Dodge Caravan 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1999 Platform: NS Codes Chassis Code: NS 👋 Introduction Market Position Vehicle Segment: Compact/Minivan Target Audience: Families, small businesses, tradespeople needing...

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标签: 1999 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Platform:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact/Minivan

Target Audience:

Families, small businesses, tradespeople needing flexible cargo and passenger space.

Competitive Analysis

Key Competitors:

Chevrolet Venture, Pontiac Trans Sport, Ford Windstar, Honda Odyssey, Toyota Previa.

Key Features

Versatility:

Flexible seating configurations, ample cargo space, optional all-wheel drive (AWD).

Value Proposition:

Offered a compelling balance of practicality, affordability, and features for its segment.

Design Philosophy:

Functional and practical design prioritizing passenger comfort and cargo utility.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (likely PDF, implied by common sales practice)

Page Count:

Estimated 1000+ pages (typical for a comprehensive repair manual)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly for all gasoline engines.

Transmission Service:

Manual and automatic transmission diagnosis, repair, overhaul, and fluid servicing.

Drivetrain Components:

Front-wheel drive axle, CV joints, differential, and bearing service.

Suspension And Steering:

Front and rear suspension components, shock absorbers, struts, ball joints, tie rods, steering rack, power steering system.

Brake System:

Front and rear disc/drum brakes, ABS system, hydraulic lines, master cylinder, wheel cylinders, calipers, brake pads/shoes.

Electrical System:

Wiring diagrams, charging system (alternator, battery), starting system (starter motor), ignition system, lighting, instrument cluster, power windows, locks, mirrors, wipers.

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel tank, evaporative emissions control (EVAP).

Cooling System:

Radiator, water pump, thermostat, cooling fans, heater core, coolant hoses.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers.

HVAC System:

Air conditioning compressor, refrigerant lines, condenser, evaporator, blower motor, climate control panel.

Body And Frame:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, chassis specifications.

Procedures Included

Preventive Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tire rotation.

Diagnostic Troubleshooting:

Step-by-step diagnostic charts and procedures for identifying and resolving common and uncommon issues.

Component Repair And Replacement:

Detailed instructions for removing, repairing, and reinstalling all major vehicle components.

Alignment Specifications:

Wheel alignment angles (caster, camber, toe) for front and rear axles.

Torque Specifications:

Precise torque values for critical fasteners throughout the vehicle.

Wiring Diagrams Interpretation:

Detailed and color-coded wiring diagrams for all electrical circuits.

Technical Depth

Depth Of Information:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers basic maintenance to complete engine and transmission rebuilds.

Diagnostic Codes:

Includes information on On-Board Diagnostics (OBD-I / OBD-II) fault codes and their interpretation.

Special Tools Requirements:

Identifies specialized tools or equipment required for specific repair procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - commonly used for digital manuals, offering searchability and printability.

Print Quality

Image Resolution:

High-resolution images and diagrams, ensuring clarity for repair tasks.

Binding Type

Physical Manual Binding:

Not applicable for digital format, but if printed, would typically be spiral-bound or perfect-bound for lay-flat usability.

Paper Type

Physical Manual Paper:

Not applicable for digital format, but a high-quality manual would use durable, glossy paper for longevity.

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

2.4L Inline 4-Cylinder (2.4L DOHC) (Code: EDZ)

Engine Option 2:

3.0L V6 (3.0L SOHC) (Code: ECE)

Performance

2.4L Horsepower:

150 hp @ 5,800 rpm

2.4L Torque:

170 lb-ft @ 4,400 rpm

3.0L Horsepower:

180 hp @ 5,200 rpm

3.0L Torque:

240 lb-ft @ 4,400 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Management

ECU Type:

Proprietary Chrysler PCM (Powertrain Control Module)

🔧 Transmission

Standard

Transmission Option 1:

4-Speed Automatic (41TE/AE)

Optional

Transmission Option 2:

4-Speed Automatic with All-Wheel Drive (AWD) (45RFE variant adapted for AWD)

Features

Shift Logic:

Electronic control with adaptive shift patterns.

Fluid Specification

Transmission Fluid:

Chrysler ATF+4 (formerly ATF+3 for some earlier specs), Mopar part number: 05013457GA or equivalent.

📐 Dimensions

Exterior

Length:

Approx. 179.4 inches

Width:

Approx. 72.0 inches

Height:

Approx. 67.0 inches

Wheelbase:

Approx. 111.8 inches

Cargo

Cargo Volume Behind First Row:

Approx. 140.0 cu ft

Cargo Volume Behind Second Row:

Approx. 79.0 cu ft

Weights

Curb Weight Min:

Approx. 3,500 lbs (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,000 - 5,500 lbs

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact:

4/5 Stars (1999 model year estimates)

NHTSA Front Passenger Side Impact:

4/5 Stars (1999 model year estimates)

Active Features

Available Anti-lock Braking System (ABS) on all four wheels.

Passive Features

Airbags:

Driver and front passenger airbags.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system on rear seats (may vary by trim/option).

Side Impact Beams:

Reinforced side-impact protection beams in doors.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and optional CD player. Up to 6 speakers.

Driver Assistance

Cruise Control:

Standard or optional cruise control for highway driving.

Connectivity

Remote Keyless Entry:

Optional remote keyless entry system for convenient access.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendations).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, or as per severe service schedule.

Spark Plug Replacement:

Around 60,000 - 100,000 miles, depending on spark plug type (e.g., platinum/iridium).

Coolant Flush:

Every 30,000 - 60,000 miles or 2-4 years.

Fluid Specifications

Engine Oil:

SAE 5W-30 or 10W-30, API Certified (check manual for specific viscosity based on ambient temperature), Mopar part number: 05080897AB or equivalent.

Coolant:

Mopar Antifreeze/Coolant (50/50 mixture with distilled water), or equivalent HOAT coolant, Mopar part number: 05052400AA.

Brake Fluid:

DOT 3.

Power Steering Fluid:

Chrysler Power Steering Fluid or ATF+4, Mopar part number: 05013457GA.

Known Issues

Transmission Problems:

Intermittent shifting problems, torque converter shudder, and failure of the solenoid pack are common complaints with the 41TE transmission.

Engine Mounts:

Worn engine mounts can lead to excessive vibration and noise, especially under acceleration.

Power Window Motors:

Failure of power window regulators and motors is a common electrical issue.

Radiator And Coolant Leaks:

Cracked plastic radiator tanks and heater core leaks can lead to coolant loss.

Rear Suspension Sag:

Over time, rear springs can sag, affecting ride height and handling.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing practical and durable vehicles.

Model Evolution

Caravan Introduction:

The Dodge Caravan (and its Plymouth Voyager sibling) pioneered the minivan segment in 1984.

Third Generation:

The 1996-2000 Dodge Caravan is part of the third generation (NS body style), which introduced significant styling and engineering updates over the previous generation.

Production

Manufacturing Location:

Primarily manufactured in North America (Windsor, Ontario, Canada; St. Louis, Missouri, USA).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Dodge Caravan and its platform-mates have historically been well-regarded and frequently appeared on Car and Driver's 10Best lists in earlier generations, establishing the minivan as a desirable vehicle type.