This manual covers the Chrysler Caravan, a versatile minivan produced from 1996 to 2005. Built on the Chrysler Minivan Platform (NS/GS), this vehicle is renowned for its spacious interior, flexible seating, and practical design, making it an ideal choice for families, small businesses, and fleet operators. Notable features include comfortable seating, a smooth ride, and ample cargo space, further enhanced by its signature sliding doors and optional long-wheelbase configurations. The Caravan offers a range of V6 engine options, providing a balance of power and efficiency for everyday use and longer journeys.
This comprehensive Service Repair Workshop Manual provides in-depth guidance for the maintenance, repair, and troubleshooting of your Chrysler Caravan. Covering all major systems, including engine mechanical and electrical, fuel, exhaust, cooling, transmission, drivetrain, suspension, steering, brakes, and body systems, this manual offers detailed procedures for routine maintenance, component removal and installation, and even engine and transmission overhauls. With clear, high-resolution wiring diagrams, diagnostic trouble code explanations, and precise specifications, this resource empowers owners, mechanics, and technicians to effectively diagnose issues and ensure the optimal performance and longevity of their vehicle.
Generation Designation:
NS/GS
Platform Code:
Chrysler Minivan Platform (NS/GS)
Target Audience:
Families, small businesses, fleet operators
Key Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager, Nissan Quest
Versatility:
Spacious interior, flexible seating configurations
Comfort:
Smooth ride, comfortable seating
Practicality:
Ample cargo space, sliding doors
Applicable Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Page Count:
Approximately 2000+
Manual Type:
Service Repair Workshop Manual
Transmission Automatic:
Yes
Transmission Manual:
Yes (if applicable)
Anti Lock Braking System ABS:
Yes
Instrument Panel Gauges:
Yes
Power Accessories Windows:
Yes
Power Accessories Locks:
Yes
Power Accessories Doors:
Yes (e.g., sliding door, liftgate)
Security System Alarms:
Yes
Wiring Diagrams Electrical Schematics:
Yes
Troubleshooting Diagnostics:
Yes
Component Removal Installation:
Yes
Transmission Overhaul:
Yes
Suspension And Steering Repair:
Yes
Body And Interior Repair:
Yes
Electrical Component Testing:
Yes
Diagnostic Trouble Codes DTC Explanation:
Yes
Depth Of Information:
Comprehensive (from basic maintenance to full overhauls)
Diagnostic Procedures:
Detailed symptom-based troubleshooting guides
Torque Specifications:
Included for all major fasteners
Clearances And Tolerances:
Included for critical engine and drivetrain components
Wiring Diagram Clarity:
High-resolution and detailed
Searchability:
Likely searchable text-based PDF
Printability:
Designed for easy printing of individual sections
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Engine Options Available:
3.0L V6 (Vulcan), 3.3L V6 (EGA), 3.8L V6 (L32)
Horsepower Range:
150-215 HP (depending on engine)
Torque Range:
170-267 lb-ft (depending on engine)
Fuel Delivery:
Multi-Port Fuel Injection (MPFI)
Recommended Fuel:
87 Octane Unleaded Gasoline
Standard Transmission:
4-Speed Automatic (41TE/42LE)
Optional Transmission:
N/A (Automatic standard across most trims)
Transmission Features:
Electronically controlled, overdrive
Wheelbase Standard:
113.3 inches
Wheelbase Long Wheelbase Lwb:
119.3 inches
Max Cargo Volume Standard Wheelbase:
Approx. 133.4 cu ft
Max Cargo Volume Long Wheelbase:
Approx. 159.1 cu ft
Curb Weight Range:
Approx. 3800 - 4400 lbs (depending on configuration)
NHTSA Front Impact Driver:
4 Stars (1996-1999 models, specific tests vary)
NHTSA Front Impact Passenger:
4 Stars (1996-1999 models, specific tests vary)
Anti Lock Braking System ABS:
Standard or Optional depending on year/trim
Airbags Front:
Driver and Passenger Airbags (SRS)
Child Seat Anchors Latch:
Available (may require specific installation kit for earlier years)
Audio Options:
AM/FM radio, cassette player, CD player (optional), premium sound systems
Cruise Control:
Standard on most trims
Power Adjustable Pedals:
Available on some later models
Auxiliary Input:
Not typically factory equipped; aftermarket solutions available.
Oil Change Interval:
3,000-7,500 miles or 6 months (refer to manual for specific engine/oil type)
Engine Air Filter Replacement:
15,000-30,000 miles
Spark Plug Replacement:
30,000-100,000 miles (depending on plug type)
Transmission Fluid Change:
30,000-60,000 miles
Engine Oil Type:
API SN/SP, ILSAC GF-6A (typically 5W-30, consult manual for exact spec)
Transmission Fluid Type:
ATF+4 (for later models), ATF+3 (for earlier models) - consult manual
Coolant Type:
Chrysler HOAT (Hybrid Organic Additive Technology) coolant
Transmission Problems:
Premature wear in automatic transmissions (especially 41TE/42LE) due to heat and fluid degradation, torque converter shudder.
Suspension Wear:
Front suspension components (ball joints, tie rods, control arm bushings) can wear prematurely.
Power Sliding Door Actuators:
Actuators and related mechanisms can fail over time.
Heater Core Leaks:
Leaking heater cores are a common complaint, often requiring dashboard removal for replacement.
Ignition Coil Failure:
Individual ignition coils can fail, causing misfires.
Chrysler Minivan Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984.
Generation Transition:
This generation (NS for 1996-2000, GS for 2001-2007) represented a significant redesign from the previous AS platform.
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Car And Driver 10Best:
Car and Driver named the Dodge Caravan (a sibling model) to its 10Best list in 1997.