Generation:
Second Generation (1996-2000)
Production Years Covered:
1996, 1997, 1998, 1999, 2000
Target Audience:
Families, small businesses, fleet operators.
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture.
Vehicle Strengths:
Spacious interior, versatile seating configurations, affordability, robust powertrain options.
Manual Value:
Provides mechanics and DIY enthusiasts with the authoritative information needed for accurate diagnosis and repair.
Overall Coverage:
Comprehensive service, repair, and diagnostic information for all major systems of the Dodge Caravan.
Estimated Page Count:
Over 1500 pages (typical for comprehensive service manuals of this era)
Type:
Factory Authorized Service Manual / Workshop Manual
Engine:
3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EBB), 3.8L V6 (Chrysler EGT)
Transmission:
4-Speed Automatic Transmissions (A604/41TE, A670/42LE)
Brakes:
Front Disc, Rear Drum, ABS System (where applicable)
Suspension:
Front Independent (MacPherson Strut), Rear Torsion Beam Axle
Steering:
Power Assisted Rack and Pinion
Electrical:
Complete wiring diagrams, fuses, relays, lighting, ignition system, starting and charging system, instrument cluster, comfort features.
HVAC:
Heating, Ventilation, and Air Conditioning system components and service.
Fuel:
Fuel delivery system, fuel injectors, fuel pump, fuel filter, evaporative emissions system.
Exhaust:
Exhaust system components, catalytic converter, muffler.
Body:
Exterior and interior body panels, doors, glass, seats, trim, power sliding door operation (if equipped).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush.
Diagnostics:
Troubleshooting guides, fault code diagnosis, symptom-based diagnostics.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair.
Disassembly Assembly:
Detailed step-by-step instructions for component removal and installation.
Specifications:
Torque specifications, clearance specifications, alignment specifications.
Depth:
Factory-level diagnostic procedures, component testing, wiring harness tracing, and component-level repair.
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for hands-on use in the workshop.
Quality:
High-resolution digital reproduction of original factory documentation.
Binding:
Not Applicable (Digital Format)
Paper Type:
Not Applicable (Digital Format)
Engine Option 1:
3.0L SOHC V6 (Mitsubishi 6G72)
Engine Option 2:
3.3L OHV V6 (Chrysler EBB)
Engine Option 3:
3.8L OHV V6 (Chrysler EGT)
3.0L V6 Horsepower:
Approx. 150 HP @ 5000 RPM
3.0L V6 Torque:
Approx. 180 lb-ft @ 3750 RPM
3.3L V6 Horsepower:
Approx. 158 HP @ 4600 RPM
3.3L V6 Torque:
Approx. 203 lb-ft @ 3000 RPM
3.8L V6 Horsepower:
Approx. 166 HP @ 4400 RPM
3.8L V6 Torque:
Approx. 218 lb-ft @ 3200 RPM
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Control:
Powertrain Control Module (PCM)
Wheelbase:
Approx. 112.0 inches
Length:
Approx. 178.7 inches (Standard), 193.5 inches (Long Wheelbase - Grand Caravan)
Width:
Approx. 72.0 inches
Height:
Approx. 67.9 inches
Cargo Volume Behind 3Rd Row:
Approx. 15.0 - 20.0 cu ft (depending on configuration)
Cargo Volume With 3Rd Row Folded:
Approx. 60.0 - 70.0 cu ft
Cargo Volume With 2Nd And 3Rd Rows Folded:
Approx. 140.0 - 150.0 cu ft
Curb Weight:
Approx. 3600 - 4000 lbs
Gross Vehicle Weight Rating:
Approx. 5200 - 5500 lbs
NHTSA Front Impact Driver:
4 Star (1996-1999 models) - Note: Specific year variations may exist.
NHTSA Front Impact Passenger:
4 Star (1996-1999 models) - Note: Specific year variations may exist.
IIHS Frontal Offset:
Acceptable/Good (depending on year and specific test criteria)
ABS:
Available Anti-lock Braking System (ABS)
Airbags:
Driver and Passenger Frontal Airbags
Seat Belts:
3-point seat belts in all seating positions, front seat belt pretensioners.
Audio System:
Factory AM/FM stereo with cassette player, optional CD player.
Navigation:
Not available from the factory.
Cruise Control:
Standard or optional depending on trim level.
Auxiliary Input:
Not available from the factory.
Oil Change Interval:
Every 3,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil type used (consult manual for specifics).
Transmission Fluid Service:
Every 30,000 - 60,000 miles (recommended flush and fill)
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years
Spark Plug Replacement:
Approx. 60,000 - 100,000 miles (depending on spark plug type)
Engine Oil Type:
SAE 5W-30 or 10W-30 (depending on temperature, consult owner's manual for exact spec)
Coolant Type:
Mopar Antifreeze/Coolant (Ethylene Glycol based) - Pink/Orange
Power Steering Fluid:
ATF+4 or Mopar Power Steering Fluid
Common Problem 1:
Transmission issues (e.g., Torque Converter shudder, Internal seal leaks, transmission control issues).
Common Problem 2:
Rear axle bearing noise and wear.
Common Problem 3:
Power sliding door mechanism failures or binding.
Common Problem 4:
Evaporative Emission Control (EVAP) system leaks, often resulting in Check Engine Lights.
Common Problem 5:
Cooling system leaks (radiator, hoses).
Common Problem 6:
Window regulator failures.
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan in 1984, setting the standard for family transportation.
Second Generation Introduction:
The second generation debuted for the 1996 model year, featuring a significant redesign with a more aerodynamic profile and improved interior.
Updates During Generation:
Mid-cycle refresh in 1998 brought styling updates, improved safety features, and revised powertrain options.
Manufacturing Plant:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Popularity:
Remained a segment leader in sales throughout its production run due to its value and practicality.
Car And Driver 10Best:
Frequent inclusion in Car and Driver's 10Best Trucks and Vans list during its tenure.
Consumer Reports Ratings:
Varied consumer satisfaction ratings; often praised for practicality but noted for some reliability concerns (as detailed in the manual).
Safety Certifications:
Certified to meet all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for its model years.
