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Dodge Caravan 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2004 Body Style: Minivan Codes Platform: NS (4th Generation Dodge Caravan) 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, DIY mechanics, professional repair shops Competitive Analysis Key Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Plymouth Voyager, Chrysler Town & Country Key Features Vehicle Attributes: Spacious interior, flexible seating, comfortable ride, practical for families Manual Value Proposition: Provides detailed, authoritative information for accurate repair and maintenance, saving time and money. 📋 Manual Details Coverage Areas Covered Models: All 2004 Dodge Caravan models Engine Coverage: 2.4L I4, 3.3L V6, 3.8L V6 Transmission Coverage: 4-speed automatic transmission (41TE, 42LE) Page Count Approximate Pages: Over 1800 Manual Type Type: Factory Service Repair Manual (FSM) Purpose: Repair, diagnosis, maintenance, and specifications Language Language: English Format Format: Digital (PDF) Searchability: Fully searchable PDF text Printability: Printable individual pages or sections 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel and emissions, ignition, cooling, lubrication, exhaust, powertrain control module (PCM), transmission (automatic) Chassis: Brakes (ABS, power, parking), steering, suspension (front and rear), wheels and tires Electrical: Battery, charging system, starting system, lighting, instrumentation, fuses, relays, body electrical, power accessories, HVAC controls, airbag system Body: Body construction, exterior trim, interior trim, doors, windows, seats, HVAC system (operation and components), body and frame Procedures Included Maintenance: Routine inspections, fluid changes, filter replacements, tune-ups Diagnosis: Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting charts, wiring diagrams, flowcharts Repair: Component removal and installation, overhaul procedures, assembly and disassembly instructions Adjustment: Wheel alignment, parking brake adjustment, clutch adjustment (if applicable) Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth: Comprehensive: from basic fluid checks to full engine and transmission rebuilds, detailed electrical schematics Diagnostic Level: Advanced: includes diagnostic procedures for all major systems and electronic controls 📊 Manual Specifications File Format Format Type: PDF Print Quality Image Resolution: High-resolution scans suitable for screen viewing and printing Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.4 L (147 cu in) Engine 1 Configuration: Inline-4 (DOHC) Engine 1 Power: 150 hp @ 5800 rpm (approx.) Engine 1 Torque: 170 lb-ft @ 4000 rpm (approx.) Secondary Engine Engine 2 Displacement: 3.3 L (200 cu in) Engine 2 Configuration: V6 (OHV) Engine 2 Power: 180 hp @ 5000 rpm (approx.) Engine 2 Torque: 205 lb-ft @ 3600 rpm (approx.) Tertiary Engine Engine 3 Displacement: 3.8 L (230 cu in) Engine 3 Configuration: V6 (OHV) Engine 3 Power: 195 hp @ 5200 rpm (approx.) Engine 3 Torque: 230 lb-ft @ 3200 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Recommended Fuel: 87 Octane Unleaded Gasoline 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Transmission Code 1: 41TE Transmission Code 2: 42LE Optional Optional Transmission: Not applicable for 2004 model year Features Transmission Features: Electronically controlled, lock-up torque converter 📐 Dimensions Exterior Wheelbase: 112.1 inches (2847 mm) Length: 189.7 inches (4818 mm) Width: 72.0 inches (1829 mm) Height: 67.2 inches (1707 mm) Interior Passenger Volume: Approx. 130 cu ft Cargo Cargo Volume Behind 3Rd Row: Approx. 15 cu ft Cargo Volume Behind 2Nd Row: Approx. 45 cu ft Cargo Volume Max: Approx. 130 cu ft (with 2nd & 3rd rows folded/removed) Weights Curb Weight: Starting around 3800 lbs (1724 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5500 lbs (2495 kg) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4 out of 5 stars (for most configurations) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional traction control system (TCS) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: Three-point seat belts for all occupants, LATCH child seat anchors Rollover Protection: Reinforced roof structure 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette player, optional premium audio systems Navigation: Not available from factory for this model year Driver Assistance Cruise Control: Standard on most trims Rear Parking Aid: Optional parking assist system Connectivity Auxiliary Input: Not available from factory Bluetooth: Not available from factory 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 6,000 miles (5,000 - 10,000 km) or 6 months, depending on driving conditions and oil type used. Engine Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) Spark Plug Replacement: Every 60,000 - 100,000 miles (96,000 - 160,000 km), depending on plug type (e.g., platinum/iridium) Transmission Fluid Change: Every 30,000 - 60,000 miles (48,000 - 96,000 km), or as recommended by severe service schedule. Fluid Specifications Engine Oil Specification: API Certified SAE 5W-30 (check owner's manual for exact viscosity based on temperature) Engine Oil Capacity: Approx. 4.5 quarts (4.3 liters) for 2.4L I4; Approx. 4.5 quarts (4.3 liters) for V6 engines (check dipstick) Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent...
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Dodge Caravan 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2004
Body Style:
Minivan
Codes
Platform:
NS (4th Generation Dodge Caravan)
👋 Introduction
Market Position
Segment:
Mid-size Minivan
Target Audience:
Families, DIY mechanics, professional repair shops
Competitive Analysis
Key Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Plymouth Voyager, Chrysler Town & Country
Key Features
Vehicle Attributes:
Spacious interior, flexible seating, comfortable ride, practical for families
Manual Value Proposition:
Provides detailed, authoritative information for accurate repair and maintenance, saving time and money.
📋 Manual Details
Coverage Areas
Covered Models:
All 2004 Dodge Caravan models
Engine Coverage:
2.4L I4, 3.3L V6, 3.8L V6
Transmission Coverage:
4-speed automatic transmission (41TE, 42LE)
Page Count
Approximate Pages:
Over 1800
Manual Type
Type:
Factory Service Repair Manual (FSM)
Purpose:
Repair, diagnosis, maintenance, and specifications
Language
Language:
English
Format
Format:
Digital (PDF)
Searchability:
Fully searchable PDF text
Printability:
Printable individual pages or sections
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel and emissions, ignition, cooling, lubrication, exhaust, powertrain control module (PCM), transmission (automatic)
Chassis:
Brakes (ABS, power, parking), steering, suspension (front and rear), wheels and tires
Electrical:
Battery, charging system, starting system, lighting, instrumentation, fuses, relays, body electrical, power accessories, HVAC controls, airbag system
Body:
Body construction, exterior trim, interior trim, doors, windows, seats, HVAC system (operation and components), body and frame
Procedures Included
Maintenance:
Routine inspections, fluid changes, filter replacements, tune-ups
Diagnosis:
Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting charts, wiring diagrams, flowcharts
Repair:
Component removal and installation, overhaul procedures, assembly and disassembly instructions
Adjustment:
Wheel alignment, parking brake adjustment, clutch adjustment (if applicable)
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive: from basic fluid checks to full engine and transmission rebuilds, detailed electrical schematics
Diagnostic Level:
Advanced: includes diagnostic procedures for all major systems and electronic controls
📊 Manual Specifications
File Format
Format Type:
PDF
Print Quality
Image Resolution:
High-resolution scans suitable for screen viewing and printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.4 L (147 cu in)
Engine 1 Configuration:
Inline-4 (DOHC)
Engine 1 Power:
150 hp @ 5800 rpm (approx.)
Engine 1 Torque:
170 lb-ft @ 4000 rpm (approx.)
Secondary Engine
Engine 2 Displacement:
3.3 L (200 cu in)
Engine 2 Configuration:
V6 (OHV)
Engine 2 Power:
180 hp @ 5000 rpm (approx.)
Engine 2 Torque:
205 lb-ft @ 3600 rpm (approx.)
Tertiary Engine
Engine 3 Displacement:
3.8 L (230 cu in)
Engine 3 Configuration:
V6 (OHV)
Engine 3 Power:
195 hp @ 5200 rpm (approx.)
Engine 3 Torque:
230 lb-ft @ 3200 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
87 Octane Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Transmission Code 1:
41TE
Transmission Code 2:
42LE
Optional
Optional Transmission:
Not applicable for 2004 model year
Features
Transmission Features:
Electronically controlled, lock-up torque converter
📐 Dimensions
Exterior
Wheelbase:
112.1 inches (2847 mm)
Length:
189.7 inches (4818 mm)
Width:
72.0 inches (1829 mm)
Height:
67.2 inches (1707 mm)
Interior
Passenger Volume:
Approx. 130 cu ft
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 45 cu ft
Cargo Volume Max:
Approx. 130 cu ft (with 2nd & 3rd rows folded/removed)
Weights
Curb Weight:
Starting around 3800 lbs (1724 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5500 lbs (2495 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4 out of 5 stars (for most configurations)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional traction control system (TCS)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
Three-point seat belts for all occupants, LATCH child seat anchors
Rollover Protection:
Reinforced roof structure
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette player, optional premium audio systems
Navigation:
Not available from factory for this model year
Driver Assistance
Cruise Control:
Standard on most trims
Rear Parking Aid:
Optional parking assist system
Connectivity
Auxiliary Input:
Not available from factory
Bluetooth:
Not available from factory
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 6,000 miles (5,000 - 10,000 km) or 6 months, depending on driving conditions and oil type used.
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km)
Spark Plug Replacement:
Every 60,000 - 100,000 miles (96,000 - 160,000 km), depending on plug type (e.g., platinum/iridium)
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), or as recommended by severe service schedule.
Fluid Specifications
Engine Oil Specification:
API Certified SAE 5W-30 (check owner's manual for exact viscosity based on temperature)
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) for 2.4L I4; Approx. 4.5 quarts (4.3 liters) for V6 engines (check dipstick)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (typically purple)
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid Type 4)
Power Steering Fluid:
ATF+4 or specified power steering fluid
Brake Fluid Type:
DOT 3
Known Issues
Common Problem 1:
Headliner sagging
Common Problem 2:
Transmission issues (slipping, harsh shifting, particularly in older models)
Common Problem 3:
Heater core leaks (often indicated by a sweet smell inside the cabin or fogged windows)
Common Problem 4:
Power door lock or window actuator failures
Common Problem 5:
Front suspension wear (e.g., ball joints, tie rods)
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (at the time)
Model Evolution
Generation:
4th Generation (NS Body Style: 1996-2000, with significant updates for 2001-2007)
Updates For 2004:
Minor styling tweaks, potential interior enhancements and feature availability changes.
Production
Manufacturing Plant:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years:
1996-2007 (for the NS platform, with significant updates in 2001)
🏆 Awards & Recognition
Recognitions
Award Type:
MotorTrend's Import Car of the Year (for related Chrysler Group Minivans in previous generations)
Consumer Ratings:
Generally positive for practicality and utility, mixed reviews on reliability compared to some competitors.
Certifications
Certification:
N/A (Vehicle safety certifications covered under safety section)
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