🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Model Variants:

Grand Caravan

Related Models Covered:

Plymouth Voyager, Plymouth Grand Voyager, Chrysler Town & Country

Year:

1996

Platform Code:

NS (Second Generation)

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, and dealerships.

Value Proposition:

Provides the same authoritative, factory-level information used by professional technicians, enabling cost-effective and accurate vehicle maintenance and repair.

Advantage:

Offers superior searchability, bookmarking, and on-demand printing compared to traditional physical manuals or older CD-ROM versions.

Features:

Comprehensive coverage, detailed diagrams, diagnostic flowcharts, searchable text, electronic format for portability and accessibility.

📋 Manual Details

Primary Focus:

Service, diagnosis, and repair of the 1996 Dodge Caravan and its variants.

Scope:

Comprehensive, factory-level information.

Estimated Pages:

1500-2000+ (estimated based on factory service manual scope for this era).

Type:

Factory Service Manual / Repair Manual.

Language:

English

Format:

.PDF (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Engine tune-up, cylinder head, pistons, crankshaft, camshaft, timing, lubrication, cooling systems.

Engine Performance:

Fuel system, ignition system, emission control systems, engine performance diagnosis.

Transmission:

Automatic transmission (e.g., 41TE/42LE) service, overhaul, diagnosis, fluid specifications, torque converter.

Driveline:

Front-wheel drive axle shafts, differential, wheel bearings.

Brakes:

Front and rear brake systems, ABS diagnosis and repair, parking brake, brake fluid specifications.

Suspension:

Front and rear suspension components, shock absorbers, struts, ball joints, control arms, alignment specifications.

Steering:

Power steering system, steering gear, steering column, tie rods, steering wheel.

Electrical System:

Battery, charging system, starting system, lighting system, horn, wipers, washers, power windows, power locks.

Electronics Control Modules:

PCM (Powertrain Control Module), BCM (Body Control Module) - diagnosis and testing.

Comfort Controls:

Heating system, air conditioning (HVAC), climate control system.

Safety Systems:

SRS (Supplemental Restraint System) / Airbag system diagnosis and repair, seat belts.

Security Systems:

Vehicle theft security system.

Audio Systems:

Audio system diagnosis and component replacement.

Speed Control:

Cruise control system diagnosis and repair.

Chimes Buzzers:

Chime and buzzer system troubleshooting.

Body And Interior:

Body panel removal and installation, interior trim, doors, windows, seats.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all systems.

Maintenance Tasks:

Scheduled maintenance, fluid changes, filter replacements, lubrication, belt inspection/replacement.

Diagnostic Procedures:

Step-by-step diagnostic charts and troubleshooting guides for common and complex issues.

Repair Procedures:

Detailed disassembly, repair, and reassembly instructions for all major components and systems.

Overhaul Procedures:

Complete overhaul procedures for engines and transmissions.

Component Testing:

Testing procedures for sensors, actuators, and electronic modules using multimeters and diagnostic scan tools.

Special Tool Requirements:

Identification and usage of special tools required for specific repairs.

Exhaust System Repair:

Inspection, diagnosis, and replacement of exhaust components including muffler, catalytic converter, and pipes.

Clutch Service:

While primarily automatic, if manual transmissions were offered, clutch service would be covered (though less common for this model).

Tire Wheel Service:

Tire pressure monitoring, rotation, wheel alignment procedures, and wheel bearing replacement.

Depth:

Factory-level, including component-level diagnostics, adjustments, and complete unit overhauls.

Detail Level:

Extensive detail, including torque specifications, clearances, diagnostic trouble codes (DTCs), and flow rates.

Visual Aids:

Detailed photos, exploded views, and schematic diagrams illustrating procedures and component relationships.

📊 Manual Specifications

Format:

.PDF

Software Requirement:

Adobe Acrobat Reader X or later.

Printability:

High-resolution, suitable for printing individual pages or sections.

Searchability:

Fully searchable text content.

Navigation:

Fully bookmarked and features a clickable contents page for easy navigation.

Binding:

N/A (Digital Download - Print as needed)

Paper Recommendation:

Standard copier paper or heavier weight for durability in shop environments.

⚙️ Engine Specifications

Engine Options:

2.4L (148 cu in) EDZ I4, 3.0L (181 cu in) EDB V6, 3.3L (201 cu in) EHD V6.

Horsepower Range:

Approximately 150 hp (2.4L) to 177 hp (3.3L V6).

Torque Range:

Approximately 170 lb-ft (2.4L) to 196 lb-ft (3.3L V6).

Fuel Delivery:

Multi-port fuel injection (MPI).

Fuel Type:

Unleaded gasoline.

ECU:

Chrysler's proprietary Powertrain Control Module (PCM) systems, often with OBDI/OBDII compliance depending on specific date of manufacture and emissions package.

🔧 Transmission

Transmission Type:

Automatic Transaxle.

Transmission Options:

Commonly the 41TE 4-speed automatic (with 2.4L engine) or 42LE 4-speed automatic (with V6 engines).

Transmission Features:

Electronically controlled, variable speed governer, torque converter clutch (TCC).

📐 Dimensions

Wheelbase Standard:

112.0 inches (2845 mm) for Caravan, 119.3 inches (3030 mm) for Grand Caravan.

Length Standard:

189.1 inches (4803 mm) for Caravan, 197.5 inches (5017 mm) for Grand Caravan.

Cargo Volume Max Standard:

Approximately 140.9 cu ft (Caravan), 159.1 cu ft (Grand Caravan).

Curb Weight Range:

Approximately 3500-4000 lbs depending on engine and options.

🛡️ Safety Features

NHTSA Ratings:

Early 1990s minivans generally had mixed frontal and side impact ratings. Specific 1996 ratings should be verified.

Active Safety:

Four-wheel Anti-lock Brakes (ABS) available on some models.

Passive Safety:

Driver and front passenger airbags, three-point seat belts with pretensioners.

💡 Technology Features

Audio Features:

Factory AM/FM cassette or CD player, speaker systems often upgraded in higher trims.

Driver Assistance Features:

Limited by era; primarily ABS on select models. No electronic stability control or advanced driver-assist systems.

Connectivity Features:

N/A (No factory Bluetooth, USB, or smartphone integration).

🔧 Maintenance

Oil Change Interval:

Typically 3,000-5,000 miles or 3-6 months, depending on driving conditions (refer to manual for specifics).

Transmission Fluid Interval:

Check at 30,000 miles, change at 60,000 miles or as indicated by manual (severe service may require more frequent changes).

Spark Plug Interval:

Varies by plug type, but typically 30,000-100,000 miles for platinum or iridium plugs (check manual).

Coolant Interval:

Initial change at 5 years/100,000 miles, then every 2-3 years/30,000-50,000 miles (depending on coolant type).

Engine Oil Type:

API Service SG or SH, SAE 5W-30 (or as specified by vehicle sticker/manual).

Transmission Fluid Type:

ATF+4 (or equivalent Mopar Automatic Transmission Fluid) - consult manual for exact specification.

Coolant Type:

Ethylene Glycol based coolant, 50/50 mix with distilled water (usually Mopar OAT or HOAT compatible).

Brake Fluid Type:

DOT 3 brake fluid.

Common Problems:

Transmission solenoid issues, EGR valve issues, plenum gasket leaks (V6 engines), coolant leaks (intake manifold, heater core), AC system failures, power window motor failures, front suspension wear (ball joints, tie rods).

📚 Vehicle History

Minivan Pioneer:

Dodge (and its Plymouth counterpart) are credited with popularizing the minivan segment in the North American market.

Generation:

1996 marks the second generation (NS) of the Dodge Caravan, introduced for the 1996 model year, featuring updated styling and improved aerodynamics.

Manufacturing Location:

North America (e.g., St. Louis Assembly, Windsor Assembly).

🏆 Awards & Recognition

Historical Recognition:

The Caravan platform has consistently been a strong seller and a benchmark in the minivan segment for decades, though specific awards for the 1996 model year vary.