Market Position:
The 2004 Dodge Caravan was a highly popular minivan, a segment leader for practical family transportation. This manual caters to DIY mechanics and professional technicians working on a widely used vehicle.
Competitors:
Competed directly with vehicles like the Honda Odyssey, Toyota Sienna, Ford Windstar, and Chevrolet Venture.
Key Features:
Known for its Stow 'n Go seating (introduced on some trims later), flexible interior, and robust powertrain options for its class.
Model Context:
The 2004 Caravan represents a mature product in Chrysler's minivan lineage, offering established reliability and functionality for families.
Systems:
Engine mechanical, engine performance, fuel system, ignition system, exhaust system, cooling system, lubrication system, transmission (automatic), drivetrain, suspension, steering, brakes, HVAC, body electrical, body panels, interior, safety systems, diagnostics, troubleshooting.
Procedures:
Routine maintenance, inspection, repair, overhaul, replacement, adjustment, diagnosis, troubleshooting, wiring diagrams, component locations, technical specifications, torque specifications, special tools.
Depth:
Comprehensive: from basic fluid changes and inspections to complete engine and transmission rebuilds, including advanced diagnostic procedures and wiring schematics.
Diagnostic Tools Coverage:
Includes procedures for using OBD-II scan tools for engine and transmission diagnostics, troubleshooting error codes (DTCs), and interpreting sensor data.
Electrical System Coverage:
Complete wiring diagrams for all major systems, component locations, fuse/relay information, troubleshooting guides for electrical faults.
File Format:
Searchable PDF with high-resolution diagrams and printable pages.
Print Quality:
Excellent clarity for text, diagrams, and illustrations.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Manual Completeness:
Highly comprehensive, covering all aspects of vehicle service, repair, and maintenance for the 2004 model year.
Engine Options:
2.4L (2429cc) Inline-4 (EDT) and 3.3L (3301cc) OHV V6 (EGA).
3.3L V6 Hp:
180 hp @ 5000 rpm
3.3L V6 Torque:
205 lb-ft @ 3300 rpm
Fuel System Type:
Multi-point Fuel Injection (MPI)
Spark Plug Gap:
0.040-0.045 inches (typically for Champion Platinum Plus or equivalent)
Ignition Timing:
Controlled by PCM, not adjustable (OBD-II diagnostics essential).
V6 Engine Code:
EGA (3.3L OHV V6)
Four Cylinder Engine Code:
EDT (2.4L DOHC 16V Inline-4)
Fuel Type:
Unleaded Gasoline
Transmission Type Standard:
4-speed Automatic Transaxle (41TE for V6, 41TE/42LE for 4-cyl depending on application)
Transmission Type Optional:
None (4-speed automatic was standard across most trims for this year).
Transmission Fluid Type:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Transmission Fluid Capacity:
Approx. 4.5 - 5 quarts (dry fill), 3 quarts (drain and fill)
Transmission Control:
Electronically controlled automatic transmission with overdrive.
Cargo Volume Behind First Row:
Approx. 140.5 cu ft
Curb Weight:
Approx. 3,800 - 4,200 lbs (depending on engine and configuration)
Towing Capacity:
Up to 3,800 lbs (with optional towing package and 3.3L V6)
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Standard Tire Size:
P215/65R16 (Common for most trims)
NHTSA Frontal Crash Rating Driver:
Four stars (for 2004 models)
NHTSA Frontal Crash Rating Passenger:
Four stars (for 2004 models)
ABS:
Standard on most models, optional on base trims.
Traction Control:
Optional, often paired with ABS.
Airbags:
Driver and front passenger airbags standard. Optional side airbags available on higher trims.
Seatbelts:
Three-point seatbelts for all seating positions. Integrated child seat anchors (LATCH) on rear seats.
Front Brake Type:
Ventilated Disc
Infotainment Options:
Standard AM/FM stereo with CD player or cassette tape. Optional premium audio systems and rear-seat entertainment screens available on higher trims.
Driver Assistance Features:
Limited by modern standards. Cruise control was common. Parking assist sensors were an option on some higher-trim models.
Connectivity Features:
No built-in Bluetooth or USB connectivity. Aftermarket solutions were common.
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendation).
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Around 100,000 miles for platinum or iridium plugs (e.g., Champion Platinum Plus).
Engine Oil Specification:
API Certified SAE 5W-30 (for V6), SAE 10W-30 (for 4-cyl, check manual for exact spec).
Coolant Specification:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, P/N 68048553AA (or equivalent magenta coolant).
Brake Fluid Specification:
DOT 3
Common Problems:
Transmission solenoid issues (especially 41TE/42LE), water pump leaks, power steering pump failure, EGR valve clogging, ignition coil failures, rear axle bearing noise.
Common Problems Details:
The 41TE/42LE automatic transmission is prone to internal wear and solenoid issues, often manifesting as shifting problems. The water pump is a common leak point, often requiring replacement along with the serpentine belt and tensioner.
Engine Oil Capacity:
4.5 quarts (4.3 L) with filter change (for 3.3L V6).
Brand Heritage:
Dodge, as a division of Chrysler, has a long history in American automotive manufacturing, known for its performance and utility vehicles.
Generation Overview:
The 2004 Caravan is part of the third generation (RS) of the Dodge Caravan, which ran from 1996-2007. This generation saw significant redesigns and refinements over its lifespan.
Manufacturing Plant:
Windsor, Ontario, Canada; Saltillo, Mexico.
Production Years For Model:
1996-2007 (third generation)
Minivan Pioneer:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan and Plymouth Voyager, setting standards for space and versatility.
