Description:
The Chrysler Grand Caravan was a segment-defining minivan, offering practical family transportation. This manual caters to owners and independent repair shops seeking professional-level information to maintain and repair these vehicles.
Competitors Manuals:
Competes with factory service manuals for direct competitors like the Dodge Caravan, Plymouth Voyager, Honda Odyssey, Toyota Sienna, and Ford Windstar of the same era.
Manual Benefits:
Cost savings on repairs, DIY maintenance enablement, comprehensive diagnostic tools, detailed diagrams, troubleshooting guidance, and factory-level accuracy.
Visual Aids:
Hundreds of illustrations, diagrams, and photographs to guide users through repair and maintenance tasks, including enlarged insets for intricate parts.
Systems:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle
Electrical System Details:
Detailed wiring diagrams for all major systems, including lighting, ignition, charging, starting, fuel injection, power windows, door locks, climate control, and instrument cluster.
Suspension And Steering Details:
Front and rear suspension component identification and replacement (struts, shocks, control arms, ball joints, tie rods), power steering system service, wheel alignment specifications.
Chassis Body Details:
Body panel repair, rust prevention, door mechanism service, liftgate operation, interior trim removal and installation, dashboard repair.
Restraint System Details:
Airbag system diagnostics, seatbelt operation and replacement, SRS (Supplemental Restraint System) component identification.
Procedures:
Detailed substeps, critical notes/cautions/warnings, numbered repair instructions, diagnostic procedures, electrical service procedures, maintenance, disassembly, assembly, cleaning, reinstalling procedures, troubleshooting
Engine Repair Procedures:
Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing belt/chain replacement (as applicable per engine), component testing and replacement (alternator, starter, etc.).
Transmission Repair Procedures:
Automatic transmission fluid and filter changes, internal component diagnosis, valve body service, solenoid replacement, clutch pack service, torque converter replacement.
Brake System Procedures:
Brake pad and rotor replacement, caliper service, brake line inspection and replacement, brake bleeding procedures, parking brake adjustment.
Heating And Ac Procedures:
Refrigerant system diagnosis, component replacement (compressor, condenser, evaporator), blower motor service, heater core replacement, climate control module troubleshooting.
Depth:
Comprehensive, covering basic maintenance to advanced diagnostics and repair procedures as used by professional technicians.
Diagnostic Capabilities:
Includes diagnostic trouble codes (DTCs) and their interpretation, troubleshooting flowcharts for common drivability and system faults, component testing specifications (e.g., resistance, voltage readings).
Torque Specifications:
Detailed torque specifications for all critical fasteners, including engine components, suspension parts, and bodywork.
Engine Options:
3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EDB), 3.8L V6 (Chrysler EGD)
Engine Displacement 3 0L:
3.0 Liters (181 cubic inches)
Engine Displacement 3 3L:
3.3 Liters (203 cubic inches)
Engine Displacement 3 8L:
3.8 Liters (230 cubic inches)
Horsepower Torque 3 3L:
Approx. 158 hp @ 4600 rpm, 190 lb-ft @ 3200 rpm (for 1997 model, varies slightly by year)
Horsepower Torque 3 8L:
Approx. 166 hp @ 4400 rpm, 230 lb-ft @ 3200 rpm (for 1997 model, varies slightly by year)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics).
Transmission Fluid Change Interval:
Every 30,000-60,000 miles or as recommended by service bulletins (refer to manual).
Engine Oil Type:
SAE 5W-30 or 10W-30 API Certified (check owner's manual for specific viscosity and API classification).
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification for the transmission model, e.g., ATF+3 for older units).
Coolant Type:
Chrysler Formula I (Orange) Antifreeze/Coolant, or equivalent with Ethylene Glycol base. Capacity varies by engine, typically 13-15 quarts.
Brake Fluid Type:
DOT 3 brake fluid.
Common Problems:
Transmission issues (input/output shaft seals, solenoid packs), EGR valve clogging, power steering pump leaks, rear axle bearing wear, window regulator failures, door lock actuator issues.
Electrical Gremlins:
Intermittent electrical issues, often related to ground points or faulty sensors, are not uncommon in vehicles of this age.
Minivan Pioneering:
Chrysler is credited with popularizing the minivan segment in North America with the original Dodge Caravan/Plymouth Voyager, upon which the Grand Caravan is based.
Generations Covered:
This manual covers the second generation (NS, 1996-2000) and the early years of the third generation (RS, 2001-2007) which includes the 2001-2005 models. The RS generation received a significant refresh in 2005.
Generational Differences Brief:
NS generation (1996-2000) features more rounded styling and different interior layouts compared to the RS generation (2001-2007) which introduced a more angular design and updated powertrains.
Manufacturing Location:
Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
