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Chrysler caravan 1996 1997 1998 1999 Service Workshop Manual

Chrysler caravan 1996 1997 1998 1999 Service Workshop Manual

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Vehicle data plateRef 563272
Brand
Chrysler
Vehicle
Marine
Models covered
Caravan, Misc, Outboard Engines
Years
1996, 1997, 1998, 1999
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Model Generation:
Second Generation
Years Covered:
1996, 1997, 1998, 1999
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, individuals seeking versatile people and cargo transport
Competitive Analysis
Key Competitors Era:
Ford Windstar, Chevrolet Venture/Pontiac Trans Sport/Oldsmobile Silhouette, Honda Odyssey, Toyota Sienna
Key Features
Vehicle Selling Points:
Spacious interior, flexible seating, comfortable ride, accessible pricing (historically)
Manual Value Proposition
Manual Benefit:
Empowers owners and technicians with detailed repair and maintenance procedures, diagnostic guidance, and technical specifications, enabling cost-effective upkeep and problem resolution.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Page Count:
Over 3000 pages
Language:
English
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging, diagnostics, troubleshooting, performance tuning
Transmission Systems:
Automatic Transmission (e.g., 42LE), clutch, drivetrain, drive axles, differentials
Brake Systems:
Front and rear brakes, ABS, parking brake, hydraulic systems, components
Suspension Steering:
Front and rear suspension, steering gear, power steering, alignment, wheels, tires
Electrical Electronics:
Battery, starting system, charging system, lighting, instruments, gauges, ignition system, power distribution, wiring diagrams, fuses, relays, control modules (PCM, BCM, etc.)
Body Chassis:
Body construction, doors, windows, seats, interior trim, exterior trim, bumpers, frame, exhaust system, fuel tank, climate control system (HVAC), power accessories
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections
Repair:
Component removal and installation, engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, component testing, diagnostic procedures for various systems
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters
Technical Depth
Depth Of Coverage:
Comprehensive, covering routine maintenance to major component overhaul and advanced diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, allowing for quick information retrieval
Print Quality:
Varies with original scan, typically good for digital reference, printable pages
Binding Type
Binding:
Not applicable (PDF format)
Paper Type
Paper Quality:
Not applicable (PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
Various, likely includes EGN (3.0L OHV V6), EAS (3.3L OHV V6), and potentially EGW (3.8L OHV V6) depending on specific sub-model and region.
Performance
Displacement Common:
3.0L (182 cu in), 3.3L (201 cu in), 3.8L (230 cu in)
Horsepower Range:
Approximately 150 hp to 170 hp, depending on engine and year.
Torque Range:
Approximately 170 lb-ft to 215 lb-ft, depending on engine and year.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition Type:
Distributorless Ignition System (DIS) or distributor-based systems, depending on specific engine
ECU Type:
Powertrain Control Module (PCM)
🔧 Transmission
Standard Transmission
Type:
Automatic
Optional Transmission
Type:
Not generally offered for these model years in this segment.
Features
Transmission Model Common:
42LE (4-speed automatic)
Transmission Fluid Type:
ATF+4 (or equivalent service fill, check manual for specific recommendations)
📐 Dimensions
Exterior
Wheelbase Approx:
112.5 inches (2858 mm)
Length Approx:
189.1 inches (4803 mm)
Width Approx:
72.5 inches (1841 mm)
Height Approx:
67.8 inches (1722 mm)
Cargo
Cargo Volume Behind 3Rd Row Approx:
Varies by configuration, typically around 15-20 cu ft.
Cargo Volume Max Approx:
Over 140 cu ft with rear seats removed.
Weights
Curb Weight Range:
Approximately 3,900 - 4,300 lbs (1769 - 1950 kg)
Gross Vehicle Weight Rating Gvwr Approx:
Approximately 5,500 - 6,000 lbs (2495 - 2722 kg)
Wheel Tire
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Standard Tire Size:
P215/70R15, P225/70R15, or P225/60R16 depending on trim/options.
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Likely 3 or 4 stars for these model years (review specific year's data if available).
Active Features
ABS Availability:
Available on most trims, standard on higher trims
Passive Features
Airbags Front:
Driver and Passenger Frontal Airbags
Seat Belts:
Three-point seat belts for all occupants, integrated child seats may be optional.
Child Safety Anchors:
LATCH system not standard, child seat tether anchors present.
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with cassette and CD player options, various speaker configurations.
Driver Assistance
Cruise Control:
Standard on most trims.
Traction Control:
Optional on some models/trims.
Connectivity
Auxiliary Inputs:
Not typically available for this era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 miles (12,000 km) or 6 months, whichever comes first (refer to manual for specific usage conditions).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed.
Spark Plug Replacement:
Around 100,000 miles (160,000 km) for platinum tipped plugs, check manual for exact interval.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), depending on driving conditions.
Fluid Specifications
Engine Oil Spec:
API Certified SAE 5W-30 (check manual for specific viscosity grade recommendations based on temperature).
Coolant Type:
Chrysler Long Life Antifreeze/Coolant (OAT) or equivalent, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
Suspension components (ball joints, tie rods, bushings), brake pads/rotors, fuel pumps, ignition coils, transmission solenoids.
Typical Engine Problems:
Head gasket leaks (especially on 3.3L and 3.8L), intake manifold gasket leaks, oil leaks, occasional piston slap on cold starts.
Typical Transmission Problems:
Slipping, delayed engagement, harsh shifts can indicate internal wear or solenoid issues in the 42LE transmission.
Electrical Issues:
Faulty window regulators, power door lock actuators, intermittent dashboard warning lights, PCM issues.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation
Model Evolution
Generation Intro:
The Caravan (and its Plymouth Voyager and Dodge Grand Caravan siblings) debuted in 1983, revolutionizing the minivan segment.
Second Generation Era:
1996-2000 model years.
Key Updates Second Gen:
Completely redesigned platform, 'cab-forward' design, improved aerodynamics, increased interior space, dual sliding doors became standard.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Chrysler minivan platform has received numerous accolades over its history, though specific mentions for these exact model years might vary. It was instrumental in defining the segment.
Consumer Reports:
Consumer Reports ratings for these years often reflected average to below-average reliability, particularly in later models of this generation. The manual helps mitigate these issues.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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