2004 Dodge Caravan Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2004 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics, professional technicians....

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标签: 2004 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform:

NS (Third Generation)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, fleet operators, DIY mechanics, professional technicians.

Competitive Analysis

Competitors 2004:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza, Kia Sedona.

Key Features

Vehicle Strengths:

Spacious interior, versatile seating configurations, Stow 'n Go seating (available on later models of this generation but not standard on all 2004 trims), affordable pricing, robust powertrain options.

Manual Value Proposition:

Provides comprehensive DIY repair capabilities, reduces dealership service costs, ensures proper maintenance for longevity.

📋 Manual Details

Coverage Areas

General:

Comprehensive service and repair for all aspects of the 2004 Dodge Caravan.

Page Count

Estimated:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Primary:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine performance, fuel system, exhaust system, cooling system, lubrication system, starting and charging system, ignition system.

Drivetrain:

Automatic Transmission (41TE/42LE), Front-Wheel Drive (FWD), Axles, Drivelines, Torque Converter.

Chassis:

Braking system (ABS, RWAL), Steering system, Suspension system (front and rear), Wheels and tires.

Body:

Body structure, exterior panels, doors, windows, interior trim, HVAC system, seating systems.

Electrical:

Wiring diagrams, lighting system, instrument cluster, power accessories, body control module (BCM), Powertrain Control Module (PCM), audio system, airbags (SRS).

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil change procedures, fluid checks and top-offs, filter replacements, tire rotations.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics.

Repair:

Step-by-step repair instructions for all major components, including engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal.

Component Replacement:

Detailed instructions for replacing common wear items like spark plugs, belts, hoses, batteries, alternator, starter motor, water pump, fuel pump, radiators.

Specifications:

Torque specifications, electrical component resistance values, fluid capacities and types, alignment specifications, engine timing specifications.

Technical Depth

Level:

Expert-level detailed, covering complete engine overhaul, transmission rebuild, and advanced electrical diagnostics.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF with clear diagrams and text.

Print Quality

Scalability:

Printable pages with clear graphics and readable text at various zoom levels.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1 Option:

3.3L V6 OHV 12-Valve (EGA)

Engine 1 Displacement:

3301 cc

Engine 1 Horsepower:

180 hp @ 5000 rpm

Engine 1 Torque:

205 lb-ft @ 3400 rpm

Optional Engine

Engine 2 Option:

3.8L V6 OHV 12-Valve (L32)

Engine 2 Displacement:

3778 cc

Engine 2 Horsepower:

200 hp @ 5000 rpm

Engine 2 Torque:

230 lb-ft @ 3200 rpm

Fuel System

Induction Type:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Management

ECU Type:

Powertrain Control Module (PCM)

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Model:

41TE (with 3.3L) / 42LE (with 3.8L)

Optional

Optional Transmission:

N/A for 2004 model year

Features

Overdrive:

Torque Converter Lockup:

Electronically controlled

📐 Dimensions

Exterior

Wheelbase:

119.3 inches

Overall Length:

189.6 inches

Overall Width:

76.0 inches

Overall Height:

67.5 inches

Interior

Seating Capacity:

7 passengers (2-2-3 configuration standard)

Cargo

Cargo Volume Behind 1St Row:

Approx. 146.5 cu. ft.

Cargo Volume Behind 2Nd Row:

Approx. 74.2 cu. ft.

Cargo Volume Behind 3Rd Row:

Approx. 25.7 cu. ft.

Weights

Curb Weight Min:

Approx. 4,250 lbs

Gross Vehicle Weight Rating Gvwr:

Approx. 5,600 lbs

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

5-Star (2004 Model Year)

NHTSA Frontal Passenger:

5-Star (2004 Model Year)

NHTSA Side Driver:

4-Star (2004 Model Year)

NHTSA Side Rear Passenger:

4-Star (2004 Model Year)

Active Features

Standard on all models (Rear Wheel Anti-lock - RWAL on some base models, 4-wheel ABS on higher trims)

Traction Control:

Optional on some models

Passive Features

Airbags:

Driver and front passenger airbags (SRS), Optional side-impact airbags.

Seat Belts:

Three-point seat belts in all seating positions, LATCH child seat anchors.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player and optional cassette tape. Available premium audio with amplifier and rear entertainment system (RES) on higher trims.

Rear Entertainment:

Optional overhead or seat-mounted DVD player with integrated screen on select models.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Sensors:

Optional rear park assist system.

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions often available.

Bluetooth:

Not available from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (with synthetic blend or full synthetic oil).

Air Filter Replacement:

Every 30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Every 100,000 miles (for iridium-tipped spark plugs, typically installed from the factory).

Transmission Fluid Service:

Inspect every 30,000 miles, change fluid and filter every 60,000 miles or as indicated by fluid condition.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified, Synthetic Blend or Full Synthetic recommended for longer drain intervals).

Engine Oil Capacity:

3.8 Liters (4.0 Quarts) for 3.3L engine, 4.3 Liters (4.5 Quarts) for 3.8L engine (filter included).

Coolant Type:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Prediluted (50/50).

Coolant Capacity:

Approx. 12.5 Liters (13.2 Quarts)

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid)

Transmission Fluid Capacity:

Approx. 4.2 Liters (4.5 Quarts) for fluid change with filter, 8.5 Liters (9.0 Quarts) for complete overhaul.

Known Issues

Engine:

Head gasket leaks (especially on earlier 3.3L), intake manifold gasket leaks, occasional oil pressure sensor failures.

Transmission:

Torque converter shudder or failure, solenoid pack issues, potential for planetary gear set wear in high-mileage units.

Suspension:

Worn control arm bushings, ball joints, and tie rod ends due to vehicle weight and typical usage.

Electrical:

Faulty power window regulators, HVAC blower motor resistor failure, intermittent dashboard warning lights.

📚 Vehicle History

Brand Heritage

Dodge History:

Dodge, established in 1914, has a long history of producing robust and practical vehicles, including a significant presence in the minivan segment.

Model Evolution

Caravan Genesis:

The Dodge Caravan, along with its Plymouth Voyager counterpart, is credited with creating the minivan segment in the early 1980s.

Third Generation Ns:

The 2004 model year represents the final year of the third-generation (NS) Caravan, which debuted for the 1996 model year with significant updates including longer wheelbase options and improved aerodynamics.

Production

Production Location:

Windsor, Ontario, Canada (Dodge Caravan production plant).

Production Years Ns Gen:

1996-2004

🏆 Awards & Recognition

Recognitions

Initial Reception:

The original Caravan revolutionized the automotive market and consistently received positive reviews for practicality and value upon its introduction.

Ratings

Consumer Reports Historical:

Varied over the generation; early third-gen models generally rated average to above average for the class, with some reliability concerns in later years reported.

Certifications

Manual Certification:

Represents factory service procedures, adhering to all automotive engineering standards for Chrysler Group.