DODGE CARAVAN 1996-2000 (NS) Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Model Generation: NS Production Years Covered: 1996, 1997, 1998, 1999, 2000 👋 Introduction Market Position Vehicle Class: Compact Minivan Target Audience: Families, small businesses requiring versatile passenger and cargo hauling. Competitive Analysis Key Competitors: Ford Windstar, Chevrolet Venture, Plymouth Voyager/Grand Voyager, Honda Odyssey. Key Features Vantages: Practicality, spacious interior, flexible seating configurations, often good value. Manual Value Proposition: Empowers owners and technicians to perform accurate diagnostics and repairs, reducing labor costs and extending vehicle life. 📋 Manual Details Coverage Areas General Coverage: Service and repair procedures for the entire vehicle. Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive factory-style service manuals). Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (e.g., PDF) or Printed 📖 Manual Coverage Systems Covered Engine: All engine systems including diagnosis, repair, and specifications. Transmission: Automatic Transaxle (e.g., 41TE, 42LE) service and repair. Brakes: Hydraulic brake system, ABS (if equipped), parking brake. Suspension: Front and rear suspension components, alignment specifications. Steering: Power steering system, steering column, linkage. Electrical: Full electrical system coverage including wiring diagrams, fuses, relays, lighting, starting, charging. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Body: Exterior and interior body panels, doors, glass, seats, trim, collision repair information. Chassis: Frame, underbody components, fuel system, exhaust system. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements. Troubleshooting: Diagnostic procedures for common and complex issues, symptom-based troubleshooting charts. Repair: Step-by-step repair instructions for all major components and systems. Diagnosis: Detailed diagnostic procedures, including OBD-II (On-Board Diagnostics II) codes and interpretations. Disassembly Assembly: Instructions for component removal, inspection, and reinstallation. Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission overhauls. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Print Version Quality: Professional printing with durable binding, clear illustrations, and quality paper. Binding Type Print Binding: Often a robust comb binding or sewn binding for durability. Paper Type Print Paper: Durable, semi-gloss paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Common: 3.0L V6 (6G72) Mitsubishi-sourced Engine Displacement 1: 3.0 Liters (181.7 cubic inches) Engine Configuration 1: SOHC V6 Horsepower 1: Approx. 150-155 hp @ 5000-5200 rpm Torque 1: Approx. 170-180 lb-ft @ 3700-4000 rpm Optional Engine Engine Code Optional: 3.3L V6 (EGA) Chrysler Engine Displacement 2: 3.3 Liters (201.4 cubic inches) Engine Configuration 2: OHV V6 Horsepower 2: Approx. 158-170 hp @ 4800-5200 rpm Torque 2: Approx. 195-205 lb-ft @ 3300-4000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Cooling System Coolant Capacity: Approx. 10.5 US quarts (9.9 liters) Ignition System Ignition Type: Distributorless Ignition System (DIS) or distributor-based (depending on engine/year). 🔧 Transmission Standard Type: 4-Speed Automatic Transaxle Common Codes: 41TE, 42LE Fluid Type Automatic Transmission Fluid: ATF+4 (Chrysler Spec MS-9224) or equivalent (check manual for specific recommendation). Transmission Capacity Fluid Capacity: Approx. 7.0 US quarts (6.6 liters) for a fluid change. 📐 Dimensions Exterior Wheelbase: Approx. 111.8 inches (2840 mm) Length: Approx. 175.4 inches (4455 mm) Width: Approx. 72.2 inches (1834 mm) Height: Approx. 68.8 inches (1748 mm) Cargo Cargo Volume Behind 1St Row: Approx. 136.4 cubic feet (3863 liters) Cargo Volume Behind 2Nd Row: Approx. 78.1 cubic feet (2211 liters) Weights Curb Weight: Approx. 3800-4100 lbs (1724-1860 kg), varies by configuration. 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star Driver, 4-Star Passenger (for 1996 model year typical, check specific year). Active Features ABS: Anti-lock Braking System (ABS) often standard or optional. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Front, second, and third-row seat belts; front seat belt pretensioners. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Basic speaker systems. Driver Assistance Cruise Control: Standard or optional cruise control. Rear Entertainment: Not typically available or aftermarket. Connectivity Aux Input: Not available from factory. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics). Transmission Fluid Change: Typically every 30,000-60,000 miles (48,000-96,000 km). Spark Plug Replacement: Around 100,000 miles (160,000 km) for platinum-tipped plugs. Fluid Specifications Engine Oil Type: SAE 5W-30 (check manual for viscosity by temperature range). Engine Oil Capacity: Approx. 4.0-4.5 US quarts (3.8-4.3 liters), depending on engine. Coolant Type: Ethylene glycol-based, 50/50 mix with distilled water (often Mopar HOAT). Brake Fluid Type: DOT 3 Known Issues Transmission Issues: Valve body issues, torque converter shudder, occasional solenoid failures in automatic transmissions. Engine Cooling: Water pump leaks, radiator leaks, thermostat failures. Electrical Issues: Power window regulators, door lock actuators, dashboard warning light issues. Suspension Components: Worn ball joints, tie rod ends, sway bar links. 📚 Vehicle History Brand Heritage Dodge...
Diagnostic procedures for common and complex issues, symptom-based troubleshooting charts.
Repair:
Step-by-step repair instructions for all major components and systems.
Diagnosis:
Detailed diagnostic procedures, including OBD-II (On-Board Diagnostics II) codes and interpretations.
Disassembly Assembly:
Instructions for component removal, inspection, and reinstallation.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution, searchable PDF with clear diagrams and text.
Print Quality
Print Version Quality:
Professional printing with durable binding, clear illustrations, and quality paper.
Binding Type
Print Binding:
Often a robust comb binding or sewn binding for durability.
Paper Type
Print Paper:
Durable, semi-gloss paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
3.0L V6 (6G72) Mitsubishi-sourced
Engine Displacement 1:
3.0 Liters (181.7 cubic inches)
Engine Configuration 1:
SOHC V6
Horsepower 1:
Approx. 150-155 hp @ 5000-5200 rpm
Torque 1:
Approx. 170-180 lb-ft @ 3700-4000 rpm
Optional Engine
Engine Code Optional:
3.3L V6 (EGA) Chrysler
Engine Displacement 2:
3.3 Liters (201.4 cubic inches)
Engine Configuration 2:
OHV V6
Horsepower 2:
Approx. 158-170 hp @ 4800-5200 rpm
Torque 2:
Approx. 195-205 lb-ft @ 3300-4000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Capacity:
Approx. 10.5 US quarts (9.9 liters)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) or distributor-based (depending on engine/year).
🔧 Transmission
Standard
Type:
4-Speed Automatic Transaxle
Common Codes:
41TE, 42LE
Fluid Type
Automatic Transmission Fluid:
ATF+4 (Chrysler Spec MS-9224) or equivalent (check manual for specific recommendation).
Transmission Capacity
Fluid Capacity:
Approx. 7.0 US quarts (6.6 liters) for a fluid change.
📐 Dimensions
Exterior
Wheelbase:
Approx. 111.8 inches (2840 mm)
Length:
Approx. 175.4 inches (4455 mm)
Width:
Approx. 72.2 inches (1834 mm)
Height:
Approx. 68.8 inches (1748 mm)
Cargo
Cargo Volume Behind 1St Row:
Approx. 136.4 cubic feet (3863 liters)
Cargo Volume Behind 2Nd Row:
Approx. 78.1 cubic feet (2211 liters)
Weights
Curb Weight:
Approx. 3800-4100 lbs (1724-1860 kg), varies by configuration.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star Driver, 4-Star Passenger (for 1996 model year typical, check specific year).
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or optional.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Front, second, and third-row seat belts; front seat belt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Basic speaker systems.
Driver Assistance
Cruise Control:
Standard or optional cruise control.
Rear Entertainment:
Not typically available or aftermarket.
Connectivity
Aux Input:
Not available from factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics).
Transmission Fluid Change:
Typically every 30,000-60,000 miles (48,000-96,000 km).
Spark Plug Replacement:
Around 100,000 miles (160,000 km) for platinum-tipped plugs.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (check manual for viscosity by temperature range).
Engine Oil Capacity:
Approx. 4.0-4.5 US quarts (3.8-4.3 liters), depending on engine.
Coolant Type:
Ethylene glycol-based, 50/50 mix with distilled water (often Mopar HOAT).
Brake Fluid Type:
DOT 3
Known Issues
Transmission Issues:
Valve body issues, torque converter shudder, occasional solenoid failures in automatic transmissions.
Engine Cooling:
Water pump leaks, radiator leaks, thermostat failures.
Electrical Issues:
Power window regulators, door lock actuators, dashboard warning light issues.
Suspension Components:
Worn ball joints, tie rod ends, sway bar links.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing practical and durable vehicles, establishing a reputation for value and utility.
Model Evolution
Ns Generation:
The NS generation marked a significant redesign for the Caravan, moving to a more aerodynamic and modern platform. It offered improved interior space and features over its predecessors.
Production
Manufacturing Location:
Primarily Windsor, Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Automotive Journal Ratings:
Often praised for practicality and value; specific awards may vary by publication and year.
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