🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Model Years Covered:

1996, 1997, 1998, 1999

Platform:

NS (Second Generation)

👋 Introduction

Segment:

Compact Minivan / Family Vehicle

Key Selling Point:

Versatility, practicality, passenger and cargo capacity, family-oriented features.

Key Competitors:

Chevrolet Venture/Lumina APV, Pontiac Trans Sport, Ford Windstar, Honda Odyssey (early models), Toyota Previa.

Chassis Design:

Unibody construction, front-wheel drive (FWD) as standard.

Body Styles:

Standard wheelbase and Long wheelbase (Grand Caravan) variants available.

Door Configuration:

Standard swing-out rear doors and optional power sliding side door (particularly on higher trims or later models).

📋 Manual Details

Manual Type:

Workshop Service Manual (WSM) / Service Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

Estimated Page Count:

Over 1500 pages (typical for a full WSM of this era)

📖 Manual Coverage

Powertrain:

Engine mechanical (including cylinder head, block, pistons, crankshaft, camshafts), fuel system, ignition system, exhaust system, cooling system, lubrication system, engine performance diagnostics.

Transmission:

Automatic Transmission (e.g., 41TE/42LE) repair, overhaul, diagnostics, fluid specifications, torque converter, shift control systems.

Chassis:

Front suspension (MacPherson struts, control arms, ball joints), rear suspension (torsion beam axle, leaf springs), steering system (power steering, steering column), brake system (front discs, rear drums, ABS, parking brake), wheel bearings, hub assemblies.

Electrical:

Battery, charging system (alternator, starter), lighting systems, ignition switch, power distribution, fuses, relays, wiring diagrams, instrument cluster, gauges, warning lights, body control modules (BCM), power windows, power locks, power sliding door (if equipped), remote keyless entry.

Body:

Exterior body panels (doors, fenders, hood, liftgate), interior trim, seats, seat belts, airbags, body sealing, weatherstripping, glass, mirrors, body repair procedures, corrosion protection.

Maintenance:

Scheduled maintenance (oil changes, filter replacements, spark plugs, drive belts, coolant flushes), fluid checks and top-offs, tire rotation, brake inspections, battery testing.

Diagnostics:

On-Board Diagnostics (OBD-II) troubleshooting, fault code retrieval and interpretation, symptom-based troubleshooting guides, wiring diagram analysis.

Repair:

Engine component replacement (e.g., water pump, alternator, starter, manifold gaskets), transmission service, brake caliper replacement, suspension component replacement, electrical component diagnosis and replacement, HVAC system repairs.

Overhaul Rebuild:

Detailed procedures for engine and transmission rebuilds, including disassembly, cleaning, inspection, part replacement, assembly, and initial setup.

Depth Level:

Comprehensive professional level, suitable for dealership technicians and advanced DIY mechanics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for easy information retrieval.

Image Resolution:

High-resolution, clear images, diagrams, and schematics.

Diagram Clarity:

Detailed, easy-to-understand wiring diagrams, exploded views, and assembly illustrations.

Binding Method:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Options:

2.4L 16-valve 4-cylinder (DOHC I4) and 3.0L 12-valve V6 (SOHC V6) (Mitsubishi-sourced for early models), 3.3L 12-valve V6 (OHV V6) and 3.8L 12-valve V6 (OHV V6) (Chrysler-sourced).

Engine Code Common V6:

EPE (3.0L), EGD (3.3L), EGH (3.8L)

Horsepower Range:

Approx. 150 hp (2.4L I4) to 180 hp (3.8L V6)

Torque Range:

Approx. 170 lb-ft (2.4L I4) to 240 lb-ft (3.8L V6)

Fuel Delivery:

Multi-point fuel injection (MPI) for all engines.

Fuel Type:

Unleaded gasoline (87 octane recommended).

Timing Belt Chain:

Timing belt for 2.4L I4 and 3.0L V6 (Mitsubishi). Timing chain for 3.3L and 3.8L V6 (Chrysler).

🔧 Transmission

Transmission Type Common:

4-speed Automatic Transmission (e.g., Chrysler 41TE/42LE)

Transmission Options:

Manual transmission was generally not offered on US market Caravans during this period, focus is on automatics.

Transmission Control:

Electronic Pressure Control (EPC) for enhanced shift quality and diagnostics.

Transmission Fluid Type:

ATF+4 (or equivalent for earlier models, check specific manual/owner's guide for exact spec like ATF+3).

Transmission Fluid Capacity Approx:

Approx. 6-8 quarts (dry fill) / 4-5 quarts (drain and fill).

📐 Dimensions

Length Standard Wheelbase Approx:

177.7 inches (4514 mm)

Length Long Wheelbase Approx:

191.7 inches (4869 mm)

Width Approx:

72.0 inches (1829 mm)

Height Approx:

68.0 inches (1727 mm)

Seating Capacity:

7 passengers (typical 2-2-3 configuration)

Cargo Volume Behind 3Rd Row Approx:

30-35 cubic feet (standard wheelbase), 40-45 cubic feet (long wheelbase)

Cargo Volume Max Approx:

140-150 cubic feet (standard wheelbase), 150-160 cubic feet (long wheelbase) with seats removed/folded.

Curb Weight Range Approx:

3,500 - 4,000 lbs (1588 - 1814 kg)

Gross Vehicle Weight Rating Gvwr Approx:

5,000 - 5,500 lbs (2268 - 2495 kg)

🛡️ Safety Features

NHTSA Front Crash Test Rating:

Likely 4-star ratings for driver and passenger in frontal impact (based on contemporary testing for this class).

Braking System:

Front disc brakes, rear drum brakes. Optional Anti-lock Braking System (ABS) available on most models.

Traction Control:

Traction control system (TCS) was an optional feature on some higher trim levels and later model years.

Airbags:

Driver and front passenger airbags standard. Side airbags were not typically available on this generation.

Seat Belts:

Three-point seat belts for all occupants. Integrated child safety seats were an optional feature on some models.

💡 Technology Features

Audio System:

Standard AM/FM stereo with cassette player. Optional CD player, premium sound systems, and rear seat entertainment systems (later in the generation).

Dashboard Features:

Analog gauges for speedometer, tachometer (optional), fuel, and engine temperature. Warning lights for critical systems.

Cruise Control:

Standard on most trims, electronically controlled.

Parking Assistance:

Rear parking assist sensors were an aftermarket or very late-model option, not standard.

Remote Keyless Entry:

Optional remote keyless entry system available on higher trims and as an option.

Power Features:

Power windows, power door locks, power mirrors standard on some trims, optional on others. Power sliding doors became a significant feature.

🔧 Maintenance

Oil Change Interval Approx:

Every 3,000 - 5,000 miles (or as per oil type and driving conditions, consult manual for exact recommendation).

Engine Coolant Flush Interval Approx:

Every 30,000 - 50,000 miles or 2-3 years.

Transmission Fluid Change Interval Approx:

Every 30,000 - 60,000 miles (depending on usage and fluid type, consult manual).

Spark Plug Replacement Interval:

Varies by engine type: 30,000 miles for older designs, up to 100,000 miles for platinum or iridium plugs (if equipped).

Engine Oil Viscosity:

Typically SAE 5W-30 or 10W-30 depending on climate (refer to manual for precise specification).

Engine Oil Type:

API Service SN or newer, or as specified in the owner's manual. Synthetic blends often recommended for improved performance.

Coolant Type:

Chrysler-specific long-life (HOAT - Hybrid Organic Acid Technology) coolant, typically pink or orange in color. Mopar OAT or HOAT recommended.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact specification).

Common Complaints Powertrain:

Transmission issues (slipping, harsh shifts, cooler line leaks), head gasket failures (especially on 3.3L/3.8L engines under high heat/load), intake manifold gasket leaks, oil cooler line leaks.

Common Complaints Suspension Steering:

Worn front suspension components (ball joints, tie rod ends), noisy power steering pumps, rear axle bearings.

Common Complaints Electrical:

Faulty power window motors/regulators, issues with door lock actuators, intermittent electrical problems due to corrosion in connectors or BCM failures, alternator and starter failures.

Common Complaints HVAC:

HVAC blower motor resistor failure, A/C compressor clutch issues, blend door actuator failures.

Common Filter Part Numbers:

Oil filter (e.g., Mopar 5018081AA or equivalent Wix/Fram), Air filter (e.g., Mopar 4677117 or equivalent), Cabin air filter (if equipped, often not standard).

📚 Vehicle History

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan and Plymouth Voyager in 1984, establishing a dominant market presence.

Generation Identifier:

NS Platform (Second Generation Minivan), introduced for the 1996 model year, replacing the ST platform. Significant redesign with improved aerodynamics, interior space, and available features.

Key Updates During Generation:

Introduction of OBD-II compliant engines, improved safety features (airbags), enhanced interior modularity, optional power sliding doors became more common, introduction of the 3.8L V6 engine.

Manufacturing Locations:

Primarily manufactured at the Windsor Assembly Plant in Windsor, Ontario, Canada.

Production Period:

1996-2000 (NS platform, with minor facelifts and updates).

🏆 Awards & Recognition

Decade Awards:

The Dodge Caravan and its siblings were consistently ranked among the best-selling vehicles and frequently appeared on 'best family vehicle' lists throughout the 1990s due to their practicality and value.

Reliability Rankings:

While generally well-regarded for its segment, specific model years within this generation could have variable reliability ratings; a comprehensive service manual is crucial for addressing potential issues.

Safety Certifications:

Manufactured to meet all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for its model years.