🏷️ Basic Information

Make:

Dodge

Model:

Grand Caravan

Years Covered:

2002, 2003, 2004

Platform Code:

NS (Third Generation)

👋 Introduction

Market Position:

The Dodge Grand Caravan was a highly popular and versatile minivan, positioned as a family-oriented vehicle offering spacious interiors, flexible seating, and a comfortable ride. It was a segment leader in practicality and value for money.

Target Audience:

Families, individuals needing ample cargo and passenger space, businesses requiring a versatile vehicle for transporting people or goods.

Competitive Analysis:

Competitors during this era included the Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, and Pontiac Montana. The Grand Caravan distinguished itself with its Stow 'n Go seating (introduced later, but the underlying flexibility was a key trait) and often more aggressive pricing.

Key Features:

Front-wheel drive, available all-wheel drive (less common on this generation), three rows of seating, sliding rear doors, ample cargo space, comfortable ride quality, and a wide range of powertrain options.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Trim Level Coverage:

Likely covers all standard trim levels for the 2002-2004 Grand Caravan (e.g., SE, Sport, SXT, ES).

Page Count:

4580

Language:

English

Format:

PDF

Searchable:

Yes (typical for PDF service manuals)

Downloadable:

Instant Download

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Performance, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Air Conditioning, Manual Transmission, Automatic Transmission, Drivetrain, Suspension (Front and Rear), Steering, Brakes (Front and Rear), Wheels and Tires, Body (Interior and Exterior), Electrical System (Body and Chassis), HVAC, Body Control Modules, Powertrain Control Modules, Diagnostic Trouble Codes (DTCs), Troubleshooting and Diagnostics, Wiring Diagrams, Maintenance Schedules, Specifications and Procedures

Body And Chassis Systems:

Frame, suspension components (struts, shocks, control arms, ball joints, bushings, leaf springs), steering gear, power steering system, brake system (master cylinder, calipers, rotors, lines, parking brake), wheel bearings, hubs, exhaust system components, fuel tank and lines, body panels, doors, windows, locks, latches, interior trim, seating mechanisms, roof rack systems, trailer towing preparation.

Electrical Systems:

Battery, starter motor, alternator, ignition system, lighting (headlights, taillights, interior lights), wiring harnesses, fuses and relays, power windows, power locks, power mirrors, horn, wiper system, instrument cluster, warning indicators, onboard diagnostics (OBD-II), Body Control Module (BCM), Powertrain Control Module (PCM), Anti-lock Braking System (ABS) module, HVAC controls, audio system wiring, power sliding door modules (if equipped).

Procedures Included:

Routine maintenance, component removal and installation, diagnostic procedures, repair and overhaul instructions, torque specifications, fluid capacities and types, electrical component testing, emissions controls, body panel repair, interior trim removal, safety system checks

Engine Repair Procedures:

Cylinder head removal/installation, piston and connecting rod service, crankshaft inspection and service, camshaft timing, valve adjustment (if applicable), oil pump removal/installation, oil pan gasket replacement, coolant system flush and refill, thermostat replacement, water pump replacement, intake manifold gasket replacement, exhaust manifold gasket replacement.

Transmission Repair Procedures:

Transmission fluid and filter change, torque converter replacement, valve body service, clutch pack inspection and replacement, seal and gasket replacement, transmission removal and installation, diagnostic checks for shifting issues.

Brake System Procedures:

Brake pad replacement, brake rotor replacement, caliper service, master cylinder replacement, brake line bleeding, parking brake adjustment, ABS component testing.

Suspension And Steering Procedures:

Strut/shock absorber replacement, ball joint replacement, tie rod end replacement, control arm bushing replacement, wheel alignment procedures, power steering fluid flush, steering rack or gearbox inspection and replacement.

Hv Ac Procedures:

Refrigerant charging, compressor replacement, evaporator and condenser service, blower motor replacement, heater core replacement, cabin air filter replacement, diagnostic troubleshooting for cooling and heating issues.

Technical Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic information)

Diagnostic Troubleshooting:

Detailed symptom-based troubleshooting guides, diagnostic trouble code (DTC) definitions and diagnostic steps, electrical circuit testing using multimeters and oscilloscopes, fuel pressure testing, compression testing, vacuum testing.

Specification Tables:

Extensive tables of specifications including engine torque values, bolt tightening sequences, fluid capacities, tire pressures, wheel torque specifications, alignment settings, and electrical component resistance values.

Wiring Diagrams:

Complete, color-coded wiring diagrams for all major electrical systems, including power distribution, lighting, engine controls, HVAC, ABS, airbags, and comfort features.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, printable pages with clear diagrams and text

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

2.4L I4 (Naturally Aspirated, 150 hp @ 5600 rpm, 170 lb-ft @ 4000 rpm), 3.3L V6 (Naturally Aspirated, 180 hp @ 4700 rpm, 205 lb-ft @ 3350 rpm), 3.8L V6 (Naturally Aspirated, 200-215 hp @ 4800-5000 rpm, 230-250 lb-ft @ 3200-3600 rpm), 4.0L V6 (Naturally Aspirated, 255 hp @ 5900 rpm, 285 lb-ft @ 3950 rpm - introduced later in the generation but relevant for context)

2002 Engine Options:

2.4L I4, 3.3L V6, 3.8L V6

2003 Engine Options:

2.4L I4, 3.3L V6, 3.8L V6

2004 Engine Options:

2.4L I4, 3.3L V6, 3.8L V6 (Note: 4.0L V6 not available in 2004 for Grand Caravan, typically found in later models or Town & Country)

Performance Notes:

Performance varied significantly with engine choice. The V6 engines provided more robust acceleration suitable for carrying passengers and cargo. Torque was generally prioritized over outright horsepower for towing and hauling.

Fuel System:

Sequential Multi-Port Fuel Injection (MPI) for all engines.

🔧 Transmission

Standard Transmission:

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

Optional Transmission:

Some early models or specific trims might have had different automatic transmission designations, but the 4-speed automatic was ubiquitous for this generation. Manual transmissions were not offered.

Transmission Features:

Electronically controlled automatic transmissions with overdrive, offering smooth shifting and fuel efficiency optimization. Torque converter lock-up for improved highway cruising.

📐 Dimensions

Wheelbase:

Approx. 119.2 inches

Length:

Approx. 199.5 inches

Width:

Approx. 73.7 inches

Height:

Approx. 68.7 inches

Track Width Front:

Approx. 63.1 inches

Track Width Rear:

Approx. 62.8 inches

Seating Capacity:

7 passengers (typically)

Cargo Volume Behind First Row:

Approx. 140-160 cubic feet (variable with seat configurations)

Cargo Volume Behind Third Row:

Approx. 30-45 cubic feet

Curb Weight:

Approx. 4,000 - 4,500 lbs (depending on engine and trim)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,700 - 6,000 lbs

Towing Capacity:

Up to 3,800 lbs (with appropriate towing package and engine, e.g., 3.8L V6)

🛡️ Safety Features

NHTSA Frontal Driver:

Likely 4 stars (typical for the era, check specific model year ratings)

NHTSA Frontal Passenger:

Likely 4 stars (typical for the era, check specific model year ratings)

NHTSA Side Impact Front:

Likely 4 stars (typical for the era, check specific model year ratings)

NHTSA Side Impact Rear:

Likely 4 stars (typical for the era, check specific model year ratings)

Active Features:

Anti-lock Braking System (ABS) standard on most models, Traction Control System (TCS) available on some trims/engines, Electronic Stability Program (ESP) not widely available on this generation but introduced later.

Passive Features:

Front airbags, side curtain airbags (optional on some trims), 3-point seat belts for all occupants, LATCH child seat anchor system, reinforced body structure.

Child Safety Features:

Integrated child seats (optional on some trims), rear door child safety locks, LATCH system.

💡 Technology Features

Infotainment Features:

Available AM/FM stereo with CD player, cassette player, optional premium audio systems, rear-seat entertainment systems (DVD player with screens) on higher trims.

Driver Assistance Features:

Cruise control, optional rear parking assist sensors (ParkSense).

Connectivity Features:

Limited by era; typically no Bluetooth or USB connectivity as standard. Optional satellite radio was available.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on oil type (conventional vs. synthetic) and driving conditions (refer to manual for specific recommendations).

Tire Rotation Interval:

Every 5,000-7,500 miles

Spark Plug Replacement:

Varies by engine: 2.4L I4 - approx. 60,000-100,000 miles; V6 engines - approx. 100,000 miles (if iridium or platinum plugs are used, refer to manual for exact type and interval)

Engine Oil Specification:

SAE 5W-30 or SAE 3.7L V6 (2004): SAE 5W-30 (depending on temperature, refer to manual for precise application)

Transmission Fluid Specification:

ATF+4 (Automatic Transmission Fluid Type 9602)

Coolant Specification:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a pink or orange color. Mopar Antifreeze/Coolant 5/100.

Brake Fluid Specification:

DOT 3

Power Steering Fluid:

ATF+4 (Chrysler Automatic Transmission Fluid Type 9602)

Washer Fluid:

Water/washer fluid concentrate mixture

Known Issues:

Transmission solenoid failure (especially on earlier models), EGR valve clogging, power steering pump leaks, rear suspension spring sag, cooling fan motor failure, alternator issues, oil filter housing leaks, dashboard crack repair, power window regulator failures.

📚 Vehicle History

Brand Heritage:

Dodge, as a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing reliable and practical vehicles, with a particular strength in trucks and minivans.

Model Evolution:

The Grand Caravan is part of the longest-running minivan lineage in North America. This 2002-2004 period represents the latter half of the third generation (NS), which debuted in 1996. It received styling and feature updates during its lifecycle, with the major redesign occurring for the next generation (RG) in 2008.

Generation Name:

NS (Third Generation)

Production Locations:

Primarily manufactured in Windsor, Ontario, Canada.

🏆 Awards & Recognition

Recognitions:

Consistently ranked as a top-selling minivan and often received accolades for its practicality and value from automotive publications. (Specific awards would need detailed historical search, but its market success indicates positive reception).