DODGE CARAVAN 1996-2000 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 1996, 1997, 1998, 1999, 2000 Market Segment: Minivan Region Coverage: US/Canada 👋 Introduction Market Position Positioning: A cornerstone of the family minivan segment, known for practicality and value Competitive Analysis Competitors: Chevrolet Venture, Pontiac Trans Sport, Ford Windstar, Toyota Sienna, Honda Odyssey Key Features Vehicle Focus: Family transport, cargo versatility, comfortable ride Manual Value Proposition Benefit To Owner: Empowers owners with detailed knowledge to perform maintenance, diagnose issues, and complete repairs, saving time and money. Benefit To Technician: Provides definitive factory-level procedures, specifications, and diagnostic flowcharts for efficient and accurate servicing. 📋 Manual Details Coverage Areas General Coverage: Comprehensive factory service and repair procedures Page Count Estimated Page Count: Extensive (typically 1000+ pages for this era/model) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine assembly, diagnosis, repair, and overhaul for all available engine variants Engine Performance: Ignition system, fuel injection, emissions controls, cooling system, lubrication system Transmission Manual: Manual transmission (if applicable), clutch, shifter mechanisms Transmission Automatic: Automatic transmission (e.g., 4-speed automatic) diagnosis, repair, fluid service, valve body Drivetrain: Front-wheel drive, axle shafts, differential, CV joints Suspension: Front suspension (e.g., MacPherson struts), rear suspension (e.g., twist-beam axle or independent), shock absorbers, springs, bushings Steering: Power steering system, steering column, tie rods, steering gear Brakes: Front disc brakes, rear drum or disc brakes, ABS (Anti-lock Braking System) diagnosis and repair, brake lines, master cylinder Electrical System: Battery, charging system, starting system, fuses, relays, wiring diagrams, lighting Body And Frame: Body panel repair, structural components, door mechanisms, liftgate, sliding doors, interior trim HVAC: Heating, ventilation, and air conditioning (HVAC) system components, diagnosis, refrigerant service Body Electronics: Power windows, power door locks, remote keyless entry (if equipped), instrument cluster, gauges Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and flushes, spark plug replacement Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, fault code interpretation Repair: Step-by-step repair instructions for all major components and systems Disassembly Reassembly: Detailed instructions for component removal, disassembly, inspection, repair, and reassembly Diagnostics: On-board diagnostics (OBD-II) procedures, scan tool usage, sensor testing Specifications: Torque specifications, clearances, alignment data, electrical specifications Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems Technical Depth Depth: In-depth factory-level technical information for professional technicians and advanced DIYers 📊 Manual Specifications File Format Format: PDF Compatibility: Windows (95/98/ME/XP/Vista/7/8/8.1/10), Linux, MAC, iOS, Android Print Quality Quality: High-resolution scans, clear text and diagrams Searchability: Fully searchable text for quick information retrieval Readability: Optimized for digital viewing and printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: 2.4L (2429cc) DOHC 16-valve Inline 4-cylinder (2.4L DOHC) Engine Code 2: 3.0L (2972cc) SOHC 12-valve V6 (EGA/ESB) Engine Code 3: 3.3L (3301cc) SOHC 12-valve V6 (EGA/ESB) Performance Hp 2.4L: Approx. 150 hp @ 5600 rpm Torque 2.4L: Approx. 160 lb-ft @ 4000 rpm Hp 3.0L: Approx. 150 hp @ 4800 rpm Torque 3.0L: Approx. 180 lb-ft @ 3600 rpm Hp 3.3L: Approx. 170 hp @ 4800 rpm Torque 3.3L: Approx. 190 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended) Engine Management ECU: Chrysler's Powertrain Control Module (PCM) 🔧 Transmission Standard Type: 4-speed Automatic Transmission (41TE / 42LE) Optional Type: 5-speed Manual Transmission (Rare, usually on 4-cylinder) Features Automatic Features: Electronically controlled, overdrive Fluid Type Automatic Fluid: Chrysler ATF+4 (or equivalent) Fluid Capacity Automatic Capacity: Approx. 8-10 quarts (varies with torque converter drain) 📐 Dimensions Exterior Length: Approx. 189.8 inches Width: Approx. 72.1 inches Height: Approx. 68.4 inches Wheelbase Wheelbase: Approx. 112.1 inches Weights Curb Weight: Approx. 3700-4100 lbs (varies by engine and trim) Cargo Cargo Volume Behind 3Rd Row: Approx. 20.6 cu ft Cargo Volume Behind 2Nd Row: Approx. 76.9 cu ft Cargo Volume All Seats Removed: Approx. 141.5 cu ft 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4 Stars (for models with passenger airbag) NHTSA Frontal Passenger: 4 Stars (for models with passenger airbag) IIHS Frontal Offset: Acceptable Active Features ABS: Standard on most models, optional on some Passive Features Airbags: Driver-side airbag standard, optional passenger-side airbag available Seat Belts: Front lap and shoulder belts, rear lap and shoulder belts (outboard), rear lap belts (center) 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player, and premium Infinity speaker systems available. Navigation: No factory integrated navigation system for this generation. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Phone Integration: No factory Bluetooth or smartphone integration. Convenience Features Power Doors: Power sliding rear doors and power liftgate were options on higher trims in later years of this generation. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (depending on...
5-speed Manual Transmission (Rare, usually on 4-cylinder)
Features
Automatic Features:
Electronically controlled, overdrive
Fluid Type
Automatic Fluid:
Chrysler ATF+4 (or equivalent)
Fluid Capacity
Automatic Capacity:
Approx. 8-10 quarts (varies with torque converter drain)
📐 Dimensions
Exterior
Length:
Approx. 189.8 inches
Width:
Approx. 72.1 inches
Height:
Approx. 68.4 inches
Wheelbase
Wheelbase:
Approx. 112.1 inches
Weights
Curb Weight:
Approx. 3700-4100 lbs (varies by engine and trim)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.6 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 76.9 cu ft
Cargo Volume All Seats Removed:
Approx. 141.5 cu ft
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
4 Stars (for models with passenger airbag)
NHTSA Frontal Passenger:
4 Stars (for models with passenger airbag)
IIHS Frontal Offset:
Acceptable
Active Features
ABS:
Standard on most models, optional on some
Passive Features
Airbags:
Driver-side airbag standard, optional passenger-side airbag available
Seat Belts:
Front lap and shoulder belts, rear lap and shoulder belts (outboard), rear lap belts (center)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player, and premium Infinity speaker systems available.
Navigation:
No factory integrated navigation system for this generation.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Phone Integration:
No factory Bluetooth or smartphone integration.
Convenience Features
Power Doors:
Power sliding rear doors and power liftgate were options on higher trims in later years of this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (depending on oil type and driving conditions)
Transmission Fluid Change:
Every 30,000-60,000 miles (check manual for specifics)
Coolant Change:
Every 30,000-50,000 miles or 2-3 years
Spark Plug Replacement:
100,000 miles (for Platinum/Iridium plugs), 30,000-50,000 miles (for copper plugs)
Fluid Specifications
Engine Oil:
API SG or higher, SAE 5W-30 (preferred) or 10W-30
Coolant:
Chrysler/Mopar OAT (Orange) or HOAT (Yellow) Antifreeze/Coolant, 50/50 mix with distilled water
Power Steering Fluid:
Chrysler/Mopar Power Steering Fluid (MS-5919 or equivalent)
Known Issues
Transmission Issues:
Common transmission issues include torque converter shudder, solenoid failures, and valve body issues, especially in early models.
Engine Issues:
Head gasket leaks (especially on V6 engines), oil cooler line leaks, rear main seal leaks.
Suspension Issues:
Worn ball joints, tie rod ends, and strut mounts; sway bar links
Electrical Issues:
Faulty power window motors, door lock actuators, intermittent electrical gremlins.
HVAC Issues:
Blend door actuator failures, blower motor issues, A/C leaks.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation
Model Evolution
Generation Name:
Second Generation (NS Platform)
Design Changes:
Introduced in 1996 with a more aerodynamic design, improved interior packaging, and optional All-Wheel Drive (AWD) on some models.
Production
Assembly Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Period:
1996-2000
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Dodge Caravan (and its Plymouth Voyager/Chrysler Town & Country siblings) was frequently honored on Car and Driver's 10Best lists in the minivan category during its various iterations.
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