Dodge Caravan 1998 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1998 Codes Platform Code: NS Vin Code: 6 👋 Introduction Market Position Vehicle Segment: Compact Minivan Target Audience: Families, individuals seeking versatile cargo and passenger transport. Competitive Analysis Key Competitors: Chevrolet Venture, Pontiac Trans Sport, Ford Windstar, Toyota Sienna, Honda Odyssey. Key Features Vehicle Type: Minivan Seating Capacity: Configurable seating, typically 5-7 passengers. Door Configuration: Standard front doors, sliding rear passenger door, liftgate. Practicality: Renowned for its cargo space, flexible seating arrangements, and ease of access. 📋 Manual Details Coverage Areas All Models Engines Trims Transmissions: Yes Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, and reassembly of all engine components. Engine Fuel System: Fuel injection system, fuel pump, injectors, pressure regulator, fuel filter replacement. Engine Ignition System: Spark plugs, ignition coils, distributor (if applicable), timing specifications. Engine Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation. Engine Lubrication System: Oil pump, oil filter, oil pan, oil pressure checks. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, emissions control components. Transmission Automatic: Torque converter, valve body, planetary gear sets, clutch packs, seals, fluid changes. Transmission Manual: Clutch assembly, gears, synchronizers, shift linkages, fluid changes. Drivetrain And Axles: CV joints, driveshafts, differential, wheel bearings. Brakes System: Brake fluid, master cylinder, brake calipers, pads, rotors, parking brake, ABS (Anti-lock Braking System). Suspension System: MacPherson struts, control arms, ball joints, tie rods, shock absorbers, springs. Steering System: Power steering pump, steering gear, steering column, tie rods. Electrical System Charging: Alternator, voltage regulator, battery testing and replacement. Electrical System Starting: Starter motor, starter solenoid, ignition switch. Lighting System: Headlights, taillights, interior lighting, bulb replacement. Instrumentation And Gauges: Speedometer, tachometer, fuel gauge, warning lights, sensor diagnostics. HVAC System: Air conditioning, heater core, blower motor, climate control panel. Body And Chassis: Frame, body panels, doors, hinges, latches, glass replacement. Interior Trim: Seats, carpets, dashboard, door panels, upholstery. Safety Restraint System: Seat belts, airbags (SRS) system diagnostics and replacement. Diagnostic Trouble Codes: OBD-II (On-Board Diagnostics II) codes and their interpretations for troubleshooting. Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks, tire rotations, tune-ups. Scheduled Maintenance: Detailed service intervals for all major components and fluids. Troubleshooting Guides: Step-by-step diagnostics for common and uncommon problems. Component Repair And Replacement: Detailed instructions for removing, repairing, and reinstalling virtually all vehicle parts. Wiring Diagrams: Comprehensive electrical schematics for all circuits. Torque Specifications: Precise torque values for all critical fasteners. Special Tool Requirements: Identification and usage of specialized tools needed for specific repairs. Diagnostic Procedures: Systematic approaches to identify the root cause of malfunctions. Recalibration Procedures: Procedures for recalibrating sensors and modules after replacement or repair. Technical Depth Depth Level: Expert-level, covering complete overhauls and advanced diagnostics. Diagnostics: In-depth diagnostic trees, symptom-based troubleshooting, and component testing. Repair Instructions: Detailed, step-by-step repair procedures with accompanying illustrations and diagrams. Specifications: Comprehensive technical data, including clearances, tolerances, and performance metrics. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes Printable: Yes Print Quality Resolution: High-resolution scans suitable for clear viewing and printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 3.0L V6 (EGA) Displacement: 182 cu in (2972 cc) Configuration: Overhead Valve (OHV), 12 Valves Bore X Stroke: 3.50 in x 3.14 in (89.0 mm x 79.8 mm) Compression Ratio: 8.9:1 Horsepower: 150 hp @ 5200 rpm Torque: 180 lb-ft @ 3200 rpm Fuel System Induction: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Unleaded Gasoline Optional Engine Engine Code: 2.4L I4 (AAC) Displacement: 146 cu in (2370 cc) Configuration: Inline 4-cylinder, 16 Valves, Single Overhead Cam (SOHC) Horsepower: 150 hp @ 5800 rpm Torque: 170 lb-ft @ 4400 rpm 🔧 Transmission Standard Type: 4-Speed Automatic (A604/41TE) Optional Type: 3-Speed Automatic (Optional on some base models, less common) Features Transmission Control: Electronic control with overdrive. Fluid Specifications Fluid Type: ATF+4 (Chrysler Automatic Transmission Fluid Type 9602) 📐 Dimensions Exterior Length: 177.1 inches (4498 mm) Width: 71.5 inches (1816 mm) Height: 67.7 inches (1720 mm) Wheelbase: 112.0 inches (2845 mm) Front Track: 60.4 inches (1534 mm) Rear Track: 59.7 inches (1516 mm) Interior Front Headroom: 40.1 inches (1019 mm) Front Legroom: 42.5 inches (1080 mm) Second Row Headroom: 39.6 inches (1006 mm) Second Row Legroom: 36.1 inches (917 mm) Cargo Cargo Volume Behind Second Row: Approximately 75-90 cu ft (variable with seating configuration) Cargo Volume Behind First Row: Approximately 140-150 cu ft (variable with seating configuration) Weights Curb Weight: 3700-4000 lbs (approximate, varies by model and equipment) Gross Vehicle Weight Rating Gvwr: 5200-5600 lbs (approximate) 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 4 Stars (Driver and Passenger) IIHS Frontal Offset Rating: Acceptable (for its time) Active Features ABS: Optional...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform Code:

Vin Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact Minivan

Target Audience:

Families, individuals seeking versatile cargo and passenger transport.

Competitive Analysis

Key Competitors:

Chevrolet Venture, Pontiac Trans Sport, Ford Windstar, Toyota Sienna, Honda Odyssey.

Key Features

Vehicle Type:

Minivan

Seating Capacity:

Configurable seating, typically 5-7 passengers.

Door Configuration:

Standard front doors, sliding rear passenger door, liftgate.

Practicality:

Renowned for its cargo space, flexible seating arrangements, and ease of access.

📋 Manual Details

Coverage Areas

All Models Engines Trims Transmissions:

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, and reassembly of all engine components.

Engine Fuel System:

Fuel injection system, fuel pump, injectors, pressure regulator, fuel filter replacement.

Engine Ignition System:

Spark plugs, ignition coils, distributor (if applicable), timing specifications.

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation.

Engine Lubrication System:

Oil pump, oil filter, oil pan, oil pressure checks.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, emissions control components.

Transmission Automatic:

Torque converter, valve body, planetary gear sets, clutch packs, seals, fluid changes.

Transmission Manual:

Clutch assembly, gears, synchronizers, shift linkages, fluid changes.

Drivetrain And Axles:

CV joints, driveshafts, differential, wheel bearings.

Brakes System:

Brake fluid, master cylinder, brake calipers, pads, rotors, parking brake, ABS (Anti-lock Braking System).

Suspension System:

MacPherson struts, control arms, ball joints, tie rods, shock absorbers, springs.

Steering System:

Power steering pump, steering gear, steering column, tie rods.

Electrical System Charging:

Alternator, voltage regulator, battery testing and replacement.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch.

Lighting System:

Headlights, taillights, interior lighting, bulb replacement.

Instrumentation And Gauges:

Speedometer, tachometer, fuel gauge, warning lights, sensor diagnostics.

HVAC System:

Air conditioning, heater core, blower motor, climate control panel.

Body And Chassis:

Frame, body panels, doors, hinges, latches, glass replacement.

Interior Trim:

Seats, carpets, dashboard, door panels, upholstery.

Safety Restraint System:

Seat belts, airbags (SRS) system diagnostics and replacement.

Diagnostic Trouble Codes:

OBD-II (On-Board Diagnostics II) codes and their interpretations for troubleshooting.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, tune-ups.

Scheduled Maintenance:

Detailed service intervals for all major components and fluids.

Troubleshooting Guides:

Step-by-step diagnostics for common and uncommon problems.

Component Repair And Replacement:

Detailed instructions for removing, repairing, and reinstalling virtually all vehicle parts.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits.

Torque Specifications:

Precise torque values for all critical fasteners.

Special Tool Requirements:

Identification and usage of specialized tools needed for specific repairs.

Diagnostic Procedures:

Systematic approaches to identify the root cause of malfunctions.

Recalibration Procedures:

Procedures for recalibrating sensors and modules after replacement or repair.

Technical Depth

Depth Level:

Expert-level, covering complete overhauls and advanced diagnostics.

Diagnostics:

In-depth diagnostic trees, symptom-based troubleshooting, and component testing.

Repair Instructions:

Detailed, step-by-step repair procedures with accompanying illustrations and diagrams.

Specifications:

Comprehensive technical data, including clearances, tolerances, and performance metrics.

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Resolution:

High-resolution scans suitable for clear viewing and printing.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

3.0L V6 (EGA)

Displacement:

182 cu in (2972 cc)

Configuration:

Overhead Valve (OHV), 12 Valves

Bore X Stroke:

3.50 in x 3.14 in (89.0 mm x 79.8 mm)

Compression Ratio:

8.9:1

Horsepower:

150 hp @ 5200 rpm

Torque:

180 lb-ft @ 3200 rpm

Fuel System

Induction:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Unleaded Gasoline

Optional Engine

Engine Code:

2.4L I4 (AAC)

Displacement:

146 cu in (2370 cc)

Configuration:

Inline 4-cylinder, 16 Valves, Single Overhead Cam (SOHC)

Horsepower:

150 hp @ 5800 rpm

Torque:

170 lb-ft @ 4400 rpm

🔧 Transmission

Standard

Type:

4-Speed Automatic (A604/41TE)

Optional

Type:

3-Speed Automatic (Optional on some base models, less common)

Features

Transmission Control:

Electronic control with overdrive.

Fluid Specifications

Fluid Type:

ATF+4 (Chrysler Automatic Transmission Fluid Type 9602)

📐 Dimensions

Exterior

Length:

177.1 inches (4498 mm)

Width:

71.5 inches (1816 mm)

Height:

67.7 inches (1720 mm)

Wheelbase:

112.0 inches (2845 mm)

Front Track:

60.4 inches (1534 mm)

Rear Track:

59.7 inches (1516 mm)

Interior

Front Headroom:

40.1 inches (1019 mm)

Front Legroom:

42.5 inches (1080 mm)

Second Row Headroom:

39.6 inches (1006 mm)

Second Row Legroom:

36.1 inches (917 mm)

Cargo

Cargo Volume Behind Second Row:

Approximately 75-90 cu ft (variable with seating configuration)

Cargo Volume Behind First Row:

Approximately 140-150 cu ft (variable with seating configuration)

Weights

Curb Weight:

3700-4000 lbs (approximate, varies by model and equipment)

Gross Vehicle Weight Rating Gvwr:

5200-5600 lbs (approximate)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

4 Stars (Driver and Passenger)

IIHS Frontal Offset Rating:

Acceptable (for its time)

Active Features

Optional on some trims, standard on higher trims.

Passive Features

Airbags:

Driver and Passenger Frontal Airbags (Standard)

Seat Belts:

3-point seat belts for all seating positions, front seat belt pretensioners.

Child Safety Anchors:

LATCH system not standard, may have top tether anchors depending on seating.

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with cassette player, optional CD player.

Speaker Configuration:

4-speaker or 6-speaker systems available.

Driver Assistance

Cruise Control:

Standard on most trims.

Anti Lock Brakes:

Optional.

Connectivity

Connectivity Features:

Limited to analog systems of the era; no Bluetooth or advanced digital connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (7,500 km) or 6-12 months, depending on oil type and driving conditions (consult manual for specific recommendations).

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km)

Cabin Air Filter Replacement:

Not typically equipped on this model year.

Spark Plug Replacement:

30,000-100,000 miles (96,000-160,000 km) depending on spark plug type (platinum or copper).

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), or as per severe service schedule.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Timing Belt Replacement:

Not applicable, both engines utilize a timing chain.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or SAE 10W-30 (refer to owner's manual for specific viscosity based on temperature).

Engine Oil Capacity:

3.8 L (4.0 US qt) for 2.4L I4, 4.4 L (4.7 US qt) for 3.0L V6 (filter included).

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar Antifreeze/Coolant (blue).

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent.

Brake Fluid Type:

DOT 3

Known Issues

Transmission Slipping:

Common issue with the 41TE automatic transmission, often related to solenoids, valve body, or torque converter.

Headlight Switch Failure:

Frequent failure of the headlight switch causing intermittent or complete loss of lighting.

Rear Wiper Failure:

Motor or linkage failure in the rear wiper system.

Ac System Leaks:

Common leaks in the AC system, particularly in the O-rings and condenser.

Door Lock Actuator Failure:

Power door lock actuators can fail, preventing doors from locking or unlocking.

Engine Mounts Wear:

Engine mounts can wear over time, leading to vibrations and increased noise.

ABS Sensor Failure:

Wheel speed sensors for the ABS system can fail, triggering the ABS warning light.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing trucks and passenger vehicles.

Model Evolution

First Generation:

1984-1990 (S Platform)

Second Generation:

1991-1995 (ST Platform - longer wheelbase introduced)

Third Generation Current:

1996-2000 (NS Platform - significant redesign, introduction of Stow 'n Go seating later)

Facelift Year:

1998 represented a mild refresh for the NS generation.

Production

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

Production Years:

1983-2007 (for the Dodge Caravan nameplate in North America)

🏆 Awards & Recognition

Recognitions

Car Of The Year:

The Caravan was instrumental in defining the minivan segment and was a strong seller throughout its lifespan, though specific awards for the 1998 model are not prominently documented as category winners.

Ratings

Consumer Reports Reliability:

Reliability ratings for this generation were often average to below average compared to some competitors, particularly concerning the automatic transmission.