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1997 Dodge Caravan Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1997 Generation Generation Code: Second Generation (RS) Codes Platform Code: NS (Platform shared with Chrysler Voyager/Town & Country and Plymouth Voyager) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Minivan Segment Contribution: The Dodge Caravan was a pioneering and highly successful minivan, often leading its segment in sales and innovation. Competitive Analysis Primary Competitors: Toyota Previa, Honda Odyssey, Ford Windstar, Chevrolet Venture, Nissan Quest. Key Features Innovations Of Generation: Second-generation models saw refinements in styling, improved safety features, and more powertrain options. Known for its practicality and spacious interior. Manual Value Proposition: This manual is crucial for owners and independent mechanics seeking accurate, dealer-level repair and maintenance information specific to the 1997 Caravan, avoiding generic advice. 📋 Manual Details Coverage Areas Coverage Scope: All Models and All Repairs A-Z Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive factory service manuals) Manual Type Manual Classification: Factory Service Manual / Repair Manual Language Language: English Format Format Type: Likely printed book (original factory), potentially available as a PDF reprint. 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cooling system, lubrication system, fuel system, ignition system, exhaust system, emissions control. Transmission Systems: Automatic transmission (A604, A670, A672), manual transmission (if applicable, though less common), transaxle operation, maintenance, and repair. Brake Systems: Front and rear brakes (disc/drum), ABS system, hydraulic components, parking brake. Suspension And Steering: Front and rear suspension components, steering gear, power steering system, alignment specifications. Electrical Systems: Battery, charging system, starting system, lighting, instruments, body electrical, wiring diagrams, fuses, relays. Body And Interior: Body panels, doors, windows, seats, trim, HVAC system, body shop repair procedures. Procedures Included Maintenance Procedures: Routine maintenance (oil change, filter replacement, fluid checks, tune-ups), scheduled maintenance intervals. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), specific component testing. Repair Procedures: Step-by-step instructions for component removal, installation, and repair (e.g., engine rebuild, transmission overhaul, brake caliper replacement). Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters. Technical Depth Depth Of Coverage: Comprehensive, covering from basic adjustments to full engine and transmission overhauls. Includes factory diagnostic procedures. 📊 Manual Specifications File Format Digital Format Details: If PDF, expect searchable text, high-resolution diagrams, and printable pages. Print Quality Printed Material Quality: Originals typically feature high-quality paper, clear printing, and durable binding. Reprints aim to match this quality. Binding Type Physical Binding: Originals often perfect bound or saddle-stitched. Reprints may vary, but typically aim for durability. Paper Type Physical Paper Quality: Durable, often glossy or semi-gloss paper for diagrams and schematics. ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L (2429cc) DOHC I4 (EDZ), 3.0L (2972cc) SOHC V6 (6G72), 3.3L (3301cc) OHV V6 (EGA/EGE). Performance 2.4L I4 (Edz) Approximate Horsepower: 150 hp @ 5800 rpm 3.0L V6 (6G72) Approximate Horsepower: 150 hp @ 5200 rpm 3.3L V6 (Ega/Ege) Approximate Horsepower: 158 hp @ 4700 rpm 3.3L V6 (Ega/Ege) Approximate Torque: 193 lb-ft @ 3300 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Recommended Fuel: 87 Octane Unleaded Gasoline Engine Codes Explained Engine Code Edz: Chrysler 2.4L DOHC 16-valve four-cylinder engine. Engine Code 6G72: Mitsubishi 3.0L SOHC 12-valve V6 engine, used in earlier models and certain configurations. Engine Code Ega Ege: Chrysler 3.3L OHV 12-valve V6 engine, known for its torque and reliability. 🔧 Transmission Standard Standard Transmission Type: 4-speed Automatic Transaxle (A604/A606 family) Optional Optional Transmission Type: Some models may have had different iterations or specific versions of the automatic transaxle (e.g., A670, A672) for different engine pairings. Features Transmission Fluid Type: ATF+3 (Chrysler specification) Transmission Fluid Capacity: Approximately 7.5 quarts (7.1 liters) for A604/A606 family, but always verify with dipstick/manual. 📐 Dimensions Exterior Wheelbase: 111.2 inches (2824 mm) Length: 177.4 inches (4506 mm) Width: 72.0 inches (1829 mm) Height: 68.7 inches (1745 mm) Cargo Max Cargo Volume: Approx. 144.3 cubic feet (with rear seats removed) Weights Curb Weight Range: Approx. 3500 - 3900 lbs (1588 - 1769 kg), depending on engine and configuration. Gross Vehicle Weight Rating Gvwr: Approx. 5250 - 5500 lbs (2381 - 2495 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star rating (for 1997 models) NHTSA Frontal Impact Passenger: 4-star rating (for 1997 models) Active Features Anti Lock Brakes ABS: Optional on some trims, standard on higher trims or certain engine configurations. Passive Features Airbags: Driver and front passenger airbags. Seat Belts: Three-point front seat belts, rear seat belts. Child Safety Anchors: LATCH (Lower Anchors and Tethers for Children) system not standard in 1997; typically relies on seat belt securing of child seats. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim. Driver Assistance Cruise Control: Standard on many trims, optional on base models. Traction Control: Optional on certain models/engine combinations. Connectivity Connectivity Features: Limited by era;...
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1997 Dodge Caravan Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
1997
Generation
Generation Code:
Second Generation (RS)
Codes
Platform Code:
NS (Platform shared with Chrysler Voyager/Town & Country and Plymouth Voyager)
👋 Introduction
Market Position
Vehicle Segment:
Compact/Mid-size Minivan
Segment Contribution:
The Dodge Caravan was a pioneering and highly successful minivan, often leading its segment in sales and innovation.
Competitive Analysis
Primary Competitors:
Toyota Previa, Honda Odyssey, Ford Windstar, Chevrolet Venture, Nissan Quest.
Key Features
Innovations Of Generation:
Second-generation models saw refinements in styling, improved safety features, and more powertrain options. Known for its practicality and spacious interior.
Manual Value Proposition:
This manual is crucial for owners and independent mechanics seeking accurate, dealer-level repair and maintenance information specific to the 1997 Caravan, avoiding generic advice.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models and All Repairs A-Z
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for comprehensive factory service manuals)
Manual Type
Manual Classification:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format Type:
Likely printed book (original factory), potentially available as a PDF reprint.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, cooling system, lubrication system, fuel system, ignition system, exhaust system, emissions control.
Transmission Systems:
Automatic transmission (A604, A670, A672), manual transmission (if applicable, though less common), transaxle operation, maintenance, and repair.
Brake Systems:
Front and rear brakes (disc/drum), ABS system, hydraulic components, parking brake.
Suspension And Steering:
Front and rear suspension components, steering gear, power steering system, alignment specifications.
Electrical Systems:
Battery, charging system, starting system, lighting, instruments, body electrical, wiring diagrams, fuses, relays.
Body And Interior:
Body panels, doors, windows, seats, trim, HVAC system, body shop repair procedures.
Procedures Included
Maintenance Procedures:
Routine maintenance (oil change, filter replacement, fluid checks, tune-ups), scheduled maintenance intervals.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), specific component testing.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair (e.g., engine rebuild, transmission overhaul, brake caliper replacement).
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters.
Technical Depth
Depth Of Coverage:
Comprehensive, covering from basic adjustments to full engine and transmission overhauls. Includes factory diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format Details:
If PDF, expect searchable text, high-resolution diagrams, and printable pages.
Print Quality
Printed Material Quality:
Originals typically feature high-quality paper, clear printing, and durable binding. Reprints aim to match this quality.
Binding Type
Physical Binding:
Originals often perfect bound or saddle-stitched. Reprints may vary, but typically aim for durability.
Paper Type
Physical Paper Quality:
Durable, often glossy or semi-gloss paper for diagrams and schematics.
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.4L (2429cc) DOHC I4 (EDZ), 3.0L (2972cc) SOHC V6 (6G72), 3.3L (3301cc) OHV V6 (EGA/EGE).
Performance
2.4L I4 (Edz) Approximate Horsepower:
150 hp @ 5800 rpm
3.0L V6 (6G72) Approximate Horsepower:
150 hp @ 5200 rpm
3.3L V6 (Ega/Ege) Approximate Horsepower:
158 hp @ 4700 rpm
3.3L V6 (Ega/Ege) Approximate Torque:
193 lb-ft @ 3300 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
87 Octane Unleaded Gasoline
Engine Codes Explained
Engine Code Edz:
Chrysler 2.4L DOHC 16-valve four-cylinder engine.
Engine Code 6G72:
Mitsubishi 3.0L SOHC 12-valve V6 engine, used in earlier models and certain configurations.
Engine Code Ega Ege:
Chrysler 3.3L OHV 12-valve V6 engine, known for its torque and reliability.
🔧 Transmission
Standard
Standard Transmission Type:
4-speed Automatic Transaxle (A604/A606 family)
Optional
Optional Transmission Type:
Some models may have had different iterations or specific versions of the automatic transaxle (e.g., A670, A672) for different engine pairings.
Features
Transmission Fluid Type:
ATF+3 (Chrysler specification)
Transmission Fluid Capacity:
Approximately 7.5 quarts (7.1 liters) for A604/A606 family, but always verify with dipstick/manual.
📐 Dimensions
Exterior
Wheelbase:
111.2 inches (2824 mm)
Length:
177.4 inches (4506 mm)
Width:
72.0 inches (1829 mm)
Height:
68.7 inches (1745 mm)
Cargo
Max Cargo Volume:
Approx. 144.3 cubic feet (with rear seats removed)
Weights
Curb Weight Range:
Approx. 3500 - 3900 lbs (1588 - 1769 kg), depending on engine and configuration.
Gross Vehicle Weight Rating Gvwr:
Approx. 5250 - 5500 lbs (2381 - 2495 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star rating (for 1997 models)
NHTSA Frontal Impact Passenger:
4-star rating (for 1997 models)
Active Features
Anti Lock Brakes ABS:
Optional on some trims, standard on higher trims or certain engine configurations.
Passive Features
Airbags:
Driver and front passenger airbags.
Seat Belts:
Three-point front seat belts, rear seat belts.
Child Safety Anchors:
LATCH (Lower Anchors and Tethers for Children) system not standard in 1997; typically relies on seat belt securing of child seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim.
Driver Assistance
Cruise Control:
Standard on many trims, optional on base models.
Traction Control:
Optional on certain models/engine combinations.
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic vehicle functions. No integrated Bluetooth or USB ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles (4,800-12,000 km) or 6 months, depending on driving conditions and oil used. Manual provides specific recommendations.
Transmission Fluid Service:
Recommended every 30,000-60,000 miles (48,000-96,000 km) or as per manual, depending on transmission type and usage.
Spark Plug Replacement:
Varies by engine: 2.4L I4 typically 60,000-100,000 miles. 3.3L V6 often around 30,000-60,000 miles (depending on plug type). Refer to manual for exact intervals and plug types.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 (common for 3.3L V6), SAE 10W-30 or 10W-40 for 2.4L I4. Always confirm with the manual for specific engine and climate.
Coolant Type:
Chrysler Antifreeze/Coolant (Ethylene Glycol based), typically a 50/50 mix with distilled water. Refer to manual for specific color/type.
Power Steering Fluid:
ATF+3 or specific Mopar power steering fluid.
Known Issues
Common Problem 1:
Transmission issues, particularly with early A604 transmissions, including solenoid failures, torque converter shudder, and internal seal leaks.
Common Problem 2:
Cooling system leaks, often from radiator, hoses, or water pump, due to age and material degradation.
Common Problem 3:
Power door lock and window motor failures.
Common Problem 4:
Exhaust system corrosion and leaks.
Common Problem 5:
A/C system compressor and refrigerant leaks.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan in 1984, establishing a dominant market presence that continued through subsequent generations.
Model Evolution
Second Generation Launch:
The second generation (RS) was introduced for the 1996 model year, featuring a more aerodynamic design, expanded interior space, and improved safety.
Production
Manufacturing Location:
Windsor, Ontario, Canada (Chrysler Canada assembly plant).
Production Span For Generation:
1996-2000
🏆 Awards & Recognition
Recognitions
10 Best Lists:
Caravan models, particularly earlier ones, frequently appeared on '10 Best' lists for their segment-defining practicality.
Ratings
Consumer Reports Rankings:
Consumer Reports ratings for the 1997 model year would provide insights into reliability and owner satisfaction, which varied by powertrain and specific year.
Certifications
Epa Fuel Economy City:
Approximately 18-21 MPG (city) for V6 models, 20-23 MPG (city) for 4-cylinder models (estimates, varies by engine and configuration).
Epa Fuel Economy Highway:
Approximately 23-26 MPG (highway) for V6 models, 25-29 MPG (highway) for 4-cylinder models (estimates, varies by engine and configuration).
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