- Child's Play
- Mother-In-Laws Do It
- Tricky at Times
- Instructions Required
   (client to provide)
- You'll Be Here for a few
   hours
  • Spark plugs
  • Distributor Cap & Rotor
  • Ignition Wires

  • Spark Plug wire boot puller
  • Spark Plug Socket (5/8 or 15/16)
  • 3/8 drive Ratchet
  • 3/8 drive Extension
  • 3/8 ujoint adaptor
  • Spark Plug Gapper
  • Battery wrench
  • Screwdriver (flat & phillips)
  • Pliers
  • Torque Wrench (Using this tool is the best way to ensure the plugs are tightened properly.)
  • Dielectric grease
  • Anti-seize compound


Can't find the manual for your 1996-2002 Dodge Caravan? No problem. This month our pros walk you through routine maintenance and show you how to replace your spark plugs, spark plug wires, and distributor cap, to get your ride ready for Spring.

So go grab your tools, and let's get started. With our easy steps, you'll be done with enough time to check the lawn mower too. Sorry about that.

Make Safety Your Top Priority

Every vehicle is different. When it comes to maintenance and repairs, always follow the vehicle's owner's manual. Don't work with a Philips when the job calls for a flat. Substituting tools can compromise your safety or your vehicle's performance.

Safety should be your number one priority. Don't smoke, drink alcoholic beverages, or wear a necktie while working on the car. And watch out for hot objects, sharp instruments, hazardous materials and other potential safety hazards in and around your workspace.

Finally, when the fun turns to frustration or if the job requires specialized knowledge beyond your abilities, seek the assistance of a Parts Pro, professional mechanic or installer. The last thing we want is someone getting hurt.



Dodge Caravan (1996-2002)
5,000KM to 20,000 KM, all models

5,000 km 10,000 km 15,000 km 20,000 km
Inspect Inspect Inspect Inspect
1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps 1.Front & rear brake linings 1.Cooling system, hoses and clamps
2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots 2.Cooling system, hoses and clamps 2.Drive shaft axle, cv joints and boots
3.Exhaust system 3.Exhaust system 3.Drive shaft axle, cv joints and boots 3.Exhaust system
4.Suspension components 4.Suspension components 4.Exhaust system 4.Suspension components
Replace:
Engine oil
Rotate the tires 3.Suspension components Rotate the tires
 
Replace:
Engine oil
Replace:
Engine oil
Replace:
Engine oil

Dodge Caravan (1996-2002)
25,000KM to 40,000 KM, all models

25,000 km 30,000 km 35,000 km 40,000 km
Inspect Inspect Inspect Inspect
1.Air cleaner element, replace if necessary 1.Front & rear brake linings 1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps
2.Cooling system, hoses and clamps 2.Cooling system, hoses and clamps 2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots
3.Drive shaft axle, cv joints and boots 3.Drive shaft axle, cv joints and boots 3.Exhaust system 3.Exhaust system
4.Exhaust system 4.Exhaust system 4.Suspension components 4.Suspension components
5.Suspension components 5.Suspension components
Replace:
Engine oil
Rotate the tires
Replace:
Engine oil

2.4l engine
Adjust the alternator drive belt

3 spd transmission
Adjust the transaxle bands
Rotate the tires

Replace:
Engine oil
 
Replace:
Engine oil

Dodge Caravan (1996-2002)
45,000KM to 60,000 KM, all models

45,000 km 50,000 km 55,000 km 60,000 km
Inspect Inspect Inspect Inspect
1.Front & rear brake linings 1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps 1.Front & rear brake linings
2.Cooling system, hoses and clamps 2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots 2.Cooling system, hoses and clamps
3.Drive shaft axle, cv joints and boots 3.Exhaust system 3.Exhaust system 3.Drive shaft axle, cv joints and boots
4.Exhaust system 4.PCV valve 4.Suspension components 4.Exhaust system
5.Suspension components 5.Suspension components
Replace:
Engine oil
5.Suspension components
Replace:
Engine oil
6.Tie rod ends and dust boots

Rotate the tires

Replace:
1.Air cleaner element

2.Engine oil

2.4l engine
1.Inspect the power steering belt and replace if necessary

2.Replace the spark plugs

3.0l engine
Replace the spark plugs

3 spd transmission
Adjust the automatic transaxle bands
  Rotate the tires

Replace:
Engine oil

Dodge Caravan (1996-2002)
65,000KM to 80,000 KM, all models

65,000 km 70,000 km 75,000 km 80,000 km
Inspect Inspect Inspect Inspect
1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps 1.Air cleaner element, replace if necessary 1.Cooling system, hoses and clamps
2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots 2.Front & rear brake linings 2.Drive shaft axle, cv joints and boots
3.Exhaust system 3.Exhaust system 3.Cooling system, hoses and clamps 3.Exhaust system
4.Suspension components 4.Suspension components 4.Drive shaft axle, cv joints and boots 4.Suspension components
Replace:
Engine oil
Rotate the tires 5.Exhaust system Rotate the tires
 
Replace:
Engine oil
6.Suspension components

Replace:
Engine oil

2.4l engine
Adjust the alternator drive belt

3 spd transmission
Adjust the transaxle bands
Replace:
1.Engine oil

2.Automatic transmission filter

3.Automatic transmission fluid

Dodge Caravan (1996-2002)
85,000KM to 100,000 KM, all models

85,000 km 90,000 km 95,000 km 100,000 km
Inspect Inspect Inspect Inspect
1.Cooling system, hoses and clamps 1.Front & rear brake linings 1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps
2.Drive shaft axle, cv joints and boots 2.Cooling system, hoses and clamps 2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots
3.Exhaust system 3.Drive shaft axle, cv joints and boots 3.Exhaust system 3.Exhaust system
4.Suspension components 4.Exhaust system 4.Suspension components 4.PCV valve
Replace:
Engine oil
5.Suspension components

Rotate the tires
Replace:
Engine oil
5.Suspension components

6.Tie rod ends and dust boots
 
Replace:
Engine oil
  Rotate the tires

Replace:
1.Air cleaner element

2. Engine oil

2.4l engine
1.Inspect the power steering belt and replace if necessary

2.Replace the spark plugs

3.Replace Ignition wires

3.0l engine
1.Inspect timing belt

2.Replace the spark plugs

3.Replace ignition wires

3.3l engine
Inspect drive belts and replace if necessary

3 spd transmission
Adjust the automatic transaxle bands

Dodge Caravan (1996-2002)
105,000KM to 120,000 KM, all models

105,000 km 110,000 km 115,000 km 120,000 km
Inspect Inspect Inspect Inspect
1.Front & rear brake linings 1.Cooling system, hoses and clamps 1.Cooling system, hoses and clamps 1.Front & rear brake linings
2.Cooling system, hoses and clamps 2.Drive shaft axle, cv joints and boots 2.Drive shaft axle, cv joints and boots 2.Cooling system, hoses and clamps
3.Drive shaft axle, cv joints and boots 3.Exhaust system 3.Exhaust system 3.Drive shaft axle, cv joints and boots
4.Exhaust system 4.Suspension components 4.Suspension components 4.Exhaust system
5.Suspension components Rotate the tires
Replace:
Engine oil
5.Suspension components
Replace:
Engine oil
Replace:
Engine oil
  Rotate the tires

Replace:
Engine oil
  Before you Begin
 

Free print outs of vehicle specific instructions are available at your local PartSource.
Allow the engine to cool completely before attempting the ignition tune up. You can use this time to inspect and gap the new spark plugs. There are different types of gappers for certain plugs so make sure you ask the PartsPro at your local Partsource for the correct spark plug gap tool when you purchase your new plugs. The PartsPro will also know the specific gap for the type of plug you are buying as well.

 
  How to replace your Spark Plugs
 

Depending on which angle you're working from cover the front of the vehicle or the fender to prevent damaged to paint. Damaged can be caused from the snaps or buttons on your clothes. For safety, remember to disconnect the ground cable on the battery.

Remember: Only remove one plug at a time to ensure proper placement of the wires.
Remove the spark plug wire. Only pull on the boot end, never on the wire. Use a left and right twisting motion to free the wire boot from the spark plug. Use a spark plug boot puller tool to avoid damaging the wire.

TIP: If you have an air compressor, use it to blow any dirt from the spark plug area. A common bicycle pump will do the trick as well. We do not want any dirt falling into the cylinder upon removal of the spark plug.

Place the spark plug socket over the spark plug and remove by turning in a counterclockwise direction.

Now you are ready to install the new plug which we gapped while waiting for the engine to cool down.
Apply anti-seize to the threads of the spark plug. Apply dielectric grease to the ceramic part of the spark plug, to seal the plug to the wire boot.
Thread the plug into the hole tightening as much as possible by hand. Some vehicles come with aluminum cylinder heads which can strip very easily if we are not careful.
Use a torque wrench to tighten to specified torque. Torque specifications can be found using Mitchell onDemand at your local PartSource.

TIP: If you do not have a torque wrench, a good rule of thumb is to bring the plug up snug (finger tight) then give it between one-fourth to one-half turn more. For tapered seat plugs give it one-sixteen turn more.

Remember: Over tightening the plugs can change the gap and cause other damage. Low torque may cause the plug to overheat and possibly cause preignition.

Place the wire back onto the spark plug by using the same twisting motion we used to take it off. You can do this by hand, the tool is only required for taking the spark plug wire off. Repeat the steps above for the rest of the spark plugs, making sure they are done one at a time so we do not mix up the wires.

 
  How to replace the Distributor Cap and Rotor

Before you begin:
 

Apply dielectric grease to contact points on the new distributor cap and rotor.
Disconnect the battery ground cable.
Remove the old distributor cap with the wires attached. Depending on the vehicle your distributor cap is either held down by screws or clips. For specific instructions for your make and model refer to Mitchell onDemand at your local PartSource.
Remove one wire at a time from the old distributor cap, pull only on the boot end never on the wire.
Install the wire on the new distributor cap in the same position. We want to do this one at a time so we do not mix up the firing order.

TIP: Not all distributor caps have terminal ends that the wires go over, on some vehicles the spark plug wire is held inside the cap by a wire retainer. When removing the wires on this style of distributor cap, use a pair of pliers to compress the wire retaining clips inside the distributor cap before pulling the wires out.
Remove the old distributor rotor, it will simply pull off. If the rotor does not pull off, use a twisting pulling motion until it comes free. Do not try to pry the rotor off with a screwdriver you may cause damage to the distributor.
Install the new distributor rotor by lining up the notch in the distributor shaft with the notch in the rotor.
Apply anti-seize to the distributor hold down screws.
Install the new distributor cap with wires in the same position as the old one.

 
  How to replace your Spark Plug Wires

Before you begin:
 

Check the new wires to see if they come with dielectric grease applied already. If they don't make sure you have some dielectric grease to apply to the spark plug terminal. Disconnect the battery ground cable.
Remove one wire at a time so we do not mix up the firing order. Only pull on the boot end, never on the wire. Use a left and right twisting motion to free the wire boot from the spark plug.
Match the old wire to the new wire. The wires come in different lengths so make sure you match up the right length.
Before you install the wire on the spark plug terminal make sure to apply some dielectric grease to the wire if it did not come preapplied inside the spark plug wire boot.
Apply dielectric grease to the distributor cap contacts. Depending on your vehicle apply to the distributor cap terminals or the wire retainers inside the cap.
Attach the new plug wire to the spark plug using a twisting motion on the boot until it's seated on the spark plug.
Repeat the steps above for the remaining plug wires.

 
  Other easy jobs you might want to try while you are at it:

Air Filter
Oil Filter
PCV Valve