Chrysler Caravan 1996-2005 Service Repair Workshop Manual

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Taper: Car

Distributeur:

UGS: 69817

Mots clés: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Car Caravan Chrysler Marine Misc Outboard Engines

Variantes de produits

Description

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.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Caravan

Generation

Generation Designation:

NS/GS

Codes

Platform Code:

Chrysler Minivan Platform (NS/GS)

👋 Introduction

Market Position

Vehicle Type:

Minivan

Target Audience:

Families, small businesses, fleet operators

Competitive Analysis

Key Competitors:

Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager, Nissan Quest

Key Features

Versatility:

Spacious interior, flexible seating configurations

Comfort:

Smooth ride, comfortable seating

Practicality:

Ample cargo space, sliding doors

📋 Manual Details

Coverage Areas

Applicable Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Page Count

Estimated Page Count:

Approximately 2000+

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine Electrical:

Fuel System:

Exhaust System:

Cooling System:

Transmission Automatic:

Transmission Manual:

Yes (if applicable)

Drivetrain Axles:

Suspension Front:

Suspension Rear:

Steering System:

Brake System Front:

Brake System Rear:

Anti Lock Braking System ABS:

Body Frame:

Body Panels Doors:

Interior Trim:

Seating Systems:

HVAC System:

Lighting System:

Instrument Panel Gauges:

Power Accessories Windows:

Power Accessories Locks:

Power Accessories Doors:

Yes (e.g., sliding door, liftgate)

Audio System:

Security System Alarms:

Airbag System Srs:

Wiring Diagrams Electrical Schematics:

Procedures Included

Routine Maintenance:

Troubleshooting Diagnostics:

Component Removal Installation:

Engine Rebuild:

Transmission Overhaul:

Brake System Repair:

Suspension And Steering Repair:

Body And Interior Repair:

Electrical Component Testing:

HVAC System Repair:

Diagnostic Trouble Codes DTC Explanation:

Technical Depth

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

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text-based PDF

Print Quality

Printability:

Designed for easy printing of individual sections

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Options Available:

3.0L V6 (Vulcan), 3.3L V6 (EGA), 3.8L V6 (L32)

Performance

Horsepower Range:

150-215 HP (depending on engine)

Torque Range:

170-267 lb-ft (depending on engine)

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Standard Transmission:

4-Speed Automatic (41TE/42LE)

Optional

Optional Transmission:

N/A (Automatic standard across most trims)

Features

Transmission Features:

Electronically controlled, overdrive

📐 Dimensions

Exterior

Wheelbase Standard:

113.3 inches

Wheelbase Long Wheelbase Lwb:

119.3 inches

Cargo

Max Cargo Volume Standard Wheelbase:

Approx. 133.4 cu ft

Max Cargo Volume Long Wheelbase:

Approx. 159.1 cu ft

Weights

Curb Weight Range:

Approx. 3800 - 4400 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (1996-1999 models, specific tests vary)

NHTSA Front Impact Passenger:

4 Stars (1996-1999 models, specific tests vary)

Active Features

Anti Lock Braking System ABS:

Standard or Optional depending on year/trim

Passive Features

Airbags Front:

Driver and Passenger Airbags (SRS)

Child Seat Anchors Latch:

Available (may require specific installation kit for earlier years)

💡 Technology Features

Infotainment

Audio Options:

AM/FM radio, cassette player, CD player (optional), premium sound systems

Driver Assistance

Cruise Control:

Standard on most trims

Power Adjustable Pedals:

Available on some later models

Connectivity

Auxiliary Input:

Not typically factory equipped; aftermarket solutions available.

🔧 Maintenance

Service Intervals

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

Fluid Specifications

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

Known Issues

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.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984.

Model Evolution

Generation Transition:

This generation (NS for 1996-2000, GS for 2001-2007) represented a significant redesign from the previous AS platform.

Production

Manufacturing Location:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Car and Driver named the Dodge Caravan (a sibling model) to its 10Best list in 1997.