The Chrysler Grand Caravan, a cornerstone of the minivan segment, offered practical family transportation from its NS generation beginning in 1996 through 2005. Built in Windsor, Ontario, Canada, this front-wheel-drive vehicle was available with a selection of V6 engines, including 3.0L, 3.3L, and 3.8L options, paired with automatic transaxles. Known for its spacious interior and versatility, the Grand Caravan was designed to accommodate families and their cargo with ease. The legacy in pioneering the minivan segment provided a strong foundation for this model, which continued to evolve with minor updates and feature enhancements throughout its production years, aiming to provide reliable and comfortable journeys.
This comprehensive factory service manual is designed to be an indispensable resource for owners, DIY mechanics, and professional technicians working on Grand Caravan models from 1996 to 2005. It provides detailed, step-by-step repair procedures, general maintenance guidelines, troubleshooting assistance, and essential technical specifications covering all major systems. This includes engine and transmission service, brake systems, electrical and wiring diagrams, suspension, steering, cooling, fuel, emission control, HVAC, chassis, and interior components. The manual's extensive coverage, presented in English, ensures that users have access to the same factory-level information needed to maintain and repair their vehicle effectively and efficiently.
Generation Years:
1996-2000
Generation Facelift:
2001-2007 (shared platform for Grand Caravan)
Target Audience:
Vehicle Owners, DIY Mechanics, Professional Technicians
Manual Authenticity:
Genuine Factory Service Manuals (Not 3rd party)
Completeness:
COMPLETE official full factory service repair manual
Searchability:
Searchable PDF for quick information retrieval
Cost Savings:
Enables DIY servicing, saving $50-$60 per hour on labor costs
Information Source:
Provides same information as professional technicians
Applicable Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Pages:
Extensive (Hundreds of pages)
Type:
Factory Service Manual (FSM) / Repair Manual
Engine Service Repair:
Yes
Transmission Service Repair:
Yes
Fuel Injection Fuel System:
Yes
Emission Control System:
Yes
Heating Air Conditioning:
Yes
Engine Control System:
Yes
Differential Drive Axle:
Yes
Troubleshooting:
Yes (Advanced guide included)
Periodic Lubrication:
Yes
Repair Procedures:
Yes (Step-by-step, detailed)
Rebuilding Procedures:
Yes
Refurbishing Restoration:
Yes
Depth:
Comprehensive (Factory trained technician level)
Illustrations Diagrams:
Yes (Includes illustrations, drawings, and photos)
Diagnostic Procedures:
Yes (All diagnostic procedures covered)
Special Tools:
Likely detailed (Implied by factory FSM)
Printability:
Printable (Entire manual or specific pages)
Resolution:
High Resolution
Binding:
Digital (Printable at user's discretion)
Paper Type:
N/A (Digital)
Reader Software:
Adobe PDF Reader
Operating Systems:
Windows, macOS
Engine Options:
3.0L (2972cc) SOHC V6 (12 valve) Vulcan; 3.3L (3301cc) OHV V6 (12 valve) ERE (or EGA); 3.8L (3778cc) OHV V6 (12 valve) LSE
Horsepower 3.0L:
Approx. 150 hp @ 5000 rpm
Torque 3.0L:
Approx. 170 lb-ft @ 3200 rpm
Horsepower 3.3L:
Approx. 175 hp @ 5200 rpm
Torque 3.3L:
Approx. 205 lb-ft @ 3200 rpm
Horsepower 3.8L:
Approx. 180 hp @ 4400 rpm
Torque 3.8L:
Approx. 230 lb-ft @ 3200 rpm
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Cylinder Block Material:
Cast Iron
Cylinder Head Material:
Aluminum
Timing Drive:
Timing Chain (3.0L Vulcan, 3.3L/3.8L OHV)
Transmission Type:
4-speed Automatic Transaxle
Transmission Variants:
A604 (4-speed automatic) for 3.0L; 42LE (4-speed automatic) for 3.3L and 3.8L
Drive Type:
Front-Wheel Drive (FWD)
Wheelbase:
Approx. 112.1 inches
Length:
Approx. 193.1 - 196.5 inches (depending on year/trim)
Width:
Approx. 72.0 - 73.5 inches
Height:
Approx. 67.6 - 68.5 inches
Curb Weight:
Approx. 3,700 - 4,200 lbs (depending on configuration)
NHTSA Front Impact Driver:
Could vary by year, generally fair to good ratings for the era.
NHTSA Front Impact Passenger:
Could vary by year, generally fair to good ratings for the era.
ABS:
Standard on many models, optional on some early trims
Traction Control:
Optional on some higher trims, particularly later years
Airbags Driver Passenger:
Standard dual front airbags
Child Seat Anchors:
LATCH system available on later models
Audio System:
Various factory radio options, including cassette players and CD players, some with premium speaker systems.
Cruise Control:
Standard or optional depending on trim level.
Onboard Diagnostics:
OBD-II compliant starting from 1996, allowing for electronic diagnostic scanning.
Oil Change Interval:
Typically every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics).
Spark Plug Replacement:
Generally around 100,000 miles for platinum/iridium plugs (check specific engine). Original plugs may have shorter intervals.
Timing Belt Chain Replacement:
Timing chain is generally considered maintenance-free for the life of the engine. If timing belt were applicable (which it is not for these engines), it would be critical.
Engine Oil Type:
SAE 5W-30 is common, but always verify specific engine requirement (refer to manual for exact API service classification).
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification, e.g., MS-9602) for later models, ATF+3 for earlier models. Crucial to use correct type.
Coolant Type:
Chrysler long-life antifreeze/coolant (typically 50/50 mix with distilled water). Verify color specification.
Transmission Issues:
Some early transmissions (e.g., A604) were known for occasional rough shifting or solenoid issues. Periodic fluid and filter changes are vital.
Power Steering Leaks:
Can develop leaks from hoses or the pump over time.
Heating And Cooling System:
Heater cores can leak, and A/C evaporator issues are not uncommon with age.
Ignition System:
Spark plug wires and ignition coils can degrade, leading to misfires.
Body And Interior:
Interior trim can become loose, and power sliding doors/windows may require adjustment or repair.
Chrysler Minivan Legacy:
Chrysler is widely credited with inventing the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in the early 1980s. The Grand Caravan served as the upscale Chrysler-branded version.
Generation Ns Introduction:
The NS generation debuted for the 1996 model year, marking a significant redesign with a smoother, more aerodynamic body style and improved interior packaging. It shared its platform with the Dodge Caravan and Plymouth Voyager.
Post 2000 Facelift:
While the core platform remained similar, minor updates and refreshes occurred between 2001-2007, including styling tweaks and feature additions, though the manual specifically covers up to 2005 for the Grand Caravan.
Manufacturing Locations:
Windsor, Ontario, Canada (Chrysler Canada Inc.)
Car And Driver 10Best:
The original Caravan/Voyager platform received multiple '10 Best' awards from Car and Driver in its early years, setting the standard for the minivan segment. While specific awards for the Grand Caravan 1996-2005 aren't universally cited in the same way, it benefited from the established reputation.
