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Dodge Caravan 1996-1999 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 1996, 1997, 1998, 1999 Vehicle Type: Minivan Generation Generation Name: Second Generation (RS) Generation Years: 1996-2000 Codes Chassis Code: RS...
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Dodge Caravan 1996-1999 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
1996, 1997, 1998, 1999
Vehicle Type:
Minivan
Generation
Generation Name:
Second Generation (RS)
Generation Years:
1996-2000
Codes
Chassis Code:
RS
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Minivan
Original Target Audience:
Families, individuals seeking versatile cargo and passenger transport
Competitive Analysis
Key Competitors:
Ford Windstar, Chevrolet Venture/Lumina APV, Pontiac Trans Sport, Honda Odyssey, Toyota Sienna
Key Features
Unique Selling Points:
Practicality, spacious interior, flexible seating arrangements, powerful engine options for its class.
Manual Value Proposition:
Provides essential information for DIY mechanics and professional technicians to maintain, diagnose, and repair the vehicle effectively.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models and Engines for the specified years
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission (Automatic and Manual), Drivetrain, Fuel System, Cooling System, Exhaust System
Chassis:
Suspension (Front and Rear), Steering, Brakes (ABS and Standard), Wheels and Tires
Electrical:
Wiring Diagrams, Lighting, Ignition System, Charging System, Starting System, Instrumentation, Power Accessories, HVAC Controls, Audio System
Body And Interior:
Body Panels, Doors, Windows, Seats, Trim, Restraint Systems (Airbags, Seatbelts), HVAC System
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication
Troubleshooting:
Diagnostic Charts, Symptom-Based Diagnostics, Component Testing
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Electrical Component Replacement, Body Panel Repair, Suspension Component Replacement
Installation:
Component Installation and Removal (e.g., engine, transmission, suspension parts)
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete overhaul and diagnostics)
Diagnostic Level:
Advanced (includes diagnostic trouble codes, component testing, and wiring diagrams)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text (if original PDF is text-based)
Print Quality
Print Readability:
High (designed for clarity of diagrams and text)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
3.0L V6 (EGA)
Engine Description Base:
24-valve SOHC V6
Horsepower Base:
150 hp @ 5200 rpm
Torque Base:
180 lb-ft @ 4000 rpm
Optional Engine
Engine Code Optional:
3.3L V6 (EHD)
Engine Description Optional:
12-valve OHV V6
Horsepower Optional:
158 hp @ 4800 rpm
Torque Optional:
195 lb-ft @ 3600 rpm
Optional Engine 2
Engine Code Optional 2:
3.8L V6 (EWE/430)
Engine Description Optional 2:
12-valve OHV V6
Horsepower Optional 2:
170 hp @ 4400 rpm
Torque Optional 2:
215 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 Octane
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic
Optional
Transmission Type Optional:
None (Manual transmission was discontinued in this generation for the US market)
Features
Transmission Control:
Electronic Control Unit (ECU)
Transmission Fluid Type:
ATF+4 (or equivalent specification like Chrysler 7176E)
📐 Dimensions
Exterior
Wheelbase Standard:
112.1 inches
Length Standard:
186.1 inches
Width Standard:
73.5 inches
Height Standard:
68.8 inches
Weights
Curb Weight Base:
Approx. 3,900 lbs
Gross Vehicle Weight Rating Base:
Approx. 5,200 lbs
Cargo
Cargo Volume Behind First Row:
Approx. 145.4 cu ft
Cargo Volume Behind Second Row:
Approx. 77.5 cu ft
Cargo Volume Behind Third Row:
Approx. 20.9 cu ft
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating Driver:
4 out of 5 stars (1996-1997 models)
NHTSA Frontal Crash Rating Passenger:
4 out of 5 stars (1996-1997 models)
IIHS Frontal Offset Rating:
Good (for 1996 models)
Active Features
ABS:
Standard or Optional depending on trim and model year
Passive Features
Airbags:
Driver and Passenger Frontal Airbags (Standard)
Seatbelts:
Front and Rear Seatbelts, Front Shoulder Belt Height Adjusters
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with cassette player, optional CD player, optional premium sound systems.
Climate Control:
Manual or optional Automatic Climate Control (ACC).
Driver Assistance
Cruise Control:
Standard on most models.
Parking Assistance:
Rear parking assist sensors were an option on some later models, but not common.
Connectivity
Phone Integration:
No factory integrated Bluetooth or smartphone connectivity in this era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (severe) or 7,500 miles (normal) with synthetic oil, or as per owner's manual recommendations based on driving conditions.
Tire Rotation Interval:
Every 5,000-7,500 miles
Transmission Fluid Change Interval:
Every 30,000-60,000 miles, depending on driving conditions and service history.
Fluid Specifications
Engine Oil Type:
API Service SG or SH, SAE 5W-30 (for most conditions)
Coolant Type:
Mopar Antifreeze/Coolant (50/50 mixture with distilled water)
Brake Fluid Type:
DOT 3
Known Issues
Common Problems Powertrain:
Head gasket leaks on some V6 engines, transmission solenoid issues, potential for oil leaks from valve cover gaskets.
Common Problems Chassis:
Worn suspension components (ball joints, tie rod ends), front brake wear, potential for power steering leaks.
Common Problems Electrical:
Faulty power window regulators, HVAC blower motor failures, dashboard instrument cluster issues, door lock actuator failures.
Common Problems Body:
Rust around wheel wells and rocker panels, issues with sliding door mechanisms.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (at the time)
Model Evolution
Generation Start:
Second generation debuted for the 1996 model year, introducing a significant redesign from the first generation.
Platform Sharing:
Shared platform with Plymouth Voyager and Chrysler Town & Country.
Production
Production Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Market Presence:
One of the best-selling minivans in North America during its production run.
🏆 Awards & Recognition
Recognitions
Consumer Guide Rankings:
Frequently rated as a recommended buy by automotive publications like Consumer Guide during its production.
Car And Driver Best 10:
While not a consistent recipient of top '10 Best' awards, it was recognized for its practicality and family-friendliness.
Certifications
Emission Standards:
Meets prevailing Federal and California emission standards for its model years.
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