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Dodge Grand Caravan 2008-2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Grand Caravan Year: 2008-2009 Codes Chassis Code: RT 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, Fleet Operators, DIY Mechanics Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Freestar, Kia Sedona Key Features Defining Feature: Stow 'n Go Seating System (available on many trims) Versatility: Spacious interior, flexible seating configurations, excellent cargo capacity 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Service, Maintenance, and Repair Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 3.3L V6, 3.8L V6 (detailed diagnosis, repair, and overhaul procedures) Transmission: 4-Speed Automatic (41TE/42LE) and 6-Speed Automatic (62TE) (service, overhaul, and electronic controls) Brakes: ABS, EBD, Traction Control, Brake System Diagnostics, Component Replacement (rotors, pads, lines) Suspension: Front Struts, Rear Shock Absorbers, Control Arms, Bushings, Wheel Bearing Replacement, Alignment Specifications Steering: Power Steering System (pump, rack and pinion), Column and Linkage Service Electrical: Wiring Diagrams, Fuse and Relay Locations, Battery, Alternator, Starter, Lighting Systems, Power Accessories, Diagnostics HVAC: Air Conditioning System Service, Heater Core, Blower Motor, Climate Control Unit Diagnostics Fuel System: Fuel Pump, Injectors, Lines, Tank, Fuel Pressure Diagnosis Exhaust System: Catalytic Converter, Muffler, Exhaust Pipes, Oxygen Sensors Body And Trim: Body Panel Repair, Door Mechanisms, Interior Trim, Seating Systems, Stow 'n Go Operation Safety Systems: Airbag System Diagnosis and Service, Seatbelt Mechanisms Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Level Checks and Top-offs Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Charts, Component Testing Repair: Component Removal and Installation, Overhaul Procedures, Gearbox Rebuilds Diagnostics: Scan Tool Usage, Live Data Interpretation, Circuit Testing Specifications: Torque Specifications, Clearances, Fluid Capacities, Alignment Angles Wiring Diagrams: Complete Electrical Schematics for All Systems Technical Depth Depth: Extremely High (covers basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Fully Searchable Text Print Quality Print Readability: High Resolution for Clear Printing Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA (3.3L V6 12-Valve OHV) Engine Code 2: EGG (3.8L V6 12-Valve OHV) Performance 3.3L Horsepower 3.3L: 175 hp @ 5000 rpm Torque 3.3L: 205 lb-ft @ 4000 rpm Performance 3.8L Horsepower 3.8L: 197 hp @ 5000 rpm Torque 3.8L: 230 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Multiport Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Engine Management ECU: NGC (Next Generation Controller) 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (41TE/42LE) Optional Transmission Type: 6-Speed Automatic (62TE) (with 3.8L engine and AWD option) Features Overdrive: Yes (OD gear for improved fuel economy) Towing Package: Available with trailer tow group (includes transmission cooler) Fluid Specs Transmission Fluid Type: ATF+4 (Mopar) 📐 Dimensions Exterior Wheelbase: 121.1 inches (3076 mm) Length: 199.5 inches (5067 mm) Width: 78.5 inches (1994 mm) Height: 68.9 inches (1750 mm) Cargo Max Cargo Volume: 140.1 cubic feet (3967 L) Weights Curb Weight Min: 4,345 lbs (1,971 kg) Curb Weight Max: 4,707 lbs (2,135 kg) Gross Vehicle Weight Rating Gvwr: 6,050 lbs (2,744 kg) - 6,450 lbs (2,926 kg) depending on configuration 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars NHTSA Side Impact Front Seat: 5 Stars NHTSA Side Impact Rear Seat: 5 Stars IIHS Frontal Offset Good: Good Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Electronic Stability Control: Optional (ESC) Passive Features Airbags Front: Standard Advanced Frontal Airbags Airbags Side: Optional Side-Curtain Airbags (all rows) 💡 Technology Features Infotainment Audio Options: AM/FM Stereo with CD player, optional Sirius Satellite Radio, rear-seat entertainment system. Navigation: Optional navigation system available on higher trims. Driver Assistance Parking Sensors: Optional rear park assist. Connectivity Remote Keyless Entry: Standard Remote Start: Optional 🔧 Maintenance Service Intervals Oil Oil Change Interval: Every 3,000-6,000 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations). Service Intervals Filters Engine Oil Filter Replacement: With every oil change Engine Air Filter Replacement: Every 15,000-30,000 miles or as needed Cabin Air Filter Replacement: Every 15,000-20,000 miles or as needed Service Intervals Fluids Coolant Replacement: Every 60,000 miles or 5 years Brake Fluid Flush: Every 30,000 miles or 2 years Transmission Fluid Service: Every 60,000-100,000 miles (refer to manual for specific transmission type) Fluid Specifications Engine Oil Specification: SAE 5W-30 (API Certified) Engine Oil Capacity 3.3L: 4.5 quarts (4.3 L) with filter Engine Oil Capacity 3.8L: 5.0 quarts (4.7 L) with filter Coolant Type: Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant Power Steering Fluid: ATF+4 (Mopar) Known Issues Common Problem 1: Transmission solenoid pack failure (especially in earlier 41TE/42LE units). Common Problem 2: Front suspension wear (ball...
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Dodge Grand Caravan 2008-2009 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Grand Caravan
Year:
2008-2009
Codes
Chassis Code:
RT
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, Fleet Operators, DIY Mechanics
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Freestar, Kia Sedona
Key Features
Defining Feature:
Stow 'n Go Seating System (available on many trims)
Versatility:
Spacious interior, flexible seating configurations, excellent cargo capacity
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Service, Maintenance, and Repair
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
3.3L V6, 3.8L V6 (detailed diagnosis, repair, and overhaul procedures)
Transmission:
4-Speed Automatic (41TE/42LE) and 6-Speed Automatic (62TE) (service, overhaul, and electronic controls)
Brakes:
ABS, EBD, Traction Control, Brake System Diagnostics, Component Replacement (rotors, pads, lines)
Suspension:
Front Struts, Rear Shock Absorbers, Control Arms, Bushings, Wheel Bearing Replacement, Alignment Specifications
Steering:
Power Steering System (pump, rack and pinion), Column and Linkage Service
Electrical:
Wiring Diagrams, Fuse and Relay Locations, Battery, Alternator, Starter, Lighting Systems, Power Accessories, Diagnostics
HVAC:
Air Conditioning System Service, Heater Core, Blower Motor, Climate Control Unit Diagnostics
Fuel System:
Fuel Pump, Injectors, Lines, Tank, Fuel Pressure Diagnosis
Exhaust System:
Catalytic Converter, Muffler, Exhaust Pipes, Oxygen Sensors
Body And Trim:
Body Panel Repair, Door Mechanisms, Interior Trim, Seating Systems, Stow 'n Go Operation
Safety Systems:
Airbag System Diagnosis and Service, Seatbelt Mechanisms
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Level Checks and Top-offs
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Charts, Component Testing
Repair:
Component Removal and Installation, Overhaul Procedures, Gearbox Rebuilds
Diagnostics:
Scan Tool Usage, Live Data Interpretation, Circuit Testing
Specifications:
Torque Specifications, Clearances, Fluid Capacities, Alignment Angles
Wiring Diagrams:
Complete Electrical Schematics for All Systems
Technical Depth
Depth:
Extremely High (covers basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully Searchable Text
Print Quality
Print Readability:
High Resolution for Clear Printing
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA (3.3L V6 12-Valve OHV)
Engine Code 2:
EGG (3.8L V6 12-Valve OHV)
Performance 3.3L
Horsepower 3.3L:
175 hp @ 5000 rpm
Torque 3.3L:
205 lb-ft @ 4000 rpm
Performance 3.8L
Horsepower 3.8L:
197 hp @ 5000 rpm
Torque 3.8L:
230 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Sequential Multiport Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Engine Management
ECU:
NGC (Next Generation Controller)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (41TE/42LE)
Optional
Transmission Type:
6-Speed Automatic (62TE) (with 3.8L engine and AWD option)
Features
Overdrive:
Yes (OD gear for improved fuel economy)
Towing Package:
Available with trailer tow group (includes transmission cooler)
Fluid Specs
Transmission Fluid Type:
ATF+4 (Mopar)
📐 Dimensions
Exterior
Wheelbase:
121.1 inches (3076 mm)
Length:
199.5 inches (5067 mm)
Width:
78.5 inches (1994 mm)
Height:
68.9 inches (1750 mm)
Cargo
Max Cargo Volume:
140.1 cubic feet (3967 L)
Weights
Curb Weight Min:
4,345 lbs (1,971 kg)
Curb Weight Max:
4,707 lbs (2,135 kg)
Gross Vehicle Weight Rating Gvwr:
6,050 lbs (2,744 kg) - 6,450 lbs (2,926 kg) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Seat:
5 Stars
NHTSA Side Impact Rear Seat:
5 Stars
IIHS Frontal Offset Good:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard
Electronic Stability Control:
Optional (ESC)
Passive Features
Airbags Front:
Standard Advanced Frontal Airbags
Airbags Side:
Optional Side-Curtain Airbags (all rows)
💡 Technology Features
Infotainment
Audio Options:
AM/FM Stereo with CD player, optional Sirius Satellite Radio, rear-seat entertainment system.
Navigation:
Optional navigation system available on higher trims.
Driver Assistance
Parking Sensors:
Optional rear park assist.
Connectivity
Remote Keyless Entry:
Standard
Remote Start:
Optional
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 3,000-6,000 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).
Service Intervals Filters
Engine Oil Filter Replacement:
With every oil change
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed
Cabin Air Filter Replacement:
Every 15,000-20,000 miles or as needed
Service Intervals Fluids
Coolant Replacement:
Every 60,000 miles or 5 years
Brake Fluid Flush:
Every 30,000 miles or 2 years
Transmission Fluid Service:
Every 60,000-100,000 miles (refer to manual for specific transmission type)
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 (API Certified)
Engine Oil Capacity 3.3L:
4.5 quarts (4.3 L) with filter
Engine Oil Capacity 3.8L:
5.0 quarts (4.7 L) with filter
Coolant Type:
Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant
Power Steering Fluid:
ATF+4 (Mopar)
Known Issues
Common Problem 1:
Transmission solenoid pack failure (especially in earlier 41TE/42LE units).
Common Problem 2:
Front suspension wear (ball joints, tie rod ends, bushings).
Common Problem 3:
Power sliding door motor failures or binding issues.
Common Problem 4:
Heater blend door actuator failure leading to HVAC temperature issues.
Common Problem 5:
Oil leaks from valve covers or oil pan gaskets.
Common Problem 6:
Water pump failure.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing practical and robust vehicles, often with a focus on performance and value.
Model Evolution
Generation:
This falls within the fourth generation (2001-2007) which was updated for 2008 with a significant facelift and revised powertrains.
Platform:
Dodge Caravan/Grand Caravan platform shared with Chrysler Town & Country and Volkswagen Routan (for later years).
Production
Assembly Location:
Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Family Car Awards:
The Grand Caravan, in its era, was frequently recognized for its family-friendly features and practicality, though specific awards for the 2008-2009 model year would need detailed research. It consistently ranked well in consumer satisfaction for its class.
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