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Chrysler caravan 1996 1997 1998 1999 Service Workshop Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Model Generation: Second Generation Years Covered: 1996, 1997, 1998, 1999 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals seeking versatile people and cargo transport Competitive Analysis Key Competitors Era: Ford Windstar, Chevrolet Venture/Pontiac Trans Sport/Oldsmobile Silhouette, Honda Odyssey, Toyota Sienna Key Features Vehicle Selling Points: Spacious interior, flexible seating, comfortable ride, accessible pricing (historically) Manual Value Proposition Manual Benefit: Empowers owners and technicians with detailed repair and maintenance procedures, diagnostic guidance, and technical specifications, enabling cost-effective upkeep and problem resolution. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Page Count: Over 3000 pages Language: English Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging, diagnostics, troubleshooting, performance tuning Transmission Systems: Automatic Transmission (e.g., 42LE), clutch, drivetrain, drive axles, differentials Brake Systems: Front and rear brakes, ABS, parking brake, hydraulic systems, components Suspension Steering: Front and rear suspension, steering gear, power steering, alignment, wheels, tires Electrical Electronics: Battery, starting system, charging system, lighting, instruments, gauges, ignition system, power distribution, wiring diagrams, fuses, relays, control modules (PCM, BCM, etc.) Body Chassis: Body construction, doors, windows, seats, interior trim, exterior trim, bumpers, frame, exhaust system, fuel tank, climate control system (HVAC), power accessories Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections Repair: Component removal and installation, engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, component testing, diagnostic procedures for various systems Technical Specifications: Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to major component overhaul and advanced diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, allowing for quick information retrieval Print Quality: Varies with original scan, typically good for digital reference, printable pages Binding Type Binding: Not applicable (PDF format) Paper Type Paper Quality: Not applicable (PDF format) ⚙️ Engine Specifications Primary Engine Engine Code Common: Various, likely includes EGN (3.0L OHV V6), EAS (3.3L OHV V6), and potentially EGW (3.8L OHV V6) depending on specific sub-model and region. Performance Displacement Common: 3.0L (182 cu in), 3.3L (201 cu in), 3.8L (230 cu in) Horsepower Range: Approximately 150 hp to 170 hp, depending on engine and year. Torque Range: Approximately 170 lb-ft to 215 lb-ft, depending on engine and year. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management Ignition Type: Distributorless Ignition System (DIS) or distributor-based systems, depending on specific engine ECU Type: Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Type: Automatic Optional Transmission Type: Not generally offered for these model years in this segment. Features Transmission Model Common: 42LE (4-speed automatic) Transmission Fluid Type: ATF+4 (or equivalent service fill, check manual for specific recommendations) 📐 Dimensions Exterior Wheelbase Approx: 112.5 inches (2858 mm) Length Approx: 189.1 inches (4803 mm) Width Approx: 72.5 inches (1841 mm) Height Approx: 67.8 inches (1722 mm) Cargo Cargo Volume Behind 3Rd Row Approx: Varies by configuration, typically around 15-20 cu ft. Cargo Volume Max Approx: Over 140 cu ft with rear seats removed. Weights Curb Weight Range: Approximately 3,900 - 4,300 lbs (1769 - 1950 kg) Gross Vehicle Weight Rating Gvwr Approx: Approximately 5,500 - 6,000 lbs (2495 - 2722 kg) Wheel Tire Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inch) Standard Tire Size: P215/70R15, P225/70R15, or P225/60R16 depending on trim/options. 🛡️ Safety Features Ratings NHTSA Rollover Rating: Likely 3 or 4 stars for these model years (review specific year's data if available). Active Features ABS Availability: Available on most trims, standard on higher trims Passive Features Airbags Front: Driver and Passenger Frontal Airbags Seat Belts: Three-point seat belts for all occupants, integrated child seats may be optional. Child Safety Anchors: LATCH system not standard, child seat tether anchors present. 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with cassette and CD player options, various speaker configurations. Driver Assistance Cruise Control: Standard on most trims. Traction Control: Optional on some models/trims. Connectivity Auxiliary Inputs: Not typically available for this era. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 miles (12,000 km) or 6 months, whichever comes first (refer to manual for specific usage conditions). Air Filter Replacement: Every 30,000 miles (48,000 km) or as needed. Spark Plug Replacement: Around 100,000 miles (160,000 km) for platinum tipped plugs, check manual for exact interval. Transmission Fluid Change: Every 30,000-60,000 miles (48,000-96,000 km), depending on driving conditions. Fluid Specifications Engine Oil Spec: API Certified SAE 5W-30 (check manual for specific viscosity grade recommendations based on temperature). Coolant Type: Chrysler Long Life Antifreeze/Coolant (OAT) or equivalent, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 3 Known...
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Chrysler caravan 1996 1997 1998 1999 Service Workshop Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Model Generation:
Second Generation
Years Covered:
1996, 1997, 1998, 1999
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, individuals seeking versatile people and cargo transport
Competitive Analysis
Key Competitors Era:
Ford Windstar, Chevrolet Venture/Pontiac Trans Sport/Oldsmobile Silhouette, Honda Odyssey, Toyota Sienna
Key Features
Vehicle Selling Points:
Spacious interior, flexible seating, comfortable ride, accessible pricing (historically)
Manual Value Proposition
Manual Benefit:
Empowers owners and technicians with detailed repair and maintenance procedures, diagnostic guidance, and technical specifications, enabling cost-effective upkeep and problem resolution.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Page Count:
Over 3000 pages
Language:
English
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging, diagnostics, troubleshooting, performance tuning
Transmission Systems:
Automatic Transmission (e.g., 42LE), clutch, drivetrain, drive axles, differentials
Brake Systems:
Front and rear brakes, ABS, parking brake, hydraulic systems, components
Suspension Steering:
Front and rear suspension, steering gear, power steering, alignment, wheels, tires
Electrical Electronics:
Battery, starting system, charging system, lighting, instruments, gauges, ignition system, power distribution, wiring diagrams, fuses, relays, control modules (PCM, BCM, etc.)
Body Chassis:
Body construction, doors, windows, seats, interior trim, exterior trim, bumpers, frame, exhaust system, fuel tank, climate control system (HVAC), power accessories
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections
Repair:
Component removal and installation, engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, component testing, diagnostic procedures for various systems
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters
Technical Depth
Depth Of Coverage:
Comprehensive, covering routine maintenance to major component overhaul and advanced diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, allowing for quick information retrieval
Print Quality:
Varies with original scan, typically good for digital reference, printable pages
Binding Type
Binding:
Not applicable (PDF format)
Paper Type
Paper Quality:
Not applicable (PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
Various, likely includes EGN (3.0L OHV V6), EAS (3.3L OHV V6), and potentially EGW (3.8L OHV V6) depending on specific sub-model and region.
Performance
Displacement Common:
3.0L (182 cu in), 3.3L (201 cu in), 3.8L (230 cu in)
Horsepower Range:
Approximately 150 hp to 170 hp, depending on engine and year.
Torque Range:
Approximately 170 lb-ft to 215 lb-ft, depending on engine and year.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition Type:
Distributorless Ignition System (DIS) or distributor-based systems, depending on specific engine
ECU Type:
Powertrain Control Module (PCM)
🔧 Transmission
Standard Transmission
Type:
Automatic
Optional Transmission
Type:
Not generally offered for these model years in this segment.
Features
Transmission Model Common:
42LE (4-speed automatic)
Transmission Fluid Type:
ATF+4 (or equivalent service fill, check manual for specific recommendations)
📐 Dimensions
Exterior
Wheelbase Approx:
112.5 inches (2858 mm)
Length Approx:
189.1 inches (4803 mm)
Width Approx:
72.5 inches (1841 mm)
Height Approx:
67.8 inches (1722 mm)
Cargo
Cargo Volume Behind 3Rd Row Approx:
Varies by configuration, typically around 15-20 cu ft.
Cargo Volume Max Approx:
Over 140 cu ft with rear seats removed.
Weights
Curb Weight Range:
Approximately 3,900 - 4,300 lbs (1769 - 1950 kg)
Gross Vehicle Weight Rating Gvwr Approx:
Approximately 5,500 - 6,000 lbs (2495 - 2722 kg)
Wheel Tire
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Standard Tire Size:
P215/70R15, P225/70R15, or P225/60R16 depending on trim/options.
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Likely 3 or 4 stars for these model years (review specific year's data if available).
Active Features
ABS Availability:
Available on most trims, standard on higher trims
Passive Features
Airbags Front:
Driver and Passenger Frontal Airbags
Seat Belts:
Three-point seat belts for all occupants, integrated child seats may be optional.
Child Safety Anchors:
LATCH system not standard, child seat tether anchors present.
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with cassette and CD player options, various speaker configurations.
Driver Assistance
Cruise Control:
Standard on most trims.
Traction Control:
Optional on some models/trims.
Connectivity
Auxiliary Inputs:
Not typically available for this era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 miles (12,000 km) or 6 months, whichever comes first (refer to manual for specific usage conditions).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed.
Spark Plug Replacement:
Around 100,000 miles (160,000 km) for platinum tipped plugs, check manual for exact interval.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), depending on driving conditions.
Fluid Specifications
Engine Oil Spec:
API Certified SAE 5W-30 (check manual for specific viscosity grade recommendations based on temperature).
Coolant Type:
Chrysler Long Life Antifreeze/Coolant (OAT) or equivalent, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
Suspension components (ball joints, tie rods, bushings), brake pads/rotors, fuel pumps, ignition coils, transmission solenoids.
Typical Engine Problems:
Head gasket leaks (especially on 3.3L and 3.8L), intake manifold gasket leaks, oil leaks, occasional piston slap on cold starts.
Typical Transmission Problems:
Slipping, delayed engagement, harsh shifts can indicate internal wear or solenoid issues in the 42LE transmission.
Electrical Issues:
Faulty window regulators, power door lock actuators, intermittent dashboard warning lights, PCM issues.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation
Model Evolution
Generation Intro:
The Caravan (and its Plymouth Voyager and Dodge Grand Caravan siblings) debuted in 1983, revolutionizing the minivan segment.
Second Generation Era:
1996-2000 model years.
Key Updates Second Gen:
Completely redesigned platform, 'cab-forward' design, improved aerodynamics, increased interior space, dual sliding doors became standard.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Chrysler minivan platform has received numerous accolades over its history, though specific mentions for these exact model years might vary. It was instrumental in defining the segment.
Consumer Reports:
Consumer Reports ratings for these years often reflected average to below-average reliability, particularly in later models of this generation. The manual helps mitigate these issues.
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