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Dodge Caravan 1996-2000 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 1996, 1997, 1998, 1999, 2000 Codes Platform Code: NS (Second Generation) 👋 Introduction Market Position Vehicle Segment: Minivan / Family Van Target Audience: Families, fleet operators, DIY mechanics. Competitive Analysis Key Competitors: Chrysler Town & Country, Ford Windstar, Chevrolet Venture, Toyota Sienna, Honda Odyssey. Key Features Vehicle Highlights: Spacious interior, versatile seating arrangements, practical cargo space, family-friendly features, front-wheel drive or optional all-wheel drive. Manual Value Benefit To Owner: Empowers owners to perform maintenance, diagnose issues, and conduct repairs, saving time and money. 📋 Manual Details Coverage Areas General Coverage: Comprehensive factory service and repair for all systems. Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine performance diagnostics, manual transmission, automatic transmission. Chassis: Suspension (front and rear), steering system, braking system (ABS included), wheels and tires. Body: Body construction, interior trim, exterior trim, doors, windows, seats, HVAC (heating, ventilation, and air conditioning). Electrical: Battery, charging system, starting system, lighting systems, instrument panel, wipers and washers, horns, power accessories (windows, locks, mirrors), audio system, security system, onboard diagnostics (OBD-II). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication points. Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common problems and their solutions, diagnostic trouble codes (DTCs). Repair: Step-by-step repair procedures for all major components and systems, including disassembly, assembly, adjustment, and torque specifications. Component Replacement: Detailed instructions for replacing specific parts like engines, transmissions, alternators, starters, brakes, suspension components, etc. Technical Depth Depth: Complete, from basic fluid checks and adjustments to full engine and transmission rebuilds, including electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High-resolution, printable pages with clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Features Searchability: Fully searchable text for quick access to information. ⚙️ Engine Specifications Primary Engine Engine Code: 3.0L V6 (EGE) Engine Name: 2.7L V6 (ECA) Engine Displacement Liters: 2.7 / 3.0 / 3.3 Engine Configuration: V6 Performance Horsepower 2.7L: 150 hp @ 4800 rpm Torque 2.7L: 170 lb-ft @ 3600 rpm Horsepower 3.0L: 158 hp @ 5000 rpm Torque 3.0L: 170 lb-ft @ 3700 rpm Horsepower 3.3L: 170 hp @ 4700 rpm Torque 3.3L: 190 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Engine Management ECU Type: Chrysler DRB III diagnostics recommended 🔧 Transmission Standard Transmission Type 2.7L: 4-Speed Automatic (A604, 41TE) Transmission Type 3.0L/3.3L: 4-Speed Automatic (A604, 41TE) Optional Transmission Type AWD: 4-Speed Automatic (41TE with AWD) Features Transmission Fluid Type: ATF+4 (refer to manual for exact specification and change intervals) 📐 Dimensions Exterior Wheelbase Inches: 112.1 Length Inches: 176.1 - 187.7 (depending on model/trim) Interior Passenger Capacity: 7 Cargo Cargo Volume Cu Ft: 146.9 (max with seats removed) Weights Curb Weight Lbs Approx: 3600 - 4000 (depending on engine/features) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: N/A (Testing methods varied significantly for this era) NHTSA Front Impact Passenger: N/A (Testing methods varied significantly for this era) Active Features ABS: Optional on most models, standard on some higher trims. Passive Features Airbags: Driver and front passenger airbags. Seat Belts: Three-point seat belts for all seating positions. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player, and speaker configurations (e.g., 4, 6, or 8 speakers). Display: Basic analog gauges, center stack with radio and HVAC controls. Driver Assistance Cruise Control: Standard on most trims. Connectivity OBD Ii: On-Board Diagnostics II (OBD-II) compliant, enabling scan tool diagnostics. Comfort Features HVAC: Manual or automatic climate control, front and rear heating/cooling vents. 🔧 Maintenance Service Intervals Oil Change Interval Miles: 3,000-7,500 miles (depending on oil type and driving conditions, consult manual). Transmission Fluid Change Miles: 60,000 - 100,000 miles (refer to manual for specific interval and conditions). Spark Plug Replacement Miles: 100,000 miles (for Platinum/Iridium plugs). Fluid Specifications Engine Oil Type: SAE 5W-30 (API certified, consult manual for specific recommendations). Coolant Type: Ethylene Glycol based coolant (Chrysler's HOAT formula, typically pink). Brake Fluid Type: DOT 3 Known Issues Common Problems: Transmission solenoid failure (especially in early models), power steering pump leaks, EGR valve issues, door lock actuator failures, rear axle bearing wear. Check Engine Light: Often related to EGR, O2 sensors, or minor vacuum leaks. 📚 Vehicle History Brand Heritage Dodge Legacy: Dodge, a division of Chrysler, has a long history of producing reliable and practical vehicles. Model Evolution Generation: This period represents the NS generation of the Dodge Caravan. Redesign: This generation saw significant updates from the previous one, including updated styling and powertrains. Production Manufacturing Location: Windsor, Ontario, Canada; St. Louis, Missouri, USA. 🏆 Awards...
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Dodge Caravan 1996-2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
1996, 1997, 1998, 1999, 2000
Codes
Platform Code:
NS (Second Generation)
👋 Introduction
Market Position
Vehicle Segment:
Minivan / Family Van
Target Audience:
Families, fleet operators, DIY mechanics.
Competitive Analysis
Key Competitors:
Chrysler Town & Country, Ford Windstar, Chevrolet Venture, Toyota Sienna, Honda Odyssey.
Key Features
Vehicle Highlights:
Spacious interior, versatile seating arrangements, practical cargo space, family-friendly features, front-wheel drive or optional all-wheel drive.
Manual Value
Benefit To Owner:
Empowers owners to perform maintenance, diagnose issues, and conduct repairs, saving time and money.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive factory service and repair for all systems.
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine performance diagnostics, manual transmission, automatic transmission.
Chassis:
Suspension (front and rear), steering system, braking system (ABS included), wheels and tires.
Body:
Body construction, interior trim, exterior trim, doors, windows, seats, HVAC (heating, ventilation, and air conditioning).
Electrical:
Battery, charging system, starting system, lighting systems, instrument panel, wipers and washers, horns, power accessories (windows, locks, mirrors), audio system, security system, onboard diagnostics (OBD-II).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication points.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common problems and their solutions, diagnostic trouble codes (DTCs).
Repair:
Step-by-step repair procedures for all major components and systems, including disassembly, assembly, adjustment, and torque specifications.
Component Replacement:
Detailed instructions for replacing specific parts like engines, transmissions, alternators, starters, brakes, suspension components, etc.
Technical Depth
Depth:
Complete, from basic fluid checks and adjustments to full engine and transmission rebuilds, including electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
High-resolution, printable pages with clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
Features
Searchability:
Fully searchable text for quick access to information.
⚙️ Engine Specifications
Primary Engine
Engine Code:
3.0L V6 (EGE)
Engine Name:
2.7L V6 (ECA)
Engine Displacement Liters:
2.7 / 3.0 / 3.3
Engine Configuration:
V6
Performance
Horsepower 2.7L:
150 hp @ 4800 rpm
Torque 2.7L:
170 lb-ft @ 3600 rpm
Horsepower 3.0L:
158 hp @ 5000 rpm
Torque 3.0L:
170 lb-ft @ 3700 rpm
Horsepower 3.3L:
170 hp @ 4700 rpm
Torque 3.3L:
190 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine Management
ECU Type:
Chrysler DRB III diagnostics recommended
🔧 Transmission
Standard
Transmission Type 2.7L:
4-Speed Automatic (A604, 41TE)
Transmission Type 3.0L/3.3L:
4-Speed Automatic (A604, 41TE)
Optional
Transmission Type AWD:
4-Speed Automatic (41TE with AWD)
Features
Transmission Fluid Type:
ATF+4 (refer to manual for exact specification and change intervals)
📐 Dimensions
Exterior
Wheelbase Inches:
112.1
Length Inches:
176.1 - 187.7 (depending on model/trim)
Interior
Passenger Capacity:
7
Cargo
Cargo Volume Cu Ft:
146.9 (max with seats removed)
Weights
Curb Weight Lbs Approx:
3600 - 4000 (depending on engine/features)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
N/A (Testing methods varied significantly for this era)
NHTSA Front Impact Passenger:
N/A (Testing methods varied significantly for this era)
Active Features
ABS:
Optional on most models, standard on some higher trims.
Passive Features
Airbags:
Driver and front passenger airbags.
Seat Belts:
Three-point seat belts for all seating positions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player, and speaker configurations (e.g., 4, 6, or 8 speakers).
Display:
Basic analog gauges, center stack with radio and HVAC controls.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
OBD Ii:
On-Board Diagnostics II (OBD-II) compliant, enabling scan tool diagnostics.
Comfort Features
HVAC:
Manual or automatic climate control, front and rear heating/cooling vents.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
3,000-7,500 miles (depending on oil type and driving conditions, consult manual).
Transmission Fluid Change Miles:
60,000 - 100,000 miles (refer to manual for specific interval and conditions).
Spark Plug Replacement Miles:
100,000 miles (for Platinum/Iridium plugs).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API certified, consult manual for specific recommendations).
Coolant Type:
Ethylene Glycol based coolant (Chrysler's HOAT formula, typically pink).
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Transmission solenoid failure (especially in early models), power steering pump leaks, EGR valve issues, door lock actuator failures, rear axle bearing wear.
Check Engine Light:
Often related to EGR, O2 sensors, or minor vacuum leaks.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge, a division of Chrysler, has a long history of producing reliable and practical vehicles.
Model Evolution
Generation:
This period represents the NS generation of the Dodge Caravan.
Redesign:
This generation saw significant updates from the previous one, including updated styling and powertrains.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Often featured on Car and Driver's Ten Best lists in earlier generations for its practicality.
Ratings
Consumer Reports:
Generally received average to above-average ratings for reliability and owner satisfaction during its production run, with some years noted for transmission issues.
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