Dodge Caravan Year 1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1997 Codes Platform: NS (Second Generation) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, commercial use (cargo van variants). Competitive...

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Type: Caravan

Vendor:

Sku: 372722

Tags: 1997 Caravan Cars Dodge Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform:

NS (Second Generation)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, commercial use (cargo van variants).

Competitive Analysis

Key Competitors:

Ford Windstar, Chevrolet Venture/Lumina APV, Toyota Sienna (introduced later in segment), Chrysler Town & Country/Voyager.

Key Features

Versatility:

Spacious interior, flexible seating configurations, available long-wheelbase (Grand Caravan).

Practicality:

Sliding rear doors, high seating position, focus on utility and passenger comfort.

📋 Manual Details

Coverage Areas

Engine Coverage:

3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EHA), 3.8L V6 (Chrysler EVE)

Transmission Coverage:

3-speed automatic (A500/42TE), 4-speed automatic (A604/41TE)

Drivetrain Coverage:

Front-wheel drive (FWD)

Page Count

Estimated Pages:

1500-2000+ (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Printed book (original factory issue)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, overhaul, timing systems, lubrication, cooling, exhaust.

Fuel System:

Fuel delivery, injection (MPI), evaporative emissions control (EVAP), fuel pump, injectors.

Ignition System:

Ignition timing, coil packs, spark plugs, control modules.

Transmission Automatic:

Diagnosis, repair, overhaul, valve bodies, torque converter, electronic controls.

Brake System:

Front disc, rear drum brakes, ABS (Anti-lock Braking System) diagnosis and repair, hydraulic components.

Suspension System:

Front MacPherson struts, rear torsion beam axle, steering components, alignment specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, power windows, locks, mirrors, interior controls.

HVAC System:

Air conditioning, heating, ventilation, blower motor, controls, refrigerant servicing.

Body And Interior:

Exterior body panels, doors, glass, trim, interior components, seating, cargo management.

Chassis And Frame:

Frame construction, subframes, unibody structure.

Body Control Modules:

Diagnosis and repair of electronic modules controlling various vehicle functions.

Safety Systems:

Seat belts, airbag system (SRS) diagnosis and component replacement (cautionary procedures included).

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks/changes, spark plug replacement, belt inspections/replacement.

Repair Procedures:

Component replacement (e.g., alternator, water pump, starter, fuel pump, brake calipers, struts), gasket replacements, seal replacements.

Diagnostic Procedures:

Troubleshooting flowcharts, symptom-based diagnostics, electrical circuit testing, use of diagnostic tools.

Overhaul Procedures:

Detailed step-by-step instructions for rebuilding engines, transmissions, and major driveline components.

Calibration Procedures:

Wheel alignment adjustments, potentially steering angle sensor recalibration (if applicable).

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission overhauls, advanced electrical diagnostics, and structural repairs.

Diagnostics:

Detailed troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams, component testing procedures.

Specifications:

Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values, diagnostic data.

📊 Manual Specifications

File Format

Digital Format:

N/A (Original is printed)

Print Quality

Quality:

Original Factory Print Quality (high-resolution diagrams, clear text)

Binding Type

Binding:

Typically perfect bound or saddle-stitched, designed for workshop use.

Paper Type

Paper:

Durable, often glossy or semi-gloss paper to withstand workshop conditions and protect diagrams.

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.0L SOHC V6 (Mitsubishi 6G72)

Engine 1 Displacement:

2972 cc (181 cu in)

Engine 1 Horsepower:

142 hp @ 5000 rpm

Engine 1 Torque:

170 lb-ft @ 3000 rpm

Engine Options

Engine 2:

3.3L OHV V6 (Chrysler EHA)

Engine 2 Displacement:

3301 cc (201 cu in)

Engine 2 Horsepower:

156 hp @ 4800 rpm

Engine 2 Torque:

185 lb-ft @ 3600 rpm

Engine 3:

3.8L OHV V6 (Chrysler EVE)

Engine 3 Displacement:

3770 cc (230 cu in)

Engine 3 Horsepower:

166 hp @ 4400 rpm

Engine 3 Torque:

217 lb-ft @ 3600 rpm

Fuel System

Fuel Injection:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Performance

Emission Control:

California emissions controls available on some models.

🔧 Transmission

Standard

Standard Transmission:

3-speed automatic (Chrysler A500 / 42TE)

Optional

Optional Transmission:

4-speed automatic (Chrysler A604 / 41TE) with overdrive (standard on 3.8L models)

Features

Transmission Features:

Electronic overdrive control on 4-speed models, transaxle design.

Fluid Type

Automatic Transmission Fluid:

Chrysler ATF+4 (or equivalent, previously ATF+3 or Dexron IIE)

📐 Dimensions

Exterior

Wheelbase Short:

112.0 inches (2845 mm)

Wheelbase Long:

119.3 inches (3030 mm) - Grand Caravan

Length Short:

178.3 inches (4529 mm)

Length Long:

185.6 inches (4714 mm) - Grand Caravan

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 30-40 cu ft (varies by configuration)

Weights

Curb Weight:

Approx. 3700-4200 lbs (1678-1905 kg) depending on engine and configuration

Towing Capacity:

Up to 2000 lbs (907 kg) with optional towing package

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

3-star (1997 data)

NHTSA Front Impact Passenger:

3-star (1997 data)

IIHS Side Impact:

Acceptable (1997 data, may vary by configuration)

Active Features

Optional Anti-lock Braking System (ABS) on front and rear wheels.

Traction Control:

Not typically available for this model year.

Passive Features

Airbags:

Driver and front passenger airbags (standard).

Seatbelts:

Three-point seat belts for all occupants, front seat belt pre-tensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, optional CD player, available premium sound systems.

Climate Control:

Manual or optional automatic climate control systems.

Driver Assistance

Cruise Control:

Standard on most trims.

Power Features:

Power windows, power door locks, power mirrors (availability varies by trim).

Connectivity

Connectivity Options:

No advanced connectivity features like Bluetooth or USB ports. Typically relies on aftermarket solutions for modern audio integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, depending on driving conditions.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km), inspect more frequently.

Spark Plug Replacement:

100,000 miles (160,000 km) for Platinum-tipped plugs (if equipped); check manual for specific type and interval.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), check fluid condition frequently.

Fluid Specifications

Engine Oil Type:

API certified SAE 5W-30 or 10W-30 (check Owner's Manual for specific viscosity based on temperature).

Engine Oil Capacity:

Approx. 4.0-5.0 quarts (3.8-4.7 liters) depending on engine.

Coolant Type:

Chrysler HOAT (Hybrid Organic Additive Technology) coolant, typically pink or orange.

Coolant Capacity:

Approx. 10-12 quarts (9.5-11.4 liters).

Known Issues

Transmission Problems:

Common issues include failure of the transmission control module (TCM), solenoid pack failures, and torque converter shudder, especially in the 4-speed 41TE/AE.

Engine Mounts:

Worn or broken engine and transmission mounts leading to vibration and noise, particularly during acceleration or deceleration.

Cv Axle Wear:

Front CV (Constant Velocity) axles can wear, leading to clicking noises when turning.

Power Steering Leaks:

Leaks from the power steering pump or lines are not uncommon.

Alternator Failure:

Alternators can be a weak point, especially in high-mileage vehicles.

Evaporative Emissions System:

Faults with the EVAP system (e.g., vent solenoid, purge valve) can cause check engine lights.

📚 Vehicle History

Brand Heritage

Dodge Heritage:

Chrysler Corporation's 'value' division, known for practical and family-oriented vehicles. Dodge Caravan pioneered the minivan segment.

Model Evolution

Generation:

Second Generation (NS) 1996-2000

Design Changes:

Redesigned unibody structure, improved aerodynamics, increased interior space and refinement over the first generation.

Production

Assembly Locations:

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

Production Years:

1997 model year (produced from approximately late 1996 to late 1997).

🏆 Awards & Recognition

Recognitions

Car And Driver 5 Best Trucks:

The Caravan (and its Chrysler siblings) were frequently cited by Car and Driver as among the best trucks (including minivans) in the market during the mid-1990s.

Popular Mechanics Car Of The Year:

Previous generations of the Caravan had received significant automotive awards, setting a strong precedent.

Ratings

Consumer Reports:

Consumer Reports rankings varied by year, but the segment itself was highly competitive and generally well-received for its practicality.