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DODGE Grand CARAVAN 1996-2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Grand Caravan Generation: Second Generation (2nd Gen) Codes Vehicle Platform: NS Platform Model Years Covered: 1996, 1997, 1998, 1999, 2000 👋 Introduction Market...
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Type: Caravan
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Sku: 420866
DODGE Grand CARAVAN 1996-2000 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Grand Caravan
Generation:
Second Generation (2nd Gen)
Codes
Vehicle Platform:
NS Platform
Model Years Covered:
1996, 1997, 1998, 1999, 2000
👋 Introduction
Market Position
Segment:
Minivan
Primary Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna
Competitive Analysis
Key Strengths:
Spacious interior, versatile seating, comfortable ride, competitive pricing, strong V6 engine options, robust powertrain (especially the 3.3L and 3.8L V6)
Key Features
Seating Capacity:
7-8 passengers (depending on configuration)
Doors:
Standard rear liftgate, optional sliding side cargo door
Cargo Versatility:
Fold-in-the-floor rear seats (on some models/trims), removable rear seats, abundant cargo space
📋 Manual Details
Coverage Areas
Market Coverage:
United States (US) and Canada
Page Count
Estimated Page Count:
1000+ pages (typical for a comprehensive factory service manual)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.0L V6, 3.3L V6, 3.8L V6), Transmission (3-speed automatic, 4-speed automatic), Drivetrain (FWD)
Chassis:
Suspension (front and rear), Steering, Brakes (front disc, rear drum/disc), Wheels and Tires
Electrical:
Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, Instrumentation, Audio Systems, Power Accessories (windows, locks, mirrors), HVAC Controls
Body And Interior:
Body Panels, Doors, Seats, Trim, Glass, Body Sealing, Corrosion Prevention
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections, lubrication
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, wiring diagrams, flow charts
Repair:
Engine overhaul, transmission overhaul/rebuild, brake system repair, suspension component replacement, electrical component repair/replacement, bodywork repair
Disassembly And Assembly:
Step-by-step instructions for removing and installing major components and sub-assemblies
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete vehicle disassembly and reassembly
Target Audience:
Professional Technicians and Serious DIY Mechanics
📊 Manual Specifications
File Format
PDF Features:
Searchable text, clickable links for navigation, zoomable pages, printable
Print Quality
Image Resolution:
High-resolution scans/original digital files ensuring clarity of diagrams and text
Binding Type
Binding:
N/A (Digital PDF Format)
Paper Type
Paper Type:
N/A (Digital PDF Format)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
2.4L 4-cylinder (Turbocharged - rare, primarily Canada)
Engine Option 2:
3.0L Mitsubishi V6 (6G72 SOHC)
Engine Option 3:
3.3L Chrysler V6 (EGA SOHC)
Engine Option 4:
3.8L Chrysler V6 (L32/EGH SOHC)
Performance
3.0L V6 Horsepower:
142 hp @ 4800 rpm
3.0L V6 Torque:
170 lb-ft @ 3700 rpm
3.3L V6 Horsepower:
158 hp @ 4600 rpm (later models up to 166 hp @ 4600 rpm)
3.3L V6 Torque:
190 lb-ft @ 3200 rpm (later models up to 198 lb-ft @ 3200 rpm)
3.8L V6 Horsepower:
166 hp @ 4000 rpm (later models up to 180 hp @ 4000 rpm)
3.8L V6 Torque:
230 lb-ft @ 3200 rpm (later models up to 235 lb-ft @ 3200 rpm)
Fuel System
Induction:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
🔧 Transmission
Standard
Transmission Type:
3-speed automatic (A604/41TE on some 3.0L models)
Optional
Transmission Type 2:
4-speed automatic (42LE/42TE on 3.3L and 3.8L models)
Features
Transmission Control:
Electronic Control (on 4-speed models)
Fluid Specifications
Automatic Transmission Fluid:
Chrysler ATF+4 (or equivalent, check manual for exact specification and fill procedures)
📐 Dimensions
Exterior
Length:
Approximately 180-182 inches (depending on year/trim)
Width:
Approximately 72 inches
Height:
Approximately 67-68 inches
Interior
Passenger Volume:
Approximately 140-150 cubic feet
Cargo
Cargo Volume Behind 3Rd Row:
Approximately 20-30 cubic feet
Cargo Volume With Seats Folded:
Approximately 100-120 cubic feet
Weights
Curb Weight:
Approximately 3700-4200 lbs (depending on engine and trim)
Gross Vehicle Weight Rating Gvwr:
Approximately 5500-6000 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test Driver:
4/5 stars (for models equipped with airbags, check specific year reports)
NHTSA Frontal Crash Test Passenger:
4/5 stars (for models equipped with airbags, check specific year reports)
IIHS Ratings:
Varies by year; some were rated 'Acceptable' or 'Marginal' in frontal impacts
Active Features
ABS:
Standard on most models, optional on some base trims
Traction Control:
Optional on some higher trims and later models
Passive Features
Airbags:
Driver and passenger front airbags standard (from 1996 onwards), optional side airbags on some later models
Seat Belts:
Front 3-point, rear 3-point and lap belts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player, available premium audio systems with amplifier
Rear Entertainment:
Optional rear seat video screens and VCR/DVD players on some later models
Driver Assistance
Cruise Control:
Standard on most trims
Anti Lock Braking System:
ABS available/standard depending on trim and year
Connectivity
Diagnostic Ports:
OBD-II (On-Board Diagnostics II) compliant, located under the dashboard
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 3-6 months (synthetic oil recommended for longer intervals), depending on driving conditions and oil type. Refer to manual for specific recommendations.
Transmission Fluid Change:
Every 30,000-60,000 miles, or as recommended by the manual, especially under severe usage.
Coolant Flush:
Every 30,000-50,000 miles or 2-3 years.
Spark Plug Replacement:
Varies by plug type: ~30,000 miles for conventional, ~100,000 miles for platinum/iridium. Manual specifies exact intervals.
Fluid Specifications
Engine Oil:
SAE 5W-30 API Service SG, SH, or SJ (Check manual for specific viscosity for ambient temperatures)
Coolant:
Chrysler's HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically a 50/50 mix with distilled water. Mopar OAT (Organic Additive Technology) is not compatible.
Power Steering Fluid:
ATF+3 or ATF+4 (Check manual for exact specification)
Brake Fluid:
DOT 3
Known Issues
Transmission:
Intermittent shifting issues, torque converter shudder (especially on 42LE/TE models), transmission fluid leaks.
Engine:
Intake manifold gasket leaks (3.3L/3.8L), oil pan gasket leaks, occasional head gasket issues (though less common than earlier models), PCV valve clogging.
Electrical:
Window regulator failures, power lock actuator failures, instrument cluster failures (especially the odometer), faulty door lock actuators, EGR valve issues.
Suspension:
Worn ball joints, tie rod ends, and control arm bushings leading to steering wander and uneven tire wear.
Body:
Rear liftgate support strut failure, rust on rocker panels, wheel wells, and rear quarter panels.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history in the American automotive market, known for trucks, muscle cars, and family vehicles like the Caravan.
Model Evolution
Second Generation:
This generation (1996-2000) saw a significant redesign from the first generation, featuring a more aerodynamic body, improved safety, and enhanced powertrain options. It introduced the 'Grand' moniker to differentiate from the shorter wheelbase Caravan.
Production
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; also St. Louis, Missouri, USA
Sales Performance:
Highly successful, maintaining strong sales figures in the competitive minivan segment
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Dodge Caravan/Grand Caravan platform frequently appeared on Car and Driver's 10Best lists in the minivan category during this era.
Consumer Reports:
Ratings varied by year and specific issues, but the model was generally well-regarded for its practicality and family-oriented features.
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