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2004 Dodge Caravan Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2004 Codes Platform: NS (Minivan Platform) 👋 Introduction Market Position Market Segment: Mid-size minivan, a staple in family transportation. Competitive Analysis Key Competitors 2004: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza. Key Features Vehicle Purpose: Versatile family vehicle offering flexible seating and cargo configurations. Manual Value Proposition: Provides dealership-level diagnostic and repair information, enabling accurate and efficient maintenance. 📋 Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (assumed PDF or similar, based on industry practice for technician manuals) 📖 Manual Coverage Systems Covered Engine: Full coverage for all available engine variants, including diagnosis, overhaul, and component repair. Transmission: Detailed procedures for automatic transmission service, diagnosis, and repair, including torque converter and cooler lines. Brakes: Comprehensive coverage of ABS, brake fluid, calipers, rotors, drums, parking brake, and hydraulic system diagnostics. Electrical: Extensive electrical system coverage, including wiring diagrams, fuses, relays, battery, charging system, starting system, lighting, and power accessories. Suspension Steering: Front and rear suspension components, steering system, alignment procedures, and wheel bearing service. HVAC: Air conditioning system diagnosis, refrigerant handling, compressor, condenser, evaporator, and climate control unit service. Body Chassis: Body panel removal/installation, doors, liftgate, interior trim, glass, and structural components. Emissions Control: Catalytic converter, EGR system, evaporative emissions control, and onboard diagnostics (OBD-II) relevant to emissions. Safety Restraints: Airbag system diagnosis, service, and related components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and lubrication. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for various vehicle systems. Repair: Step-by-step repair procedures for virtually all components and systems. Diagnostics: Detailed diagnostic strategies, including use of scan tools, multimeter testing, and component testing. Technical Depth Depth: Comprehensive and highly detailed, suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format File Format Details: Likely PDF, optimized for searchability and readability, with high-resolution diagrams. Print Quality Print Quality Description: Designed for clear reproduction of diagrams, schematics, and technical illustrations. Binding Type Binding Type Description: If physical, typically spiral-bound or comb-bound for lay-flat usability. Paper Type Paper Type Description: If physical, usually heavy-duty paper stock to withstand shop environment. ⚙️ Engine Specifications Primary Engine Engine 2 4L I4: 2.4L DOHC 16-valve Inline-4 (PowerTech), approximately 140-150 hp, 150-160 lb-ft torque. Engine 3 3L V6: 3.3L OHV 12-valve V6 (EGA), approximately 180 hp, 200 lb-ft torque. Engine 3 8L V6: 3.8L OHV 12-valve V6 (L32), approximately 200-205 hp, 230-235 lb-ft torque. Performance Bore Stroke 3 3L: Bore: 3.92 in (99.5 mm), Stroke: 3.31 in (84.0 mm) Bore Stroke 3 8L: Bore: 3.92 in (99.5 mm), Stroke: 3.82 in (96.9 mm) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, minimum 87 octane. Engine Codes Engine Code 2 4L: ED1 (check VIN for confirmation) Engine Code 3 3L: EGA Engine Code 3 8L: L32 🔧 Transmission Standard Standard Transmission Type: 4-speed automatic transmission. Optional Optional Transmission Type: N/A (All models equipped with automatic) Features Transmission Controller: Electronic transmission control with automatic transaxle ( டிரான்ஸ்மிஷன் ) diagnostics. Fluid Specifications Transmission Fluid Type: ATF+4 (Mopar Material Standard MS-9602) Fluid Capacities Transmission Fluid Capacity: Approximately 10.0 - 11.0 quarts (9.5 - 10.4 liters) for major service. 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Overall Length: 189.4 inches (4811 mm) Overall Width: 76.0 inches (1930 mm) Overall Height: 67.7 inches (1720 mm) Cargo Cargo Volume Behind 1St Row: Approximately 142.4 cu. ft. (4032 liters) Cargo Volume Behind 2Nd Row: Approximately 85.5 cu. ft. (2421 liters) Cargo Volume Behind 3Rd Row: Approximately 27.0 cu. ft. (765 liters) Weights Curb Weight Range: Approx. 3,800 - 4,200 lbs (1724 - 1905 kg), varies by engine and trim. Gross Vehicle Weight Rating Gvwr: Typically around 5,500 - 5,800 lbs (2495 - 2630 kg). 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Good (5-star rating in some configurations). NHTSA Frontal Impact Passenger: Good (5-star rating in some configurations). IIHS Side Impact: Acceptable or Good, depending on specific test and configuration. Active Features ABS: Standard Anti-lock Braking System (ABS) on most models. Traction Control: Optional Traction Control System (TCS) available on some models. Passive Features Airbags: Standard front airbags, optional side airbags available. Seatbelts: Three-point seat belts for all seating positions, integrated child seat anchors (LATCH). 💡 Technology Features Infotainment Audio System Options: Standard AM/FM stereo with CD player, optional premium audio systems with cassette and/or rear entertainment screens. Navigation System: Optional factory navigation system available on higher trim levels. Driver Assistance Cruise Control: Standard cruise control on most models. Connectivity Power Accessories: Power windows, power locks, power sliding doors (optional), power liftgate (optional). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used (consult...
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Stichworte: 2004 Caravan Cars Dodge Misc
2004 Dodge Caravan Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2004
Codes
Platform:
NS (Minivan Platform)
👋 Introduction
Market Position
Market Segment:
Mid-size minivan, a staple in family transportation.
Competitive Analysis
Key Competitors 2004:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza.
Key Features
Vehicle Purpose:
Versatile family vehicle offering flexible seating and cargo configurations.
Manual Value Proposition:
Provides dealership-level diagnostic and repair information, enabling accurate and efficient maintenance.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models & All Repairs A-Z
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (assumed PDF or similar, based on industry practice for technician manuals)
📖 Manual Coverage
Systems Covered
Engine:
Full coverage for all available engine variants, including diagnosis, overhaul, and component repair.
Transmission:
Detailed procedures for automatic transmission service, diagnosis, and repair, including torque converter and cooler lines.
Brakes:
Comprehensive coverage of ABS, brake fluid, calipers, rotors, drums, parking brake, and hydraulic system diagnostics.
Electrical:
Extensive electrical system coverage, including wiring diagrams, fuses, relays, battery, charging system, starting system, lighting, and power accessories.
Suspension Steering:
Front and rear suspension components, steering system, alignment procedures, and wheel bearing service.
HVAC:
Air conditioning system diagnosis, refrigerant handling, compressor, condenser, evaporator, and climate control unit service.
Body Chassis:
Body panel removal/installation, doors, liftgate, interior trim, glass, and structural components.
Emissions Control:
Catalytic converter, EGR system, evaporative emissions control, and onboard diagnostics (OBD-II) relevant to emissions.
Safety Restraints:
Airbag system diagnosis, service, and related components.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, and lubrication.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for various vehicle systems.
Repair:
Step-by-step repair procedures for virtually all components and systems.
Diagnostics:
Detailed diagnostic strategies, including use of scan tools, multimeter testing, and component testing.
Technical Depth
Depth:
Comprehensive and highly detailed, suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Format Details:
Likely PDF, optimized for searchability and readability, with high-resolution diagrams.
Print Quality
Print Quality Description:
Designed for clear reproduction of diagrams, schematics, and technical illustrations.
Binding Type
Binding Type Description:
If physical, typically spiral-bound or comb-bound for lay-flat usability.
Paper Type
Paper Type Description:
If physical, usually heavy-duty paper stock to withstand shop environment.
⚙️ Engine Specifications
Primary Engine
Engine 2 4L I4:
2.4L DOHC 16-valve Inline-4 (PowerTech), approximately 140-150 hp, 150-160 lb-ft torque.
Engine 3 3L V6:
3.3L OHV 12-valve V6 (EGA), approximately 180 hp, 200 lb-ft torque.
Engine 3 8L V6:
3.8L OHV 12-valve V6 (L32), approximately 200-205 hp, 230-235 lb-ft torque.
Performance
Bore Stroke 3 3L:
Bore: 3.92 in (99.5 mm), Stroke: 3.31 in (84.0 mm)
Bore Stroke 3 8L:
Bore: 3.92 in (99.5 mm), Stroke: 3.82 in (96.9 mm)
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Engine Codes
Engine Code 2 4L:
ED1 (check VIN for confirmation)
Engine Code 3 3L:
EGA
Engine Code 3 8L:
L32
🔧 Transmission
Standard
Standard Transmission Type:
4-speed automatic transmission.
Optional
Optional Transmission Type:
N/A (All models equipped with automatic)
Features
Transmission Controller:
Electronic transmission control with automatic transaxle ( டிரான்ஸ்மிஷன் ) diagnostics.
Fluid Specifications
Transmission Fluid Type:
ATF+4 (Mopar Material Standard MS-9602)
Fluid Capacities
Transmission Fluid Capacity:
Approximately 10.0 - 11.0 quarts (9.5 - 10.4 liters) for major service.
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Overall Length:
189.4 inches (4811 mm)
Overall Width:
76.0 inches (1930 mm)
Overall Height:
67.7 inches (1720 mm)
Cargo
Cargo Volume Behind 1St Row:
Approximately 142.4 cu. ft. (4032 liters)
Cargo Volume Behind 2Nd Row:
Approximately 85.5 cu. ft. (2421 liters)
Cargo Volume Behind 3Rd Row:
Approximately 27.0 cu. ft. (765 liters)
Weights
Curb Weight Range:
Approx. 3,800 - 4,200 lbs (1724 - 1905 kg), varies by engine and trim.
Gross Vehicle Weight Rating Gvwr:
Typically around 5,500 - 5,800 lbs (2495 - 2630 kg).
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (5-star rating in some configurations).
NHTSA Frontal Impact Passenger:
Good (5-star rating in some configurations).
IIHS Side Impact:
Acceptable or Good, depending on specific test and configuration.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Optional Traction Control System (TCS) available on some models.
Passive Features
Airbags:
Standard front airbags, optional side airbags available.
Seatbelts:
Three-point seat belts for all seating positions, integrated child seat anchors (LATCH).
💡 Technology Features
Infotainment
Audio System Options:
Standard AM/FM stereo with CD player, optional premium audio systems with cassette and/or rear entertainment screens.
Navigation System:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Power Accessories:
Power windows, power locks, power sliding doors (optional), power liftgate (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used (consult manual for exact OLM recommendations).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or approximately every 30,000 miles (48,000 km).
Cabin Air Filter:
Inspect annually, replace as needed (recommendation typically every 15,000-30,000 miles).
Spark Plugs 3 3L 3 8L:
Approximately 100,000 miles (160,000 km) for recommended iridium spark plugs.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 API certified synthetic or conventional engine oil. Consult owner's manual for specific viscosity grades based on temperature. Mopar recommended.
Coolant Specification:
Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water. Orange coolant.
Brake Fluid Specification:
DOT 3 brake fluid.
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent ATF+4.
Known Issues
Power Window Regulators:
Common failure point for window regulators, especially on sliding doors.
Transmission Solenoids:
Potential issues with transmission shift solenoids leading to harsh shifting or failure to engage.
Cvt Fluid Leaks:
Leaking CV axle boots can lead to joint damage and fluid loss.
Heater Core Leaks:
Heater core can develop leaks, often resulting in coolant smell inside the cabin.
Rear Shock Mounts:
Rear shock mounts can wear out, causing noise and degradation of ride quality.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the modern minivan segment with the original Caravan/Voyager in 1984.
Model Evolution
Generation:
Third Generation (1996-2000) carried over with significant updates for the 2001 model year (RS platform), this 2004 model is part of that later iteration of the third generation.
Production
Production Location:
Windsor, Ontario, Canada (Chrysler Canada Automotive Plant).
Production Years:
The NS platform was produced from 1996 to 2000. The subsequent RS platform was produced from 2001-2007, making the 2004 model part of the latter.
🏆 Awards & Recognition
Recognitions
Past Awards:
Caravan models have historically received various 'Best Buy' awards from consumer publications for value and utility.
Ratings
Consumer Satisfaction:
Mixed, with strengths in utility and value, but occasional concerns regarding reliability in some areas (as reflected in the need for detailed repair information).
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