🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

1996-1997

Chassis Code:

NS Platform (Second Generation)

👋 Introduction

Positioning:

The Dodge Caravan was a pioneering minivan, establishing and dominating the segment. This manual reflects its critical role in family transportation.

Competitors:

Primary competitors included the Plymouth Voyager (virtually identical sibling), Ford Windstar, and Chevrolet Lumina APV/Venture.

Vehicle Appeal:

Known for its spacious interior, versatile seating configurations, and comfortable ride, making it a popular choice for families.

Value:

This manual provides dealership-level expertise, enabling owners and independent technicians to perform accurate diagnostics and repairs, saving significant cost compared to dealership labor.

📋 Manual Details

Coverage:

All Models & All Repairs A-Z

Page Count:

Comprehensive (exact count not specified, but implied extensive coverage)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Likely Printed (typical for dealership manuals of this era)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for all engine variants, including cylinder head, block, pistons, rings, crankshaft, camshaft, valves, timing systems.

Engine Performance:

Diagnosis and repair of engine performance issues, including fuel injection, ignition system, emissions controls, and cooling system.

Fuel System:

Service and repair of fuel tanks, pumps, lines, filters, and fuel injection systems (MPI).

Cooling System:

Repair and maintenance of radiator, water pump, thermostat, hoses, and cooling fan systems.

Exhaust System:

Inspection, repair, and replacement of exhaust manifolds, pipes, catalytic converters, and mufflers.

Transmission Automatic:

Complete service, diagnosis, repair, and overhaul procedures for automatic transmissions, including torque converter, valve body, and gearsets.

Transmission Manual:

Service and repair procedures for manual transmissions, including clutch system and gearbox overhaul.

Driveline And Axles:

Repair and maintenance of front-wheel drive axles, CV joints, and rear axle assemblies (if applicable to specific models).

Suspension System:

Front and rear suspension diagnosis, repair, alignment specifications, and component replacement (struts, shocks, control arms, ball joints, bushings).

Steering System:

Power steering system diagnosis, repair, and component replacement (pump, rack and pinion, hoses).

Brake System:

Detailed coverage of hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), ABS system diagnosis and repair, disc and drum brake service, parking brake.

Electrical System:

Comprehensive wiring diagrams, component testing, diagnosis of starting and charging systems, lighting, instrumentation, power accessories, and body control modules.

HVAC System:

Diagnosis and repair of heating, ventilation, and air conditioning systems, including refrigerant handling, compressor, condenser, evaporator, and controls.

Body And Frame:

Exterior and interior trim removal and installation, door mechanisms, glass replacement, body panel repair, and structural information.

Body Control Modules:

Diagnosis and repair related to body control modules (BCM) and related sensors/actuators.

Safety Restraint System:

Service and safety precautions for airbags and seatbelt systems.

Preventive Maintenance:

Detailed maintenance schedules, fluid changes, filter replacements, belt inspections, and lubrication points.

Troubleshooting:

Systematic diagnostic procedures, symptom-to-cause charts, and fault code interpretations for various systems.

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and repair for all vehicle systems.

Component Rebuilds:

Instructions for complete overhauls of major components like engines and transmissions.

Diagnostics:

Advanced diagnostic techniques, including use of scan tools and electrical testing equipment.

Technical Specifications:

Torque specifications, clearances, fluid capacities, electrical parameters, and alignment data.

Wiring Diagrams:

Complete and detailed electrical wiring schematics for all vehicle systems.

Depth:

Vehicle Specific - Exact Same Manual Used by Dealership Technicians

Scope:

Covers routine maintenance, complex diagnostics, and full component overhauls (A-Z).

📊 Manual Specifications

File Format:

Assumed Print; if digital, likely PDF with searchable text.

Print Quality:

High-quality, professional dealership-grade printing.

Binding Type:

Likely Perfect Binding or Spiral Binding for durability and lay-flat use.

Paper Type:

Durable, high-quality paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Options:

2.4L Inline-4 (DOHC), 3.0L V6 (SOHC), 3.3L V6 (OHV), 3.8L V6 (OHV)

Horsepower 2 4L:

Approx. 150 hp

Torque 2 4L:

Approx. 180 lb-ft

Horsepower 3 0L V6:

Approx. 150 hp

Torque 3 0L V6:

Approx. 170 lb-ft

Horsepower 3 3L V6:

Approx. 158 hp

Torque 3 3L V6:

Approx. 190 lb-ft

Horsepower 3 8L V6:

Approx. 167-180 hp (depending on specific application/year within range)

Torque 3 8L V6:

Approx. 207-217 lb-ft (depending on specific application/year within range)

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition Type:

Distributorless Ignition System (DIS) or Distributor Ignition (depending on engine/trim)

🔧 Transmission

Standard Trans:

4-Speed Automatic (e.g., A604, A670)

Optional Trans:

Manual Transmission not typically offered on this generation, primarily automatic.

Transmission Features:

Electronically Controlled Transmission (ECT) for improved shift quality and fuel economy.

📐 Dimensions

Wheelbase:

Approx. 112.1 inches (Standard Wheelbase), 119.3 inches (Long Wheelbase - Grand Caravan)

Length:

Approx. 177.4 inches (Standard), 186.7 inches (Long)

Width:

Approx. 72.1 inches

Height:

Approx. 66.4 inches

Seating Capacity:

7-8 passengers

Cargo Volume:

Highly configurable with removable/stowable seats; significant cargo space.

Curb Weight:

Approx. 3,500 - 4,100 lbs (Varies by engine, trim, and configuration)

Towing Capacity:

Variable, often up to 3,500 lbs when properly equipped with tow package.

🛡️ Safety Features

NHTSA Front Impact:

Acceptable (5-star rating system of the time).

IIHS Side Impact:

Not rated (IIHS ratings were less comprehensive for this era, especially for minivans).

ABS:

Anti-lock Braking System (ABS) available on some models/trims.

Airbags:

Driver and Passenger Airbags (Standard on most models).

Seatbelts:

Three-point seatbelts for all seating positions.

💡 Technology Features

Audio System:

Factory AM/FM/Cassette player, optional CD player available. Basic speaker systems.

Climate Control:

Manual HVAC controls, optional Automatic Temperature Control (ATC) on higher trims.

Cruise Control:

Standard on most models, optional on base trims.

Connectivity Options:

Very limited by modern standards; no integrated Bluetooth or USB ports.

Power Options:

Optional power windows, power door locks, power mirrors, power sliding rear quarter windows.

🔧 Maintenance

Oil Change Interval:

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

Tune Up Interval:

Spark plugs typically every 60,000-100,000 miles; serpentine belt inspection/replacement as needed.

Transmission Service:

Fluid and filter change every 30,000-60,000 miles, depending on usage.

Engine Oil Type:

API certified, SAE 5W-30 or 10W-30 (check manual for specific engine variant).

Transmission Fluid Type:

Chrysler ATF+4 (or equivalent from Mopar spec before ATF+4 introduction, often ATF+2 or ATF+3).

Coolant Type:

Ethylene glycol based antifreeze (Mopar OAT or HOAT compatible).

Brake Fluid Type:

DOT 3 or DOT 4.

Common Issues:

Transmission internal failures (especially earlier models/transmissions), head gasket leaks, exhaust manifold cracks, A/C system leaks, power steering pump wear, interior component wear (door handles, seat fabric).

Ignition System Issues:

Coil pack failures, spark plug wire degradation (if equipped with distributor).

Electrical Quirks:

Window regulators, power lock actuators, and dashboard warning light issues can occur with age.

📚 Vehicle History

Brand Heritage:

Dodge, as part of Chrysler Corporation, has a long history of innovation, particularly in vehicle packaging and practicality.

Generation:

This manual covers the second generation (1991-1995) and its updated version (1996-2000) of the Dodge Caravan.

Manufacturing Location:

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

Sales Impact:

The Caravan (and its Plymouth Voyager sibling) defined the minivan segment and were best-selling vehicles for many years.

🏆 Awards & Recognition

Car And Driver 10Best:

The Dodge Caravan and Plymouth Voyager were frequently recognized on Car and Driver's '10Best' lists in the early 1990s, highlighting their segment-defining status.

Consumer Reports Reliability:

Reliability ratings varied by year and powertrain; known issues are documented in the manual for proactive maintenance.

Certification:

This manual is a factory-authorized service manual, providing the highest level of accuracy and technical detail, equivalent to OEM certifications.