Dodge Caravan 1996 Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1996 Product Type: Repair Service Manual 👋 Introduction Market Position Target Audience: Primarily professional automotive technicians, but also advanced DIY enthusiasts...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Product Type:

Repair Service Manual

👋 Introduction

Market Position

Target Audience:

Primarily professional automotive technicians, but also advanced DIY enthusiasts seeking in-depth repair information.

Competitive Analysis

Value Proposition:

Provides factory-level accuracy and detail crucial for accurate diagnostics and repairs, outperforming generic repair guides.

Key Features

Detail Level:

Exhaustive technical data, including torque specifications, clearances, diagnostic flowcharts, and wiring diagrams.

Usability:

Organized into logical sections for easy navigation and quick access to specific repair procedures or information.

📋 Manual Details

Coverage Areas

Manual Type:

Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

All gasoline engines, including 2.4L DOHC and 3.0L SOHC V6, with detailed diagnostic procedures, component removal and installation, and specifications.

Transmission:

Automatic Transmissions (e.g., A604, A670) and Manual Transmissions, covering operation, overhaul, troubleshooting, and fluid specifications.

Brakes:

Front Disc Brakes (with or without ABS), Rear Drum Brakes, parking brake system, hydraulic system, bleeding procedures, and component specifications.

Suspension:

Front MacPherson strut suspension, rear torsion beam axle, shock absorbers, springs, bushings, wheel alignment specifications, and troubleshooting.

Steering:

Power Rack and Pinion steering system, hydraulic pump, steering column, tie rod ends, and troubleshooting.

Electrical:

Complete wiring diagrams, fuse box locations, component testing, charging system (alternator, battery), starting system, ignition system, lighting, and accessories.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, component testing (compressor, condenser, evaporator), and troubleshooting.

Body:

Body panel removal and installation, door mechanisms, glass, bumpers, interior trim, and corrosion prevention.

Safety Systems:

Seat belts, airbags (SRS) system (though likely basic coverage for this era), and lighting.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, and belt inspections.

Troubleshooting:

Extensive diagnostic flowcharts and symptom-based troubleshooting guides for engine, transmission, electrical, and other systems.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation for major vehicle systems.

Overhaul:

Detailed procedures for the complete disassembly, inspection, repair, and reassembly of major components like engines and transmissions.

Diagnostics:

Diagnostic trouble codes (DTCs) interpretation (OBDI/OBDII depending on specific engine control module), sensor testing, and actuator testing.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to advanced engine and transmission overhauls, including detailed electrical schematics.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable PDF, allowing for quick finding of specific topics.

Print Quality:

Assumed to be high-resolution, suitable for printing all pages for workshop use.

Page Count:

Estimated 1000-2000 pages (typical for a comprehensive factory-level service manual of this era).

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness

Coverage:

Complete factory service manual, designed for professional technicians, offering exhaustive information.

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

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

Engine 1 Displacement:

2378 cc

Engine 1 Bore X Stroke:

90.0 mm x 93.0 mm

Engine 1 Compression Ratio:

9.5:1

Engine 1 Horsepower:

Approx. 150 hp @ 5600 RPM

Engine 1 Torque:

Approx. 160 lb-ft @ 3200 RPM

Engine 1 Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Engine 1 Ignition System:

Distributorless Ignition System (DIS) with coil packs.

Optional Engine

Engine 2 Type:

3.0L SOHC V6 (Chrysler EGH / Mitsubishi 6G72)

Engine 2 Displacement:

2972 cc

Engine 2 Bore X Stroke:

91.1 mm x 76.0 mm

Engine 2 Compression Ratio:

8.9:1

Engine 2 Horsepower:

Approx. 162 hp @ 4750 RPM

Engine 2 Torque:

Approx. 170 lb-ft @ 3750 RPM

Engine 2 Fuel System:

Multi-Port Fuel Injection (MPI)

Engine 2 Ignition System:

Distributor ignition system.

🔧 Transmission

Standard

Type 1:

4-speed Automatic Transaxle (A604, electronically controlled)

Optional

Type 2:

4-speed Automatic Transaxle (A670, heavier duty for V6 models)

Type 3:

3-speed Automatic Transaxle (less common in '96 models, but possible).

Features

Fluid Type:

ATF+3 (Mopar designation), equivalent to Dexron-III/Mercon compatible fluid.

Fluid Capacity:

Approximately 7-9 quarts (dry fill), consult manual for specific fill procedure.

📐 Dimensions

Exterior

Wheelbase:

112.2 inches (2850 mm)

Length:

181.1 inches (4600 mm)

Width:

72.0 inches (1829 mm)

Height:

68.5 inches (1740 mm)

Front Track:

60.4 inches (1534 mm)

Rear Track:

60.5 inches (1537 mm)

Weights

Curb Weight:

Approx. 3500-3900 lbs (depending on engine and configuration).

Gross Vehicle Weight Rating:

Approx. 5300 lbs

Cargo

Cargo Volume Max:

Over 150 cubic feet (with rear seats removed).

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

4 Stars (1996 model year testing if available, generally good for the era).

NHTSA Frontal Passenger:

4 Stars (1996 model year testing if available).

Active Features

Optional Anti-lock Braking System (ABS) on front wheels, potentially all four depending on configuration.

Passive Features

Airbags:

Driver-side airbag standard, passenger airbag optional on some trims.

Seatbelts:

Three-point front seat belts, rear seat belts. Child seat anchor points (LATCH system not standard in this era).

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette tape player, optional CD player on some models. Basic speaker configurations.

Driver Assistance

Cruise Control:

Standard on most models.

Trip Computer:

Optional on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change:

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

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Approximately 30,000 - 100,000 miles depending on spark plug type (e.g., copper vs. platinum).

Transmission Fluid Change:

Every 30,000 - 60,000 miles or as specified by driving conditions.

Fluid Specifications

Engine Oil Type:

API Service SG or SH, SAE 5W-30 or 10W-30 recommended for most conditions. Consult manual for specifics.

Coolant Type:

Ethylene Glycol based antifreeze, Mopar Antifreeze/Coolant (MS-7170 or equivalent).

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+3 (Mopar designation).

Known Issues

Transaxle Reliability:

Early electronically controlled transaxles (like A604) were known for potential solenoid failures and control module issues; thorough diagnostics are key.

Engine Mounts:

Worn engine and transmission mounts can lead to vibration and noise.

Evaporator Core:

HVAC evaporator core leaks can cause refrigerant loss and fogging on the windshield.

Power Window Motors:

Power window regulators and motors can wear out over time.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge, as part of Chrysler Corporation, has a long history of producing reliable and innovative vehicles, including early minivans.

Model Evolution

Generation:

This 1996 model is part of the second generation Dodge Caravan (1991-1995), with the 1996 model year often considered a carry-over or minor update before the major redesign in 1996 for the 1996-2000 generation.

Production

Manufacturing Location:

North America (e.g., Windsor, Ontario, Canada; St. Louis, Missouri, USA).

Market Impact:

The Dodge Caravan, along with its Plymouth Voyager and Chrysler Town & Country siblings, largely defined the minivan segment in North America.

🏆 Awards & Recognition

Recognitions

Segment Leadership:

Consistently ranked among the top-selling and most popular minivans, often appearing on 'Best of' lists for family vehicles.

Car And Driver:

Often cited by automotive publications like Car and Driver for its practicality and value.