The Chrysler Grand Caravan, a versatile minivan from the 2004 model year, represents the second generation facelift of the NS platform. Known for its practicality and family-oriented design, this vehicle was engineered for reliability and ease of use. It offered a comfortable and spacious interior, making it a popular choice for daily commutes and longer journeys. The Grand Caravan was assembled in Windsor, Ontario, Canada, and consistently ranked among the top minivans for its segment in practicality and family utility during its production era. This comprehensive factory service repair manual provides detailed guidance for maintaining and repairing your Chrysler Grand Caravan. It covers all styles and offers in-depth information on engine service and repair, transmission service and repair, brake systems, electrical systems, suspension, cooling systems, fuel injection, and more. The manual includes step-by-step repair procedures, advanced troubleshooting guides, and all necessary illustrations and diagrams, enabling owners and technicians to perform maintenance and repairs effectively, potentially saving on labor costs. 🏷️ Basic Information Identification Make: Chrysler Model: Grand Caravan Year: 2004 Codes Platform: NS (2nd Generation Facelift) 👋 Introduction Market Position Target Audience: Owners and DIY Mechanics Competitive Analysis Vs 3Rd Party: Actual Genuine Repair Service Factory Manuals, Not 3rd Party Key Features Benefit: Save $50-$60 per hour on shop labor costs Search Functionality: Searchable for easy information retrieval Illustrations: Includes all necessary illustrations, diagrams, and photos Instructions Format: Numbered instructions, substeps, notes, cautions, warnings 📋 Manual Details Coverage Areas Coverage: All Styles Covered, Complete Official Full Factory Service Repair Manual Page Count Estimated Pages: Hundreds (exact count not specified, but implies comprehensive) Manual Type Type: Factory Service Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Included Transmission Service Repair: Included Brake System: Included Wiring Diagram: Included Electrical System: Included Suspension: Included Periodic Lubrication: Included Steering: Included Cooling System: Included Fuel Injection Fuel System: Included Emission System: Included Heater Air Conditional HVAC: Included Engine Control System ECM PCM: Included Chassis Body: Included Restraint System Airbags: Included Interior: Included Differential Drive: Included Axle: Included Procedures Included General Maintenance: Included Troubleshooting: Included (Advanced Troubleshooting Guide) Repair Procedures: Included (Step-by-step) Rebuild Refurbish Restore: Included Technical Depth Depth: Comprehensive (Factory Trained Technician Level) 📊 Manual Specifications File Format Quality: High Resolution Print Quality Printability: Fully Printable (Entire Manual or Specific Pages) Binding Type Binding: N/A (Digital Download, Printable) Paper Type Paper Type: N/A (Digital Download, Printable) Software Requirements Reader: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Options: 3.3L V6 OHV 12V (EGA), 3.8L V6 OHV 12V (L32) - Not explicitly stated but common for the model year. Manual likely covers both. Performance Horsepower 3.3L: Approx. 180 hp @ 4800 rpm (for context, not direct manual spec) Torque 3.3L: Approx. 205 lb-ft @ 3200 rpm (for context, not direct manual spec) Horsepower 3.8L: Approx. 205 hp @ 5000 rpm (for context, not direct manual spec) Torque 3.8L: Approx. 240 lb-ft @ 3200 rpm (for context, not direct manual spec) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle (e.g., 41TE, 42LE) Optional Transmission Options: Not specified for 2004, typically automatic for this model. Features Transmission Coverage: Service/Repair of Automatic Transaxle 📐 Dimensions Exterior Body Style: Minivan Weights Curb Weight: Approx. 4,000 - 4,300 lbs (Varies by engine and trim) - Manual would contain exact specs. 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5-Star (for 2004 model year) NHTSA Frontal Passenger: 5-Star (for 2004 model year) IIHS Moderate Overlap Frontal: Good (for 2004 model year) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Optional/Standard on some trims Passive Features Airbags: Frontal airbags, optional side airbags Restraint System Coverage: Manual covers Restraint System diagnostics and repair 💡 Technology Features Infotainment Audio Options: AM/FM Radio, CD Player, Cassette Player (optional) - Availability varies by trim. Driver Assistance Cruise Control: Standard Connectivity Power Features: Power windows, power locks, power mirrors 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific intervals based on driving conditions (typically 3,000-7,500 miles) Spark Plugs: Refer to manual for replacement intervals (e.g., 100,000 miles for iridium plugs) Fluid Specifications Engine Oil: Refer to manual for exact specification (e.g., SAE 5W-30, meeting Chrysler MS-6395) Transmission Fluid: Refer to manual for exact specification (e.g., ATF+4, MS-9602) Coolant: Refer to manual for exact specification (e.g., HOAT, MS-9769) Known Issues Common Problems Summary: Potential issues include automatic transmission problems (e.g., solenoid pack failure), power window/lock failures, HVAC blower motor issues, EGR valve clogging. Manual provides detailed diagnostics. 📚 Vehicle History Brand Heritage Brand: Chrysler (Stellantis formerly Fiat Chrysler Automobiles, DaimlerChrysler) Model Evolution Generation: Second Generation (NS), 2001-2007 (2004 is a facelift year) Production Assembly Location: Windsor, Ontario, Canada 🏆 Awards & Recognition Recognitions Segment Ranking: Consistently ranked among the top minivans for practicality and family use in...