Dodge Caravan Grand Caravan Complete Workshop Service Repair Manual 1997 1998 1999
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🏷️ Basic Information Identification Make: Dodge Model: Caravan / Grand Caravan Years Covered: 1997, 1998, 1999 👋 Introduction Market Position Positioning: The Dodge Caravan and Grand Caravan were segment-defining minivans, popular for family transport and versatility. This manual addresses a critical period in their development. Competitive Analysis Competitors: Competed with vehicles like the Chrysler Town & Country, Plymouth Voyager, Ford Windstar, and Chevrolet Venture. Key Features Model Strengths: Spacious interior, flexible seating arrangements (Stow 'n Go introduced later, but versatility was key), comfortable ride, and availability of powerful V6 engines. Manual Value Proposition Value: Provides DIY mechanics and professional technicians with the essential information to diagnose, maintain, and repair these vehicles, saving significant costs compared to dealership service. 📋 Manual Details Coverage Areas Engine Coverage: All gasoline engines including 2.4L, 3.0L V6, 3.3L V6, and 3.8L V6 Transmission Coverage: Automatic Transmissions (A604, A670, 42LE) Chassis Coverage: Suspension, Steering, Brakes (ABS and non-ABS), Body and Frame Electrical Coverage: Wiring Diagrams, Fuses, Relays, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Accessories Page Count Estimated Pages: 1500+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (typically PDF) 📖 Manual Coverage Systems Covered Powertrain Systems: Engine mechanical, fuel, ignition, emissions, cooling, lubrication, starting and charging, engine diagnostics. Drivetrain Systems: Automatic transmission operation, diagnosis, overhaul, clutch, differential, drive axles. Chassis Systems: Front and rear suspension, steering system components, brake system hydraulics and mechanics (including ABS), wheel bearings, alignment. Body And Interior Systems: Body construction, doors, windows, seats, interior trim, HVAC system diagnosis and repair, body hardware. Electrical And Electronics Systems: Comprehensive wiring diagrams, fuse and relay identification, battery system, lighting systems, instrument cluster, power windows/locks, cruise control, audio system, Powertrain Control Module (PCM) and Body Control Module (BCM) functions and diagnostics. Procedures Included Maintenance Procedures: Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, brake pad replacement, belt replacement, fluid checks and changes. Diagnostic Procedures: Troubleshooting guides for common drivability issues, electrical faults, HVAC problems, using diagnostic trouble codes (DTCs). Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all major systems. Rebuilding Procedures: Detailed overhaul procedures for engines and transmissions. Special Tools And Techniques: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and wiring schematics. 📊 Manual Specifications File Format Format Details: Digital PDF, often optimized for searchability and printing. High-resolution scans of original factory service manuals. Print Quality Quality: High resolution, clear text and diagrams, allowing for easy reading and printing of specific sections. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L DOHC I4 (Naturally Aspirated), 3.0L SOHC V6 (Mitsubishi design), 3.3L OHV V6 (Chrysler design), 3.8L OHV V6 (Chrysler design). Performance Horsepower Torque 3.3L V6: Approx. 158 hp @ 4500 rpm, 190 lb-ft @ 3200 rpm (figures may vary slightly by year). Horsepower Torque 3.8L V6: Approx. 166 hp @ 4500 rpm, 230 lb-ft @ 3200 rpm (figures may vary slightly by year). Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Management ECU Type: Engine Control Module (ECM) / Powertrain Control Module (PCM) Cooling System Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically pink or orange. Refer to manual for specific Mopar part numbers (e.g., Mopar 05010855AA). Lubrication System Oil Type 3.3L 3.8L: SAE 3.8L V6: SAE 5W-30 viscosity recommended. (Consult manual for exact specification, e.g., MS-6395) Oil Capacity 3.3L: Approx. 4.5 U.S. quarts (4.3 L) with filter. (Verify in manual) 🔧 Transmission Standard Transmission Type: Automatic Transmission only. Optional Transmission Variants: A604 (4-speed automatic transaxle), A670 (4-speed automatic transaxle, evolution of A604), 42LE (4-speed automatic transaxle with improved torque converter). Features Torque Converter Lockup: Torque converter clutch for improved fuel economy at cruising speeds. Fluid Specifications Transmission Fluid Type: Chrysler ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Use Mopar or equivalent. (e.g., Mopar 05013457GA) Fluid Capacity Transmission Fluid Capacity: Approx. 4-5 U.S. quarts (3.8-4.7 L) for a fluid change. Total capacity higher for overhaul. (Verify in manual) 📐 Dimensions Exterior Wheelbase: 112.1 inches (2847 mm) for Grand Caravan, 111.8 inches (2839 mm) for Caravan. Length: Approx. 190-193 inches (4826-4896 mm) depending on model and year. Cargo Cargo Volume Max: Over 140 cubic feet (3,965 L) with rear seats removed. Weights Curb Weight: Approx. 3,800 - 4,300 lbs (1,724 - 1,950 kg) depending on configuration. Towing Capacity: Up to 2,000 lbs (907 kg) with optional towing package and the 3.8L V6 engine. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Likely 4-star rating (based on typical performance for the era, refer to specific NHTSA reports for exact data). NHTSA Front Impact Passenger: Likely 4-star rating (based on typical performance for the...
The Dodge Caravan and Grand Caravan were segment-defining minivans, popular for family transport and versatility. This manual addresses a critical period in their development.
Competitive Analysis
Competitors:
Competed with vehicles like the Chrysler Town & Country, Plymouth Voyager, Ford Windstar, and Chevrolet Venture.
Key Features
Model Strengths:
Spacious interior, flexible seating arrangements (Stow 'n Go introduced later, but versatility was key), comfortable ride, and availability of powerful V6 engines.
Manual Value Proposition
Value:
Provides DIY mechanics and professional technicians with the essential information to diagnose, maintain, and repair these vehicles, saving significant costs compared to dealership service.
📋 Manual Details
Coverage Areas
Engine Coverage:
All gasoline engines including 2.4L, 3.0L V6, 3.3L V6, and 3.8L V6
Transmission Coverage:
Automatic Transmissions (A604, A670, 42LE)
Chassis Coverage:
Suspension, Steering, Brakes (ABS and non-ABS), Body and Frame
Electrical Coverage:
Wiring Diagrams, Fuses, Relays, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Accessories
Front and rear suspension, steering system components, brake system hydraulics and mechanics (including ABS), wheel bearings, alignment.
Body And Interior Systems:
Body construction, doors, windows, seats, interior trim, HVAC system diagnosis and repair, body hardware.
Electrical And Electronics Systems:
Comprehensive wiring diagrams, fuse and relay identification, battery system, lighting systems, instrument cluster, power windows/locks, cruise control, audio system, Powertrain Control Module (PCM) and Body Control Module (BCM) functions and diagnostics.
Procedures Included
Maintenance Procedures:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, brake pad replacement, belt replacement, fluid checks and changes.
Diagnostic Procedures:
Troubleshooting guides for common drivability issues, electrical faults, HVAC problems, using diagnostic trouble codes (DTCs).
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment for all major systems.
Rebuilding Procedures:
Detailed overhaul procedures for engines and transmissions.
Special Tools And Techniques:
Identification and usage of specialized tools required for specific repairs.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and wiring schematics.
📊 Manual Specifications
File Format
Format Details:
Digital PDF, often optimized for searchability and printing. High-resolution scans of original factory service manuals.
Print Quality
Quality:
High resolution, clear text and diagrams, allowing for easy reading and printing of specific sections.
Approx. 158 hp @ 4500 rpm, 190 lb-ft @ 3200 rpm (figures may vary slightly by year).
Horsepower Torque 3.8L V6:
Approx. 166 hp @ 4500 rpm, 230 lb-ft @ 3200 rpm (figures may vary slightly by year).
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Engine Management
ECU Type:
Engine Control Module (ECM) / Powertrain Control Module (PCM)
Cooling System
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically pink or orange. Refer to manual for specific Mopar part numbers (e.g., Mopar 05010855AA).
Approx. 4.5 U.S. quarts (4.3 L) with filter. (Verify in manual)
🔧 Transmission
Standard
Transmission Type:
Automatic Transmission only.
Optional
Transmission Variants:
A604 (4-speed automatic transaxle), A670 (4-speed automatic transaxle, evolution of A604), 42LE (4-speed automatic transaxle with improved torque converter).
Features
Torque Converter Lockup:
Torque converter clutch for improved fuel economy at cruising speeds.
Fluid Specifications
Transmission Fluid Type:
Chrysler ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Use Mopar or equivalent. (e.g., Mopar 05013457GA)
Fluid Capacity
Transmission Fluid Capacity:
Approx. 4-5 U.S. quarts (3.8-4.7 L) for a fluid change. Total capacity higher for overhaul. (Verify in manual)
📐 Dimensions
Exterior
Wheelbase:
112.1 inches (2847 mm) for Grand Caravan, 111.8 inches (2839 mm) for Caravan.
Length:
Approx. 190-193 inches (4826-4896 mm) depending on model and year.
Cargo
Cargo Volume Max:
Over 140 cubic feet (3,965 L) with rear seats removed.
Weights
Curb Weight:
Approx. 3,800 - 4,300 lbs (1,724 - 1,950 kg) depending on configuration.
Towing Capacity:
Up to 2,000 lbs (907 kg) with optional towing package and the 3.8L V6 engine.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Likely 4-star rating (based on typical performance for the era, refer to specific NHTSA reports for exact data).
NHTSA Front Impact Passenger:
Likely 4-star rating (based on typical performance for the era, refer to specific NHTSA reports for exact data).
IIHS Front Barrier Frontal:
Likely Acceptable rating (based on typical performance for the era, refer to specific IIHS reports for exact data).
Active Features
ABS:
Anti-lock Braking System (ABS) available, often standard on higher trims or with specific engines.
Traction Control:
Traction control system was an option on some models.
Passive Features
Airbags:
Driver and passenger front airbags standard.
Seatbelts:
Three-point seatbelts for all seating positions, including shoulder belts in the second and third rows.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette and CD player options. Optional premium sound systems were available.
Display Screens:
Basic dashboard display for instrumentation. No integrated navigation or touchscreen displays in this era.
Driver Assistance
Cruise Control:
Electronic cruise control system available on most trims.
Connectivity
Auxiliary Input:
No standard auxiliary audio input (e.g., 3.5mm jack) or USB ports. Aftermarket solutions typically required.
Interior Tech
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil. Refer to manual for exact specification and severe driving conditions.
Transmission Fluid Change:
Recommended every 60,000 - 100,000 miles (96,000 - 160,000 km), or as per severe service schedule. Fluid and filter change is crucial for longevity.
Spark Plug Replacement V6:
Platinum-tipped spark plugs typically have a service life of 100,000 miles (160,000 km).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for exact specification). Use fresh fluid from a sealed container.
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent specification (often a specific type of ATF fluid). Check manual for exact type.
Known Issues
Common Wear Items:
Front suspension components (ball joints, tie rod ends, bushings), wheel bearings, exhaust systems, HVAC blower motors, and transmission solenoid packs in early models.
Engine Specific Issues:
Oil leaks from valve covers and oil pans, potential head gasket issues on earlier 3.0L V6 engines, and distributor issues on some models.
Transmission Specific Issues:
Transmission solenoid issues, torque converter shudder, and internal component wear in higher mileage units.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge, a division of Chrysler (later DaimlerChrysler, then Fiat Chrysler Automobiles), has a long history of producing robust vehicles, including popular trucks and muscle cars.
Model Evolution
Third Generation Minivan:
These model years (1997-1999) represent the third generation of the Dodge Caravan/Grand Caravan platform, known for styling updates and continued improvements in safety and powertrain.
Production
Manufacturing Location:
Primarily manufactured in North America, with significant production facilities in Canada (Windsor, Ontario) and the United States.
🏆 Awards & Recognition
Recognitions
Segment Leader:
The Caravan/Grand Caravan was a perennial sales leader and often considered the benchmark in the minivan segment during its production years.
Ratings
Consumer Reports Historical:
Historically, Consumer Reports ratings varied, often citing good performance and utility but sometimes flagging reliability concerns in specific areas (e.g., transmissions, electrical).
Certifications
Manufacturer Certification:
Manual adheres to manufacturer's recommended service procedures and specifications.
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