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Dodge Caravan 1996-1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year Range: 1996-1999 Platform: NS Body Style Codes Chassis Codes: PG (Platform Generation) 👋 Introduction Market Position Segment: Minivan Key Selling Points: Versatility, passenger capacity, cargo space, family-oriented features Competitive Analysis Key Competitors Era: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Pontiac Trans Sport/Oldsmobile Silhouette Key Features Vantages Of Ownership: Practicality, affordability, comfortable ride, spacious interior for its time Manual Value Proposition: Empowers owners and independent repair shops with factory-level diagnostic and repair information, reducing reliance on dealerships and costly guesswork. 📋 Manual Details Coverage Areas Vehicle Coverage: 1996, 1997, 1998, 1999 Dodge Caravan Page Count Estimated Page Count: Hundreds of pages (specific count varies by engine/option configuration, typical for full factory manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (2.4L DOHC I4, 3.0L V6 SOHC, 3.3L V6 OHV, 3.8L V6 OHV), Transmission (3-speed automatic A604, 4-speed automatic A670/41TE/42LE) Chassis: Suspension (front MacPherson strut, rear beam axle with trailing arms/Panhard rod), Steering (power rack and pinion), Brakes (front disc, rear drum/disc options) Electrical: Wiring diagrams, lighting, charging system, starting system, instrument cluster, body control modules, power accessories (windows, locks, mirrors) Body: Exterior panels, interior trim, seats, doors, liftgate, HVAC system, climate control Diagnostics: OBD-II diagnostics, trouble codes (DTCs), diagnostic procedures, component testing Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, tune-ups, belt inspections and replacement, spark plug replacement Repair: Engine overhauls, transmission overhauls, brake system repairs, suspension component replacement, steering system repairs, electrical component diagnosis and replacement, body panel repair Troubleshooting: Step-by-step diagnostic guides for common and complex issues, symptom-based troubleshooting charts Special Tools: Identification and usage of specialized tools required for specific repair procedures Torque Specifications: Precise torque values for critical fasteners throughout the vehicle Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages. Text is typically searchable for ease of use. Binding Type Binding Type: N/A (Digital Download PDF) Paper Type Paper Type: N/A (Digital Download PDF) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.4L (2429cc) Engine 1 Type: DOHC I4 (Inline 4-cylinder) Engine 1 Code: EDZ (Chrysler World Engine) Engine 2 Displacement: 3.0L (2972cc) Engine 2 Type: SOHC V6 (Single Overhead Cam, V-configuration) Engine 2 Code: 6G72 (Mitsubishi 6G72 SOHC V6) Engine 3 Displacement: 3.3L (3301cc) Engine 3 Type: OHV V6 (Overhead Valve, V-configuration) Engine 3 Code: EGA Engine 4 Displacement: 3.8L (3778cc) Engine 4 Type: OHV V6 (Overhead Valve, V-configuration) Engine 4 Code: EVE/EVG Performance Horsepower Range: 150 hp - 180 hp (depending on engine) Torque Range: 180 lb-ft - 235 lb-ft (depending on engine) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Ignition System: Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on engine and year 🔧 Transmission Standard Transmission 1 Type: 3-Speed Automatic (A604) Transmission 1 Applicability: Common with 2.4L and 3.0L engines Optional Transmission 2 Type: 4-Speed Automatic (A670 / 41TE / 42LE) Transmission 2 Applicability: Standard on 3.3L and 3.8L engines, optional on others Features Transmission Control: Electronic transmission control (ETC) on later models and 4-speed transmissions Transmission Fluid Type: ATF+4 (or equivalent, e.g., Mopar ATF+3) - manual will specify exact requirement. 📐 Dimensions Exterior Wheelbase: Approx. 112.1 inches Length: Approx. 177.4 - 182.1 inches (depending on model year/configuration) Width: Approx. 72.1 inches Height: Approx. 67.1 - 68.1 inches Cargo Cargo Volume Behind First Row: Variable, often exceeding 140 cu ft Weights Curb Weight: Approx. 3600 - 4200 lbs (depending on engine and options) 🛡️ Safety Features Ratings NHTSA Ratings: Varies by year and specific test. Generally acceptable for the era, but modern standards are higher. Active Features ABS: Available on most models, standard on some later configurations Passive Features Airbags: Driver and front passenger airbags standard Seat Belts: Three-point seat belts for all outboard seating positions, lap belts for center seats 💡 Technology Features Infotainment Audio Options: AM/FM radio with cassette player, optional CD player, various speaker configurations. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Remote Keyless Entry: Available on higher trim levels. Power Accessories: Power windows, power door locks, power mirrors were available options. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific guidance). Transmission Fluid Change Interval: Every 30,000-60,000 miles, or as specified by driving conditions (check manual). Coolant Change Interval: Every 30,000-100,000 miles depending on coolant type and manufacturer recommendations (refer to manual). Fluid Specifications Engine Oil Spec: SAE 5W-30 or 10W-30 (depending on engine and temperature), API certified (refer to manual for...
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Dodge Caravan 1996-1999 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year Range:
1996-1999
Platform:
NS Body Style
Codes
Chassis Codes:
PG (Platform Generation)
👋 Introduction
Market Position
Segment:
Minivan
Key Selling Points:
Versatility, passenger capacity, cargo space, family-oriented features
Competitive Analysis
Key Competitors Era:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Pontiac Trans Sport/Oldsmobile Silhouette
Key Features
Vantages Of Ownership:
Practicality, affordability, comfortable ride, spacious interior for its time
Manual Value Proposition:
Empowers owners and independent repair shops with factory-level diagnostic and repair information, reducing reliance on dealerships and costly guesswork.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
1996, 1997, 1998, 1999 Dodge Caravan
Page Count
Estimated Page Count:
Hundreds of pages (specific count varies by engine/option configuration, typical for full factory manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (2.4L DOHC I4, 3.0L V6 SOHC, 3.3L V6 OHV, 3.8L V6 OHV), Transmission (3-speed automatic A604, 4-speed automatic A670/41TE/42LE)
Chassis:
Suspension (front MacPherson strut, rear beam axle with trailing arms/Panhard rod), Steering (power rack and pinion), Brakes (front disc, rear drum/disc options)
Electrical:
Wiring diagrams, lighting, charging system, starting system, instrument cluster, body control modules, power accessories (windows, locks, mirrors)
Body:
Exterior panels, interior trim, seats, doors, liftgate, HVAC system, climate control
Diagnostics:
OBD-II diagnostics, trouble codes (DTCs), diagnostic procedures, component testing
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, belt inspections and replacement, spark plug replacement
Repair:
Engine overhauls, transmission overhauls, brake system repairs, suspension component replacement, steering system repairs, electrical component diagnosis and replacement, body panel repair
Troubleshooting:
Step-by-step diagnostic guides for common and complex issues, symptom-based troubleshooting charts
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, printable pages. Text is typically searchable for ease of use.
Binding Type
Binding Type:
N/A (Digital Download PDF)
Paper Type
Paper Type:
N/A (Digital Download PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.4L (2429cc)
Engine 1 Type:
DOHC I4 (Inline 4-cylinder)
Engine 1 Code:
EDZ (Chrysler World Engine)
Engine 2 Displacement:
3.0L (2972cc)
Engine 2 Type:
SOHC V6 (Single Overhead Cam, V-configuration)
Engine 2 Code:
6G72 (Mitsubishi 6G72 SOHC V6)
Engine 3 Displacement:
3.3L (3301cc)
Engine 3 Type:
OHV V6 (Overhead Valve, V-configuration)
Engine 3 Code:
EGA
Engine 4 Displacement:
3.8L (3778cc)
Engine 4 Type:
OHV V6 (Overhead Valve, V-configuration)
Engine 4 Code:
EVE/EVG
Performance
Horsepower Range:
150 hp - 180 hp (depending on engine)
Torque Range:
180 lb-ft - 235 lb-ft (depending on engine)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on engine and year
🔧 Transmission
Standard
Transmission 1 Type:
3-Speed Automatic (A604)
Transmission 1 Applicability:
Common with 2.4L and 3.0L engines
Optional
Transmission 2 Type:
4-Speed Automatic (A670 / 41TE / 42LE)
Transmission 2 Applicability:
Standard on 3.3L and 3.8L engines, optional on others
Features
Transmission Control:
Electronic transmission control (ETC) on later models and 4-speed transmissions
Transmission Fluid Type:
ATF+4 (or equivalent, e.g., Mopar ATF+3) - manual will specify exact requirement.
📐 Dimensions
Exterior
Wheelbase:
Approx. 112.1 inches
Length:
Approx. 177.4 - 182.1 inches (depending on model year/configuration)
Width:
Approx. 72.1 inches
Height:
Approx. 67.1 - 68.1 inches
Cargo
Cargo Volume Behind First Row:
Variable, often exceeding 140 cu ft
Weights
Curb Weight:
Approx. 3600 - 4200 lbs (depending on engine and options)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year and specific test. Generally acceptable for the era, but modern standards are higher.
Active Features
ABS:
Available on most models, standard on some later configurations
Passive Features
Airbags:
Driver and front passenger airbags standard
Seat Belts:
Three-point seat belts for all outboard seating positions, lap belts for center seats
💡 Technology Features
Infotainment
Audio Options:
AM/FM radio with cassette player, optional CD player, various speaker configurations.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Remote Keyless Entry:
Available on higher trim levels.
Power Accessories:
Power windows, power door locks, power mirrors were available options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific guidance).
Transmission Fluid Change Interval:
Every 30,000-60,000 miles, or as specified by driving conditions (check manual).
Coolant Change Interval:
Every 30,000-100,000 miles depending on coolant type and manufacturer recommendations (refer to manual).
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 or 10W-30 (depending on engine and temperature), API certified (refer to manual for exact grade and capacity).
Coolant Spec:
Chrysler/Mopar Antifreeze/Coolant (ethylene glycol based), typically a 50/50 mix with distilled water. Refer to manual for exact type.
Brake Fluid Spec:
DOT 3 brake fluid.
Known Issues
Common Wear Items:
CV axles, wheel bearings, tie rod ends, ball joints, exhaust system components, spark plugs and wires (on older systems).
Powertrain Issues:
Head gasket leaks on some 3.3L/3.8L V6 engines, transmission solenoid pack failures, torque converter shudder.
Electrical Issues:
Power window regulators, door lock actuators, instrument cluster failure (especially odometer), ABS sensor failures.
HVAC Issues:
Blend door actuator failures, blower motor resistor failure, AC compressor clutch issues.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of building practical and durable vehicles, with a focus on value and utility in the minivan segment.
Model Evolution
Generation Name:
NS (Second Generation Dodge Caravan/Plymouth Voyager)
Key Updates During Range:
Introduction of new engines (3.3L, 3.8L V6s), updated transmissions, minor styling tweaks, improved safety features, and introduction of OBD-II diagnostics.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Customer Satisfaction:
Consistently ranked as a practical and reliable choice in the minivan segment for families, often praised for its utility and value.
Ratings
Segment Perception:
A benchmark for practicality and cargo space within its class during its production run.
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