Dodge Caravan 2004 Factory Service Repair Manual.zip

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2004 Platform: NS (Second Generation) Codes Vehicle Type: Minivan 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families seeking versatile...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Platform:

NS (Second Generation)

Codes

Vehicle Type:

Minivan

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Target Audience:

Families seeking versatile and practical transportation.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture.

Key Features

Versatility:

Flexible seating arrangements, ample cargo space, and a focus on practicality.

Value Proposition:

Offered a competitive package of features and space at an attractive price point.

Reliability Reputation:

Generally considered a reliable and robust vehicle, especially with proper maintenance.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Distribution Method:

Digital Download (ZIP archive)

Requirements:

Adobe PDF Reader, WinZip

Compatibility:

All Versions of Windows & Mac

File Format

File Type:

Searchability:

Likely searchable text within the PDF (dependent on source conversion).

Zoom Functionality:

Yes, allows zooming in and out of diagrams and text.

Printability:

Likely printable, enabling users to print specific sections or the entire manual.

📖 Manual Coverage

Systems Covered

Engine Systems:

Complete coverage of engine operation, diagnostics, and repair for all gasoline and diesel variants.

Cooling System:

Detailed procedures for radiator, water pump, thermostat, hoses, and coolant system maintenance and repair.

Fuel System:

Covers fuel pump, injectors, fuel filter, fuel tank, and evaporative emissions control system.

Exhaust System:

Includes repair and replacement of exhaust pipes, muffler, catalytic converter, and turbocharger (where applicable).

Transmission Transaxle:

Comprehensive coverage for automatic transmission service, repair, and diagnostics.

Brakes:

Detailed information on hydraulic system, brake lines, calipers, rotors, pads, ABS, and parking brake.

Suspension:

Covers front and rear suspension components, including struts, shocks, control arms, ball joints, and sway bars.

Steering:

Includes power steering system, steering gear, tie rods, and steering column.

Electrical Systems:

Extensive coverage of battery, charging system, starting system, lighting, power accessories, and body electrical.

Heating Air Conditioning:

Detailed service and repair for HVAC system, including refrigerant, compressor, evaporator, and heater core.

Body:

Covers body panels, doors, interior trim, glass, and related hardware.

Frame Bumpers:

Information on frame structure, front and rear bumpers, and collision repair.

Emissions Control:

Covers emission control systems, diagnostic trouble codes (DTCs), and testing procedures for all engine variants.

Audio System:

Covers factory audio system, speakers, wiring, and common repair procedures.

Instrument Cluster:

Detailed information on gauges, warning lights, and cluster diagnostics.

Lamps:

Covers headlights, taillights, interior lighting, and associated wiring.

Restraints:

Information on airbags, seat belts, and SRS system diagnostics and service.

Speed Control:

Covers cruise control system operation and repair.

Vehicle Theft Security:

Information on factory security systems and immobilizer.

Wipers Washers:

Covers wiper motor, linkage, blades, and washer fluid system.

Wiring Diagrams:

Extensive electrical wiring diagrams for all vehicle systems.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement, and general inspections.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all systems.

Diagnostic Procedures:

Troubleshooting guides and diagnostic steps for identifying and resolving common and complex issues.

Rebuilding Procedures:

Detailed instructions for rebuilding engines, transmissions, and other major sub-assemblies.

Torque Specifications:

All critical torque values for fasteners and assembly procedures.

Fluid Capacities:

Precise fluid capacities for engine oil, coolant, transmission fluid, brake fluid, power steering fluid, etc.

Electrical Troubleshooting:

Detailed guides for diagnosing electrical faults using wiring diagrams and test procedures.

Alignment Specifications:

Wheel alignment specifications and procedures.

Clutch Service:

Covers clutch inspection, replacement, and related components (for manual transmission models, though the provided list implies automatic focus).

Technical Depth

Diagnostic Capability:

Advanced diagnostics, including OBD-II (On-Board Diagnostics II) systems and diagnostic trouble code interpretation.

Repair Scope:

Comprehensive repair instructions, ranging from minor adjustments to complete overhauls and rebuilds.

Diagrams Illustrations:

Detailed step-by-step diagrams and illustrations to aid in understanding complex procedures.

Special Tools:

Identification and usage of any specialized tools required for specific repairs.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L I4 (GEMA), 3.3L V6 (EGA).

Diesel Option:

2.5L Turbo Diesel (VM Motori R425) available in some markets, requiring specific manual sections.

Performance

3.3L V6 Horsepower:

Approximately 180 hp @ 5000 rpm (subject to variation).

3.3L V6 Torque:

Approximately 205 lb-ft @ 3600 rpm (subject to variation).

Fuel System

Fuel Delivery:

Multi-port fuel injection (MPI).

Recommended Fuel:

87 Octane Unleaded Gasoline.

🔧 Transmission

Standard Transmission

Automatic:

4-speed automatic transmission (41TE/42LE).

Optional Transmission

Manual:

Manual transmission was not a common option for the 2004 Dodge Caravan in North America, primarily automatic.

Features

Overdrive:

All automatic transmissions feature overdrive for improved fuel economy.

📐 Dimensions

Exterior

Wheelbase:

Approximately 113.3 inches (2878 mm).

Length:

Approximately 189.4 inches (4811 mm).

Width:

Approximately 72.4 inches (1839 mm).

Height:

Approximately 67.7 inches (1720 mm).

Cargo

Cargo Volume Behind 1St Row:

Highly variable with seat configuration, but extensive.

Weights

Curb Weight:

Varies by engine and trim, typically around 3800-4200 lbs (1724-1905 kg).

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Generally received good ratings, but specific 2004 ratings may vary by test protocol.

Active Features

Standard Anti-lock Braking System (ABS) on most models.

Passive Features

Airbags:

Standard front driver and passenger airbags. Side airbags were often optional.

Seat Belts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio Options:

Factory AM/FM stereo with CD player, cassette player (optional), and multiple speaker configurations.

Driver Assistance

Cruise Control:

Standard or optional cruise control system.

Connectivity

Power Outlets:

12V power outlets for charging accessories.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Recommended every 3,000-7,500 miles (4,800-12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult manual for specific recommendations).

Transmission Fluid Change:

Recommended every 30,000-60,000 miles (48,000-96,000 km), or as per severe service schedule.

Coolant Flush:

Recommended every 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil:

SAE 5W-30 for most engines (verify specific engine requirement in manual).

Transmission Fluid:

ATF+4 (Automatic Transmission Fluid Type 7176) is the recommended fluid for the automatic transmissions.

Coolant:

Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water, or equivalent HOAT coolant.

Known Issues

Transmission Issues:

Some models, particularly earlier ones, experienced intermittent shifting or transmission failure. Regular fluid changes are crucial.

Headlight Switch Failure:

The headlight switch assembly is a known failure point, leading to loss of headlights or other lighting functions.

Power Window Motors:

Power window motors and regulators can fail over time.

Cooling Fan Assembly:

Cooling fan motors can fail, leading to overheating.

📚 Vehicle History

Brand Heritage

Dodge Minivan Pioneer:

Dodge, along with Chrysler, is credited with pioneering the modern minivan segment with the original Caravan/Voyager.

Model Evolution

Generation:

This 2004 model is part of the second generation (NS) of the Dodge Caravan, produced from 1996 to 2007 (with a facelift in 2001).

Production

Manufacturing Location:

Primarily manufactured in North America (e.g., Windsor, Ontario, Canada; St. Louis, Missouri, USA).

🏆 Awards & Recognition

Recognitions

Segment Leader:

The Dodge Caravan was a consistent sales leader in the minivan segment for many years, indicating strong market acceptance and consumer preference.