Chrysler Caravan 2002-2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Years Covered: 2002, 2003, 2004 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, commercial users Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Venture SV6 Key Features Vehicle Strengths: Spacious interior, flexible seating configurations, comfortable ride, optional all-wheel drive (AWD) on some models, reliable powertrain options. Manual Value Proposition: Provides essential information for DIY maintenance and repairs, reducing service costs and empowering owners with knowledge of their vehicle's systems. 📋 Manual Details Coverage Areas General Coverage: Complete official factory service repair manual Page Count Estimated Pages: Hundreds Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, driveline, exhaust Chassis: Suspension (front and rear), steering, brakes (front and rear), wheels and tires Electrical: Battery, charging system, starting system, lighting, instrumentation, body controls, power accessories, HVAC controls, audio systems, diagnostic trouble codes (DTCs), wiring diagrams Body And Interior: Body panels, doors, windows, seats, trim, HVAC system components, body structural analysis Procedures Included Maintenance: Oil change, filter replacement, fluid checks and changes, spark plug replacement, belt inspection and replacement Repair: Engine component repair (e.g., cylinder head, pistons), transmission overhaul, brake caliper/rotor replacement, suspension arm/bushings replacement, electrical component diagnosis and repair, body panel repair and replacement Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation and resolution, electrical circuit testing Special Tools: Identification and usage of Chrysler-specific special tools for various repair procedures Technical Depth Depth: Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds, including in-depth electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear text and legible diagrams. Print Quality Printability: Designed for easy printing of individual sections or the entire manual. Binding Type Binding For Print: N/A (Digital PDF) Paper Type Paper For Print: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: 3.3L V6 (EGA) - 3301cc Engine Configuration 1: Overhead Valve (OHV), V-type Horsepower 1: Approx. 180 hp @ 5000 rpm (varies slightly by year) Torque 1: Approx. 205 lb-ft @ 3600 rpm (varies slightly by year) Secondary Engine Engine Code 2: 3.8L V6 (L32) - 3778cc (Available on some 2003-2004 models) Engine Configuration 2: Overhead Valve (OHV), V-type Horsepower 2: Approx. 200 hp @ 5000 rpm Torque 2: Approx. 230 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPFI) Cooling System Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent extended life coolant, typically purple or orange. 🔧 Transmission Standard Transmission Type 1: 4-speed Automatic (42LE) Optional Transmission Type 2: All-Wheel Drive (AWD) option available with the 4-speed automatic. Features Transmission Fluid Spec: ATF+4 (Automatic Transmission Fluid +4) - Part Number: 05013457AA (or equivalent) Fluid Capacity Approx: 7.0 - 8.0 quarts (6.6 - 7.6 liters) for a dry fill; approx. 4-5 quarts for a standard drain and fill. 📐 Dimensions Exterior Wheelbase: 113.0 inches (2870 mm) Length: Approx. 192.0 - 195.0 inches (4877 - 4953 mm) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 68.0 - 69.0 inches (1727 - 1753 mm) Interior Passenger Volume: Approx. 150-160 cubic feet (varies by configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 20-30 cubic feet Cargo Volume Behind 2Nd Row: Approx. 70-80 cubic feet Cargo Volume Max: Approx. 140-160 cubic feet (with 2nd and 3rd rows removed/folded) Weights Curb Weight Approx: 4000 - 4400 lbs (1814 - 2000 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5700 - 6000 lbs (2585 - 2722 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4-star (2002-2003 models) NHTSA Front Impact Passenger: 4-star (2002-2003 models) NHTSA Side Impact Front Seat: 5-star (2002-2003 models) NHTSA Side Impact Rear Seat: 4-star (2002-2003 models) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) on some models Passive Features Airbags Front: Standard front driver and passenger airbags Airbags Side: Optional front side-impact airbags available on some models Seatbelts: Three-point seat belts for all outboard seating positions; lower anchors and tethers for children (LATCH) system 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette player, and optional premium Infinity speaker systems. Rear Seat Entertainment: Optional overhead or in-dash video screen with wireless headphones available on higher trims. Driver Assistance Cruise Control: Standard cruise control Parking Assist: Optional rear park assist sensors available on some models. Connectivity Auxiliary Inputs: No standard auxiliary audio input; aftermarket solutions may be available. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 7,500 miles (4,800 - 12,000 km) or 6 months, depending on driving conditions and oil type used (consult manual for specifics). Transmission Fluid Change: Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 36 months, especially under severe use (towing, stop-and-go traffic). Always...
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Venture SV6
Key Features
Vehicle Strengths:
Spacious interior, flexible seating configurations, comfortable ride, optional all-wheel drive (AWD) on some models, reliable powertrain options.
Manual Value Proposition:
Provides essential information for DIY maintenance and repairs, reducing service costs and empowering owners with knowledge of their vehicle's systems.
📋 Manual Details
Coverage Areas
General Coverage:
Complete official factory service repair manual
Page Count
Estimated Pages:
Hundreds
Manual Type
Type:
Factory Service Repair Manual (FSM)
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, driveline, exhaust
Chassis:
Suspension (front and rear), steering, brakes (front and rear), wheels and tires
Identification and usage of Chrysler-specific special tools for various repair procedures
Technical Depth
Depth:
Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds, including in-depth electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear text and legible diagrams.
Print Quality
Printability:
Designed for easy printing of individual sections or the entire manual.
Binding Type
Binding For Print:
N/A (Digital PDF)
Paper Type
Paper For Print:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
3.3L V6 (EGA) - 3301cc
Engine Configuration 1:
Overhead Valve (OHV), V-type
Horsepower 1:
Approx. 180 hp @ 5000 rpm (varies slightly by year)
Torque 1:
Approx. 205 lb-ft @ 3600 rpm (varies slightly by year)
Secondary Engine
Engine Code 2:
3.8L V6 (L32) - 3778cc (Available on some 2003-2004 models)
Engine Configuration 2:
Overhead Valve (OHV), V-type
Horsepower 2:
Approx. 200 hp @ 5000 rpm
Torque 2:
Approx. 230 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPFI)
Cooling System
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent extended life coolant, typically purple or orange.
🔧 Transmission
Standard
Transmission Type 1:
4-speed Automatic (42LE)
Optional
Transmission Type 2:
All-Wheel Drive (AWD) option available with the 4-speed automatic.
7.0 - 8.0 quarts (6.6 - 7.6 liters) for a dry fill; approx. 4-5 quarts for a standard drain and fill.
📐 Dimensions
Exterior
Wheelbase:
113.0 inches (2870 mm)
Length:
Approx. 192.0 - 195.0 inches (4877 - 4953 mm)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 68.0 - 69.0 inches (1727 - 1753 mm)
Interior
Passenger Volume:
Approx. 150-160 cubic feet (varies by configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20-30 cubic feet
Cargo Volume Behind 2Nd Row:
Approx. 70-80 cubic feet
Cargo Volume Max:
Approx. 140-160 cubic feet (with 2nd and 3rd rows removed/folded)
Weights
Curb Weight Approx:
4000 - 4400 lbs (1814 - 2000 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5700 - 6000 lbs (2585 - 2722 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (2002-2003 models)
NHTSA Front Impact Passenger:
4-star (2002-2003 models)
NHTSA Side Impact Front Seat:
5-star (2002-2003 models)
NHTSA Side Impact Rear Seat:
4-star (2002-2003 models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some models
Passive Features
Airbags Front:
Standard front driver and passenger airbags
Airbags Side:
Optional front side-impact airbags available on some models
Seatbelts:
Three-point seat belts for all outboard seating positions; lower anchors and tethers for children (LATCH) system
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette player, and optional premium Infinity speaker systems.
Rear Seat Entertainment:
Optional overhead or in-dash video screen with wireless headphones available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Optional rear park assist sensors available on some models.
Connectivity
Auxiliary Inputs:
No standard auxiliary audio input; aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 7,500 miles (4,800 - 12,000 km) or 6 months, depending on driving conditions and oil type used (consult manual for specifics).
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 36 months, especially under severe use (towing, stop-and-go traffic). Always check level and condition.
Coolant Change:
Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 5 years with HOAT coolant.
Spark Plug Replacement:
Typically 60,000 - 100,000 miles (96,000 - 160,000 km) for platinum or iridium plugs (check specific plug type and manual).
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 API certified oil (check manual for specific viscosity and API service classification, e.g., API SN or earlier).
Rear heat control valve failure (leading to no heat or constant heat).
Common Issue 2:
Power sliding door motor failure or mechanism issues.
Common Issue 3:
Water pump leaks or failure, especially the plastic impeller.
Common Issue 4:
Transmission solenoid issues or internal wear leading to shifting problems.
Common Issue 5:
Ignition coil failure (especially on the 3.3L V6) causing misfires.
Common Issue 6:
Evaporative Emission (EVAP) system leaks, often related to the charcoal canister or vent solenoid.
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler has a long history of innovation in the minivan segment, pioneering the concept in 1984 with the original Dodge Caravan/Plymouth Voyager.
Model Evolution
Generation:
This manual covers the third generation (NS) of the Chrysler Caravan, which debuted for the 1996 model year and underwent facelifts and updates through 2007.
Updates 2002-2004:
The 2002 model received a significant refresh, including updated styling (new grille, headlights, taillights), a more refined interior with improved materials, and the introduction of the 3.8L V6 engine as an option. Minor revisions continued through 2004.
The Caravan (and its Dodge/Plymouth siblings) were frequently cited as 'Best Buys' by publications like Consumer Guide during this era for their value and practicality.
Jd Power Ratings:
Ratings varied by year and specific metric, but the vehicle generally performed adequately in its segment for initial quality and dependability at the time of release.