Dodge Caravan 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2004 Body Style: Minivan Codes Platform: NS (4th Generation Dodge Caravan) 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families,...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Body Style:

Minivan

Codes

Platform:

NS (4th Generation Dodge Caravan)

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Target Audience:

Families, DIY mechanics, professional repair shops

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Plymouth Voyager, Chrysler Town & Country

Key Features

Vehicle Attributes:

Spacious interior, flexible seating, comfortable ride, practical for families

Manual Value Proposition:

Provides detailed, authoritative information for accurate repair and maintenance, saving time and money.

📋 Manual Details

Coverage Areas

Covered Models:

All 2004 Dodge Caravan models

Engine Coverage:

2.4L I4, 3.3L V6, 3.8L V6

Transmission Coverage:

4-speed automatic transmission (41TE, 42LE)

Page Count

Approximate Pages:

Over 1800

Manual Type

Type:

Factory Service Repair Manual (FSM)

Purpose:

Repair, diagnosis, maintenance, and specifications

Language

Language:

English

Format

Format:

Digital (PDF)

Searchability:

Fully searchable PDF text

Printability:

Printable individual pages or sections

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel and emissions, ignition, cooling, lubrication, exhaust, powertrain control module (PCM), transmission (automatic)

Chassis:

Brakes (ABS, power, parking), steering, suspension (front and rear), wheels and tires

Electrical:

Battery, charging system, starting system, lighting, instrumentation, fuses, relays, body electrical, power accessories, HVAC controls, airbag system

Body:

Body construction, exterior trim, interior trim, doors, windows, seats, HVAC system (operation and components), body and frame

Procedures Included

Maintenance:

Routine inspections, fluid changes, filter replacements, tune-ups

Diagnosis:

Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting charts, wiring diagrams, flowcharts

Repair:

Component removal and installation, overhaul procedures, assembly and disassembly instructions

Adjustment:

Wheel alignment, parking brake adjustment, clutch adjustment (if applicable)

Special Tools:

Identification and usage of specialized tools required for specific repairs

Technical Depth

Depth:

Comprehensive: from basic fluid checks to full engine and transmission rebuilds, detailed electrical schematics

Diagnostic Level:

Advanced: includes diagnostic procedures for all major systems and electronic controls

📊 Manual Specifications

File Format

Format Type:

Print Quality

Image Resolution:

High-resolution scans suitable for screen viewing and printing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.4 L (147 cu in)

Engine 1 Configuration:

Inline-4 (DOHC)

Engine 1 Power:

150 hp @ 5800 rpm (approx.)

Engine 1 Torque:

170 lb-ft @ 4000 rpm (approx.)

Secondary Engine

Engine 2 Displacement:

3.3 L (200 cu in)

Engine 2 Configuration:

V6 (OHV)

Engine 2 Power:

180 hp @ 5000 rpm (approx.)

Engine 2 Torque:

205 lb-ft @ 3600 rpm (approx.)

Tertiary Engine

Engine 3 Displacement:

3.8 L (230 cu in)

Engine 3 Configuration:

V6 (OHV)

Engine 3 Power:

195 hp @ 5200 rpm (approx.)

Engine 3 Torque:

230 lb-ft @ 3200 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transaxle

Transmission Code 1:

Transmission Code 2:

Optional

Optional Transmission:

Not applicable for 2004 model year

Features

Transmission Features:

Electronically controlled, lock-up torque converter

📐 Dimensions

Exterior

Wheelbase:

112.1 inches (2847 mm)

Length:

189.7 inches (4818 mm)

Width:

72.0 inches (1829 mm)

Height:

67.2 inches (1707 mm)

Interior

Passenger Volume:

Approx. 130 cu ft

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 15 cu ft

Cargo Volume Behind 2Nd Row:

Approx. 45 cu ft

Cargo Volume Max:

Approx. 130 cu ft (with 2nd & 3rd rows folded/removed)

Weights

Curb Weight:

Starting around 3800 lbs (1724 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5500 lbs (2495 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4 out of 5 stars (for most configurations)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional traction control system (TCS)

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags

Seatbelts:

Three-point seat belts for all occupants, LATCH child seat anchors

Rollover Protection:

Reinforced roof structure

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional cassette player, optional premium audio systems

Navigation:

Not available from factory for this model year

Driver Assistance

Cruise Control:

Standard on most trims

Rear Parking Aid:

Optional parking assist system

Connectivity

Auxiliary Input:

Not available from factory

Bluetooth:

Not available from factory

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 6,000 miles (5,000 - 10,000 km) or 6 months, depending on driving conditions and oil type used.

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km)

Spark Plug Replacement:

Every 60,000 - 100,000 miles (96,000 - 160,000 km), depending on plug type (e.g., platinum/iridium)

Transmission Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), or as recommended by severe service schedule.

Fluid Specifications

Engine Oil Specification:

API Certified SAE 5W-30 (check owner's manual for exact viscosity based on temperature)

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) for 2.4L I4; Approx. 4.5 quarts (4.3 liters) for V6 engines (check dipstick)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (typically purple)

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 4)

Power Steering Fluid:

ATF+4 or specified power steering fluid

Brake Fluid Type:

DOT 3

Known Issues

Common Problem 1:

Headliner sagging

Common Problem 2:

Transmission issues (slipping, harsh shifting, particularly in older models)

Common Problem 3:

Heater core leaks (often indicated by a sweet smell inside the cabin or fogged windows)

Common Problem 4:

Power door lock or window actuator failures

Common Problem 5:

Front suspension wear (e.g., ball joints, tie rods)

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Corporation (at the time)

Model Evolution

Generation:

4th Generation (NS Body Style: 1996-2000, with significant updates for 2001-2007)

Updates For 2004:

Minor styling tweaks, potential interior enhancements and feature availability changes.

Production

Manufacturing Plant:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Production Years:

1996-2007 (for the NS platform, with significant updates in 2001)

🏆 Awards & Recognition

Recognitions

Award Type:

MotorTrend's Import Car of the Year (for related Chrysler Group Minivans in previous generations)

Consumer Ratings:

Generally positive for practicality and utility, mixed reviews on reliability compared to some competitors.

Certifications

Certification:

N/A (Vehicle safety certifications covered under safety section)