Dodge Caravan 1996-1997 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1996-1997 👋 Introduction Market Position Segment: Compact Minivan / Family Van Target Audience: Families, individuals seeking versatile and spacious transportation. Competitive...

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类型: Car

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标签: 1996 1997 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

1996-1997

👋 Introduction

Market Position

Segment:

Compact Minivan / Family Van

Target Audience:

Families, individuals seeking versatile and spacious transportation.

Competitive Analysis

Key Competitors:

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

Key Features

Versatility:

Flexible seating arrangements, ample cargo space, sliding rear doors for easy access.

Practicality:

Designed for family hauling and everyday utility.

Value Proposition:

Often offered a strong balance of features, space, and affordability.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of all engine components (e.g., cylinder head, block, pistons, crankshaft, camshafts, timing systems).

Fuel System:

Fuel injection system diagnostics and repair, fuel pump, injectors, fuel pressure regulator, fuel filter replacement, fuel tank service.

Ignition System:

Ignition coil testing, spark plug replacement, distributor service (if applicable), ignition timing adjustment.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation and replacement, coolant specifications and bleeding procedures.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipe inspection and replacement, emissions control components.

Transmission Automatic:

Torque converter, transmission fluid, filter change, gear shift linkage, internal transmission component inspection and repair, valve body diagnostics.

Transmission Manual:

Clutch inspection and replacement, transmission fluid, gear shift mechanism, internal transmission component inspection and repair.

Drivetrain:

Front axle, driveshafts, CV joints, wheel bearings, differential inspection and service.

Suspension:

Front and rear suspension components (struts, shock absorbers, control arms, ball joints, bushings), alignment specifications.

Steering:

Power steering pump, steering rack/gearbox, tie rods, steering column, steering wheel removal and installation.

Brakes Hydraulic:

Brake fluid specifications, master cylinder, brake lines, brake hoses, caliper and wheel cylinder servicing, brake bleeding procedures.

Brakes Parking:

Parking brake mechanism inspection, adjustment, and repair.

Wheels Tires:

Wheel and tire specifications, lug nut torque, tire pressure recommendations.

Body Frame:

Body panel removal and installation, structural repair information, rust prevention, undercoating.

Interior Trim:

Seat removal and installation, dashboard disassembly, door panel removal, headliner service, carpet replacement.

Doors Windows Locks:

Door latch mechanisms, window regulators, power window systems, door lock actuators, keyless entry system service.

Lighting Exterior:

Headlight, taillight, turn signal, brake light bulb replacement and aiming, exterior lighting circuit diagnostics.

Lighting Interior:

Dome light, instrument cluster illumination, interior courtesy light service.

Instrument Panel:

Instrument cluster removal and installation, gauge diagnostics, warning light explanations.

Electrical Charging System:

Alternator testing and replacement, battery service, charging system diagnostics.

Electrical Starting System:

Starter motor testing and replacement, ignition switch service, starting system diagnostics.

Electrical Body Controls:

Power windows, power locks, power mirrors, cruise control, wiper/washer system diagnostics and repair.

Climate Control HVAC:

Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, HVAC controls, cabin air filter replacement.

Infotainment Audio:

Radio, speaker system inspection and replacement, antenna service.

Safety Restraints:

Airbag system diagnostics and component replacement (SRS module, sensors, pretensioners), seatbelt inspection and replacement.

Procedures Included

Preventative Maintenance:

Detailed maintenance schedules, oil change procedures, filter replacement intervals, lubrication points.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.

Repair Procedures:

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

Diagnostics:

OBD-II diagnostic trouble code (DTC) definitions and troubleshooting strategies, scan tool usage guidance.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle circuits, including power distribution, grounds, and signal paths.

Torque Specifications:

Precise torque values for critical fasteners in engine, chassis, and body applications.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Specifications Data:

Detailed technical data, measurements, clearances, and tolerances for engine, transmission, suspension, and brake components.

Rebuilding Instructions:

Guidelines for rebuilding major components like engines, transmissions, and steering racks.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.

📊 Manual Specifications

File Format

Type:

Quality:

High-resolution scans, likely searchable text for easy navigation.

Print Quality

Printability:

Printable for shop use or personal reference.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Displacement:

2.4 Liter (2429 cc)

Configuration:

Inline 4-cylinder

Valvetrain:

SOHC (Single Overhead Camshaft), 16 valves

Horsepower Est:

150 hp @ 5800 rpm

Torque Est:

170 lb-ft @ 4000 rpm

Fuel System

Induction:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Performance

Cooling System Capacity Qt:

Approx. 11.7 quarts (11.1 liters)

Oil Capacity Qt:

Approx. 5.0 quarts (4.7 liters) with filter

Recommended Oil Viscosity:

10W-30

🔧 Transmission

Standard

Type:

4-Speed Automatic

Optional

Type:

None for this model year and engine combination

Features

Control:

Electronic Control Unit (ECU) managed

Fluid Type:

ATF+4 (or equivalent)

Fluid Capacity Qt:

Approx. 9.0 quarts (8.5 liters)

📐 Dimensions

Exterior

Wheelbase In:

112.0

Length In:

175.0

Width In:

Height In:

Weights

Curb Weight Lbs Est:

3700-4000

Gross Vehicle Weight Rating Lbs Est:

5400-5600

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Not explicitly rated for this specific model year by NHTSA in all configurations, but generally considered acceptable for its era.

NHTSA Side Impact:

Not explicitly rated for this specific model year by NHTSA in all configurations.

Active Features

Available (Anti-lock Braking System)

Traction Control:

Rarely equipped on this model year, typically not standard.

Passive Features

Airbags Driver:

Standard (Driver's side airbag)

Airbags Passenger:

Optional (Passenger's side airbag)

Seatbelts Front:

Three-point lap and shoulder belts with pretensioners

Seatbelts Rear:

Lap belts and/or three-point belts depending on seating position.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations.

Display:

Analog gauges and basic digital readouts for odometer and trip meter. No central infotainment screen.

Driver Assistance

Cruise Control:

Standard on most trim levels.

Connectivity

Telematics:

No factory-installed telematics or advanced connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Miles:

Every 7,500 miles or 6 months, whichever comes first (using synthetic blend or full synthetic recommended).

Air Filter Replacement Miles:

Every 30,000 miles or as needed based on driving conditions.

Spark Plug Replacement Miles:

Every 100,000 miles (using platinum or iridium spark plugs recommended).

Transmission Fluid Change Miles:

Every 60,000 miles under normal driving conditions, 30,000 miles under severe driving conditions.

Coolant Flush Miles:

Every 100,000 miles or 5 years.

Fluid Specifications

Engine Oil:

API Certified SAE 10W-30 (or 5W-30 for extreme cold).

Transmission Fluid:

Chrysler ATF+4 (or equivalent licensed product).

Coolant:

Chrysler OAT (Organic Acid Technology) 5/150 or 50/50 mixture with distilled water.

Brake Fluid:

DOT 3

Power Steering Fluid:

Chrysler ATF+3 or Mopar Power Steering Fluid.

Known Issues

Trans Issues:

Transmission solenoid failures, torque converter shudder, valve body issues, potential for delayed engagement or slipping.

Engine Issues:

Head gasket leaks (especially early models), oil pan gasket leaks, intake manifold gasket leaks, PCV valve issues.

Electrical Issues:

Window motor failures, power lock actuator problems, intermittent dash lights, ignition switch wear.

HVAC Issues:

Blend door actuator failures, AC compressor clutch issues, evaporator core leaks.

Suspension Issues:

Worn ball joints, tie rod ends, control arm bushings, and sway bar links leading to clunking noises and poor handling.

📚 Vehicle History

Brand Heritage

Minivan Pioneer:

Dodge was a significant player in popularizing the minivan segment with the introduction of the original Caravan/Voyager.

Model Evolution

Generation:

Second Generation (1996-2000).

Redesign:

Significant redesign from previous generation with more aerodynamic styling and improved interior packaging.

Production

Manufacturing Plant:

Windsor, Ontario, Canada

Production Years:

1996, 1997 (covered by this manual)

🏆 Awards & Recognition

Recognitions

Segment Awards:

Frequently cited by automotive publications for its practicality and value within the minivan segment during its production run.