Dodge Caravan 2002 2003 2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2002, 2003, 2004 Codes Platform: NS (Second Generation) 👋 Introduction Market Position Segment: Minivan Competitive Analysis Competitors: Honda Odyssey, Toyota...

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类型: Car

斯库: 446488

标签: 2002 2003 2004 Car Caravan Cars Dodge Misc

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Years Covered:

2002, 2003, 2004

Codes

Platform:

NS (Second Generation)

👋 Introduction

Market Position

Segment:

Minivan

Competitive Analysis

Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture

Key Features

Unique Selling Points:

Flexible seating arrangements, Stow 'n Go seating (introduced later generations but Caravan known for practicality), powerful V6 engine options, family-oriented design

📋 Manual Details

Coverage Areas

Coverage Scope:

Full vehicle service and repair

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, cooling, lubrication, fuel, ignition, emissions control, engine management

Transmission Systems:

Automatic transmission (4-speed, model 41TE/42LE), clutch, torque converter, shift control

Drivetrain:

Front-wheel drive, axles, CV joints, differential

Brakes:

Front disc brakes, rear drum brakes (ABS optional), hydraulic system, parking brake

Suspension:

Front independent suspension (MacPherson strut), rear torsion beam axle with trailing arms, shock absorbers, springs

Steering:

Power-assisted rack and pinion steering system

Electrical System:

Battery, charging system, starting system, lighting, instrument cluster, wiring diagrams, fuses, relays

HVAC:

Heating, ventilation, and air conditioning system components and operation

Body And Interior:

Body panels, doors, windows, seats, trim, power accessories (windows, locks), liftgate, sliding doors

Safety Systems:

Airbag system, seat belts, child restraint systems

Diagnostic Troubleshooting:

Trouble codes (DTCs), diagnostic procedures, component testing

Procedures Included

Maintenance Procedures:

Routine maintenance tasks, fluid changes, filter replacements, lubrication

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and repair

Overhaul Procedures:

Engine and transmission overhaul procedures

Specifications:

Torque specifications, clearances, fluid capacities, wear limits

Wiring Diagrams:

Comprehensive electrical wiring schematics

Troubleshooting Guides:

Systematic troubleshooting trees and symptom-based diagnostics

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to major overhauls and diagnostics

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution, suitable for printing

Binding Type

Binding Method:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.3L OHV V6 (EGA)

Engine 1 Details

Horsepower 1:

158 hp @ 4600 rpm

Torque 1:

199 lb-ft @ 3200 rpm

Bore Stroke 1:

3.92 in x 3.58 in (99.5 mm x 90.9 mm)

Compression Ratio 1:

8.5:1

Engine 2

Engine 2:

3.8L OHV V6 (L32)

Engine 2 Details

Horsepower 2:

180 hp @ 4500 rpm

Torque 2:

235 lb-ft @ 3000 rpm

Bore Stroke 2:

3.92 in x 3.98 in (99.5 mm x 101.0 mm)

Compression Ratio 2:

9.4:1

Engine 3

Engine 3:

2.4L DOHC 4-Cylinder (EDZ - for specific markets/trims, less common)

Performance

Acceleration 0 60 Est:

Approx. 9.5 - 11.5 seconds depending on engine and configuration

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 18 gallons (68 liters)

🔧 Transmission

Standard

Transmission Type Standard:

4-speed automatic transmission

Optional

Transmission Type Optional:

N/A for these model years

Features

Transmission Model:

41TE (3.3L V6), 42LE (3.8L V6)

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 9602)

📐 Dimensions

Exterior

Length:

Approx. 179.5 - 181.4 inches (4559 - 4608 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 66.9 - 68.4 inches (1699 - 1737 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm)

Interior

Seating Capacity:

7 passengers

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 20.4 cubic feet (578 liters)

Cargo Volume Behind 2Nd Row:

Approx. 49.0 cubic feet (1388 liters)

Cargo Volume Max Folding Seats:

Approx. 149.0 cubic feet (4219 liters)

Weights

Curb Weight:

Approx. 3700 - 4100 lbs (1678 - 1860 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

Approx. 5300 - 5600 lbs (2404 - 2540 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

★★★★☆ (4/5 Stars) for 2002-2004 models

NHTSA Frontal Impact Passenger:

★★★★☆ (4/5 Stars) for 2002-2004 models

NHTSA Side Impact Front Seat:

★★★★★ (5/5 Stars) for 2002-2004 models

IIHS Frontal Offset:

Good (G) for 2002-2004 models

Active Features

Available (standard on some higher trims/later years)

Traction Control:

Available (often tied to ABS)

Passive Features

Airbags Front:

Standard dual front airbags

Airbags Side:

Available side curtain airbags (optional)

Seat Belts:

3-point seat belts for all outboard positions, 2-point lap belt for center rear seat

Child Safety:

LATCH (Lower Anchors and Tethers for Children) system for rear seats

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player or cassette player, optional Infinity premium sound system

Rear Entertainment:

Optional rear-seat video system with flip-down screen

Driver Assistance

Cruise Control:

Standard

Parking Assistance:

Rear parking assist sensors (optional)

Connectivity

Phone Integration:

N/A (No factory Bluetooth or integrated smartphone connectivity)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for specifics)

Engine Air Filter Replacement:

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

Cabin Air Filter Replacement:

Every 12,000 to 15,000 miles (19,000 to 24,000 km) or annually

Spark Plug Replacement 3.3L:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) with conventional plugs, up to 100,000 miles with platinum plugs

Spark Plug Replacement 3.8L:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) with conventional plugs, up to 100,000 miles with platinum plugs

Transmission Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km)

Coolant Flush Replacement:

Every 30,000 miles (48,000 km) or 2 years

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Service SG or higher)

Engine Oil Capacity 3.3L:

Approx. 3.5 quarts (3.3 liters) with filter

Engine Oil Capacity 3.8L:

Approx. 3.5 quarts (3.3 liters) with filter

Coolant Type:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (or equivalent meeting Chrysler MS-9769)

Power Steering Fluid:

Mopar Power Steering Fluid (or equivalent meeting Chrysler MS-5901)

Brake Fluid:

DOT 3

Known Issues

Common Problems:

Transmission issues (e.g., solenoid failure, torque converter shudder), power door lock/window regulator failures, headliner sagging, ABS sensor failures, EGR valve issues, rear axle bearing noise

📚 Vehicle History

Brand Heritage

Brand Established:

Dodge, founded in 1900 as Dodge Brothers Company, became part of Chrysler Corporation in 1928.

Model Evolution

First Generation:

1984 (Chrysler/Dodge M Platform)

Current Generation Start:

1996 (NS Platform - Second Generation)

Generation Covered:

NS Platform (1996-2007), with significant updates for 2001 model year

Production

Assembly Locations:

Windsor, Ontario, Canada (Windsor Assembly Plant)

Production Years Specific To Manual:

2002, 2003, 2004

🏆 Awards & Recognition

Recognitions

Consumer Reports Ratings:

Varied across model years, often rated as average or below average in reliability for certain components, particularly transmissions.

Jd Power Dependability:

Generally received average to below-average ratings in dependability studies during this era.

Certifications

Epa Fuel Economy Est City:

Approx. 15-17 MPG (Varies by engine, check specific year for details)

Epa Fuel Economy Est Highway:

Approx. 21-24 MPG (Varies by engine, check specific year for details)