🏷️ Basic Information

Make:

Dodge

Model:

Intrepid

Year:

1996

Generation Code:

Second Generation (CA)

Platform:

Chrysler JA Platform

👋 Introduction

Market Position:

The 1996 Dodge Intrepid was part of Chrysler's successful 'cab-forward' design era, aiming to provide spacious interiors and a distinctive styling. It competed in the mid-size sedan segment against rivals like the Ford Taurus, Chevrolet Lumina, and Toyota Camry.

Competitive Analysis:

The Intrepid, along with its LH platform siblings (Chrysler Concorde, Eagle Vision), offered a more European-inspired driving experience and a bold exterior design that differentiated it from many competitors. Its spacious interior and comfortable ride were key selling points.

Key Features:

Cab-forward design, distinctive styling, spacious interior, comfortable ride quality, availability of V6 engines.

📋 Manual Details

Coverage Areas:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical Systems, Body, Interior, Diagnostics, Wiring Diagrams, Maintenance

Page Count:

Estimated 1500+ pages (typical for a comprehensive factory service manual)

Manual Type:

Service and Repair Manual Software

Language:

English

Format:

Digital Software (likely PDF or proprietary software)

📖 Manual Coverage

Systems Covered:

Engine mechanical and electrical, automatic transmission, powertrain control module (PCM), anti-lock braking system (ABS), suspension (front and rear), steering system, fuel system, ignition system, cooling system, exhaust system, climate control (HVAC), lighting, instrumentation, body control modules, power accessories, safety restraint system (SRS), diagnostics and troubleshooting, wiring diagrams for all systems.

Engine Mechanical:

Detailed procedures for engine assembly, disassembly, inspection, and repair. Includes cylinder head removal, piston and connecting rod service, crankshaft and bearing inspection, valve train overhaul, timing belt replacement (for 3.5L EGE V6), and engine component torque specifications.

Engine Electrical:

Comprehensive coverage of ignition system, fuel injection system (including injector testing and replacement), starting system, charging system (alternator), starter motor, and battery service. Includes diagnostic procedures for engine sensors and actuators.

Transmission Service:

Detailed overhaul procedures for the 42LE automatic transmission. Includes valve body service, clutch pack replacement, seal replacement, torque converter service, and transmission control module (TCM) diagnostics. Covers fluid and filter change procedures and specifications.

Drivetrain Service:

Front-wheel drive axle and CV joint inspection and replacement, differential service, and related components.

Suspension Service:

Detailed service procedures for front and rear suspension components, including struts, shock absorbers, control arms, ball joints, sway bar links, bushings, and wheel bearings. Includes alignment specifications.

Steering Service:

Power steering system diagnosis and repair, including pump, steering gear, tie rod ends, and steering column components. Covers steering wheel removal and replacement.

Brake System Service:

Front and rear brake service, including pad and rotor replacement, caliper service, brake line inspection and replacement, master cylinder service, and ABS system diagnostics and component testing. Includes brake bleeding procedures.

HVAC System Service:

Air conditioning system (refrigerant charging, compressor service, leak detection), heating system, climate controls, blower motor, and ducting. Includes diagnostic procedures for HVAC sensors and actuators.

Electrical System Diagnostics:

Extensive coverage of the vehicle's electrical architecture, including battery, charging system, starting system, lighting (headlights, taillights, interior lights), power windows, power locks, mirrors, seats, horn, wipers, and all related control modules and switches. Includes detailed wiring diagrams and component location charts.

Body And Interior Service:

Procedures for interior trim removal and installation, door panel service, seat removal, instrument panel components, exterior body panel removal (fenders, hood, bumpers), glass replacement, and door hardware adjustment.

Procedures Included:

Scheduled maintenance, tune-up procedures, engine overhaul, transmission overhaul, brake service and repair, suspension component replacement, steering component replacement, HVAC system diagnostics and repair, electrical component testing and replacement, body panel repair, interior trim removal and installation, diagnostic trouble code (DTC) interpretation and repair, fuel injector cleaning and testing, emissions system diagnosis, timing belt replacement (if applicable), component specifications and tolerances.

Troubleshooting Guides:

Diagnostic flowcharts and symptom-based troubleshooting procedures for common drivability, electrical, and mechanical issues. Includes procedures for identifying and resolving diagnostic trouble codes (DTCs).

Wiring Diagrams:

Detailed, system-specific wiring diagrams for all electrical components, including fuse box layouts, relay locations, and harness routing. Crucial for diagnosing electrical faults.

Component Specifications:

Extensive list of torque specifications for engine, chassis, and body fasteners. Includes critical engine clearances, bearing preloads, and other machining specifications for engine rebuilding.

Diagnostic Tools And Techniques:

Information on using diagnostic scan tools (e.g., DRB scan tool), multimeters, and other specialized tools for troubleshooting and diagnosis. Guidance on interpreting sensor data and live data streams.

Engine Performance Diagnosis:

Detailed procedures for diagnosing misfires, rough idling, lack of power, poor fuel economy, and starting problems. Covers diagnostic flowcharts for fuel delivery, ignition, and air intake systems.

Technical Depth:

Comprehensive, ranging from basic scheduled maintenance and fluid changes to in-depth diagnostic procedures, component-level repair, and full vehicle overhauls. Includes detailed torque specifications, electrical resistance values, and diagnostic flowcharts.

📊 Manual Specifications

File Format:

Software application, potentially PDF documents. Optimized for digital access and searchability.

Searchability:

High - digital software typically allows for keyword searches across the entire document for quick access to information.

Navigation:

User-friendly interface with clickable table of contents, index, and cross-references for efficient navigation.

Print Quality:

N/A (digital format), but digital content is typically high-resolution and searchable.

Binding Type:

N/A (digital format)

Paper Type:

N/A (digital format)

⚙️ Engine Specifications

Engine Options:

3.5L EGE V6 (215 hp @ 6000 rpm, 230 lb-ft @ 4000 rpm - optional for '96 on Intrepid ES, standard on '97+ Intrepid ES); 3.3L EGD V6 (155 hp @ 4800 rpm, 195 lb-ft @ 3200 rpm - standard on Intrepid SE)

Engine Code 3 3L:

EGD

Engine Code 3 5L:

EGE

Engine Displacement:

3.3 Liters (3301 cc) and 3.5 Liters (3518 cc)

Bore X Stroke 3 3L:

3.82 in x 3.57 in (97 mm x 91 mm)

Bore X Stroke 3 5L:

3.82 in x 4.02 in (97 mm x 102 mm)

Compression Ratio 3 3L:

8.4:1

Compression Ratio 3 5L:

9.3:1

Fuel System:

Multi-Port Fuel Injection (MPFI)

Fuel Pressure:

31-45 PSI (214-310 kPa)

🔧 Transmission

Transmission Type:

4-speed automatic (e.g., 42LE)

Optional Transmission:

N/A for 1996 model year

Transmission Features:

Electronically controlled, torque converter lock-up, adaptive shift logic.

📐 Dimensions

Wheelbase:

113.0 inches (2870 mm)

Length:

202.7 inches (5148 mm)

Width:

74.1 inches (1882 mm)

Height:

55.5 inches (1410 mm)

Front Headroom:

39.9 inches (1013 mm)

Front Legroom:

42.2 inches (1072 mm)

Rear Headroom:

38.1 inches (968 mm)

Rear Legroom:

39.7 inches (1008 mm)

Trunk Capacity:

16.7 cubic feet (473 Liters)

Curb Weight:

Approximately 3500-3700 lbs (1588-1678 kg) depending on configuration.

Gross Vehicle Weight Rating:

Varies by configuration, typically around 4,850 lbs (2200 kg).

🛡️ Safety Features

NHTSA Driver Front Impact:

4 Stars (1996 Model)

NHTSA Passenger Front Impact:

4 Stars (1996 Model)

Active Features:

Four-wheel Anti-lock Brakes (ABS), Traction Control (optional on some trims).

ABS System Type:

Bosch 5.3 ABS system (typical for the era).

Passive Features:

Driver and passenger front airbags, front and rear crumple zones, side-impact protection beams, three-point seat belts with pretensioners.

💡 Technology Features

Infotainment System:

Basic AM/FM stereo with cassette player and optional CD player. Manual controls for climate and audio.

Driver Assistance:

Anti-lock Braking System (ABS), optional Traction Control System (TCS).

Connectivity:

N/A (no factory Bluetooth or USB ports)

🔧 Maintenance

Oil Change Interval:

Every 3,000 to 5,000 miles (or as per owner's manual based on driving conditions), using recommended oil viscosity. Refer to manual for specific interval.

Tune Up Interval:

Spark plugs typically recommended around 60,000 to 100,000 miles (depending on spark plug type). Timing belt (3.5L EGE V6) interval is critical, often around 70,000-90,000 miles. Refer to manual for precise intervals.

Engine Oil Specification:

API Certified SAE 5W-30 or 5W-40 (check owner's manual for exact recommendation and temperature range suitability).

Transmission Fluid Type:

Chrysler ATF+4 (MS-9602) or equivalent. For 1996 models, ATF+3 may have been specified; the manual will clarify the correct fluid and its specifications (e.g., MS-7176).

Coolant Type:

Ethylene glycol-based antifreeze/coolant. Typically a 50/50 mix with distilled water. Refer to manual for Mopar specific coolant or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

ATF Dexron II/III or equivalent.

Engine Oil Capacity 3 3L:

4.5 quarts (4.3 Liters) with filter change.

Engine Oil Capacity 3 5L:

5.0 quarts (4.7 Liters) with filter change.

Transmission Fluid Capacity:

Approximately 9.5 quarts (9.0 Liters) for refill, 11.6 quarts (11.0 Liters) for total capacity.

Known Issues:

Common issues include head gasket leaks (especially on earlier 3.3L and 3.5L V6 engines), intake manifold gasket leaks, power steering leaks, premature wear of suspension components (ball joints, tie rods), and potential issues with the automatic transmission solenoid pack or torque converter. HVAC blend door actuator failure and evaporator leaks are also noted.

Common Repair Items:

Water pump leaks, radiator leaks, exhaust manifold cracks, TPS (Throttle Position Sensor) failure, O2 sensor failure, Idle Air Control (IAC) valve issues.

📚 Vehicle History

Brand Heritage:

Dodge, a division of Chrysler Corporation, has a long history of producing a wide range of vehicles from trucks to performance cars. In the mid-1990s, Chrysler was revitalizing its lineup with innovative designs like the cab-forward architecture.

Model Evolution:

The Dodge Intrepid debuted for the 1993 model year as part of the new LH platform, designed to be a more modern and upscale sedan. The 1996 model year saw minor updates and refinements to the original design. It was part of a trio including the Chrysler Concorde and Eagle Vision.

Platform Sharing:

Shared the JA platform with the Chrysler Concorde and Eagle Vision.

Production Years:

1993-1997 (First Generation)

Manufacturing Location:

Bramalea, Ontario, Canada

🏆 Awards & Recognition

Recognitions:

The LH platform vehicles, including the Intrepid, were often praised for their innovative styling and spacious interiors at the time of their release. They contributed to Chrysler's resurgence in the mid-1990s.