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1996 Dodge Caravan CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Component Replacement & Adjustment -> Light Trucks & Vans -> Expansion Valve, Replace -> 1996 -> Cherokee -> Full Size Vans -> Minivans
Vehicle: 1996 Dodge Caravan 2.4 L4 GAS
Cherokee
1996
- Recover refrigerant as outlined under , then remove coolant bottle and bracket.
- Disconnect A/C hoses from expansion valve.
- Disconnect expansion valve from evaporator core inlet and outlet tubes, then remove expansion valve.
- Reverse procedure to install.
Full Size Vans
- Recover refrigerant as outlined under .
- Disconnect electrical connector from cutout switch, if equipped.
- Remove bolt from center of plumbing sealing plate, Fig. , then carefully pull refrigerant line toward front of vehicle...
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BRAKE SERVICE PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Disc Brakes -> Caravan, Town & Country & Voyager -> Description
Vehicle: 1996 Dodge Caravan SE 2.4 L4 GAS
The Kelsey-Hayes double pin caliper, Fig. , consists of a driving hub, braking disc rotor, caliper, pads and adapter. The calipe...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Caravan, Town & Country & Voyager w/2001-06 2.4L, 3.3L & 3.8L Engines, 1996-00 3.0L Engine
Vehicle: 1996 Dodge Caravan 3.0 V6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reco...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1996 Dodge Caravan SE 2.4 L4 GAS
Remove
- Remove cotter pin, nut lock, and spring washer from end of outer CV joint stub axle.
- Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with brakes applied. Front hub and driveshaft are splined together and retained by hub nut.
- Raise vehicle on jack stands or centered on a frame contact type hoist.
- Remove front tire and wheel assembly from hub.
- Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts.
- Remove disc brake caliper assembly from steering knuckle. Caliper is removed by f...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Starter, Replace
Vehicle: 1996 Dodge Caravan ES 3.3 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove starter motor attaching bolts and nuts.
- Disconnect all electrical connectors from starter motor and remove starter from...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Chrysler LLC Trucks -> Check Gauge Warning Lamp ->
Vehicle: 1996 Dodge Caravan ES 3.3 V6 GAS
When the ignition is turned On, the lamp will light for approximately 2 seconds as a bulb inspection. The PCM continually monitors the engine oil pressure, engine coolant temperature and electrical system voltage. The check gauges lamp w...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 Dodge Caravan ES 3.8 V6 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump inlet tube.
- Remove radiator outlet hose from water pump inlet tube and from vehicle.
- Reverse proc...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Dodge Caravan AUTOMOBILES
Serpentine Drive Belt, Replace -> Alternator & Air Conditioner Compressor -> Power Steering Pump
Vehicle: 1996 Dodge Caravan 2.4 L4 GAS
Alternator & Air Conditioner Compressor
- Raise and support vehicle.
- Remove the drive belt shield.
- Position a suitable wrench on the belt tensioner lug.
- Release belt tension by rotating the tensioner clockwise, do not allow drive belt tensioner to snap back, as damage to tensioner and/or personal injury c...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Dodge Caravan AUTOMOBILES
Component location diagrams for most 1996 Dodge Caravan cars and light trucks sold in the U.S. from 1990+.
I/P Component Locations Diagram for 1996 Dodge Caravan 3.0 V6 GAS Components on diagram: |
Fuel Tank Component Locations Diagram for 1996 Dodge Caravan SE 3.3 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 Dodge Caravan AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Dodge Caravan cars and light trucks sold in the U.S.
1996 Dodge Caravan SE 3.0 V6 GAS Wiring Diagram Components on diagram: |
1996 Dodge Caravan ES 3.8 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Dodge Caravan AUTOMOBILES
OEM TSB listings for most 1996 Dodge Caravan cars and light trucks sold in the U.S. from 1985+.
Document: CHILD SEAT TETHER ANCHOR INSTALLATION - REV Vehicle: 1996 Dodge Caravan 3.0 V6 GAS Auto Systems: |
Document: AUTOMATIC TRANSMISSION DIAGNOSTIC TEARDOWN PROCEDURE - REVISED Vehicle: 1996 Dodge Caravan 3.0 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Dodge Caravan AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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