Chrysler Caravan 1996-2005 Service Repair Workshop Manual

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🏷️ 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...

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Type: Car

Vendor:

Sku: 20977

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

Product variants

Description

🏷️ 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.