Caravan and Plymouth Voyager in 1983. This 2004 model is part of the highly successful 4th generation (RS body style).
4Th Gen Features:
Introduced for the 2001 model year, featuring a revised exterior and interior, increased safety features, and powertrain enhancements. The 2.4L engine was a carryover, while the 3.3L and 3.8L V6s were popular choices. The 2.5L diesel was more common in European markets (Voyager).
Manufacturing Locations:
Primarily produced at Chrysler's Windsor Assembly Plant in Windsor, Ontario, Canada.
