🏷️ Basic Information

Make:

Chrysler

Model:

Grand Caravan

Model Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Platform:

NS (1996-2000), RS (2001-2007, with mid-cycle refresh affecting 2001-2005)

👋 Introduction

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.

📋 Manual Details

Coverage:

All Models, Engines, Trim Levels, and Transmission Types

Estimated Pages:

Detailed information suggests hundreds of pages, typical for a complete factory workshop manual.

Type:

Workshop Repair and Service Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

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.

📊 Manual Specifications

File Type:

PDF

PDF Features:

Searchable text for quick information retrieval, bookmarked chapters for easy navigation.

Printability:

Full Printable

Zoom:

Zoom In/OUT

Delivery:

Instant Download

Software Requirements:

Adobe PDF Reader & WinZip

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

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)

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle (e.g., 41TE for FWD models)

Optional Transmissions:

Manual transmission less common in North American Grand Caravans, primarily automatic.

Transmission Features:

Includes features like TorqueFlite (earlier designations) or similar advanced automatic control systems for the era.

📐 Dimensions

Wheelbase:

Approx. 112.1 inches (NS), 113.0 inches (RS)

Seating Capacity:

7-8 passengers (depending on configuration)

Curb Weight Range:

Approx. 3,800 - 4,200 lbs, depending on engine and configuration.

🛡️ Safety Features

NHTSA Frontal Impact Driver:

4-star (1996-2000 models, specific year testing applies)

Active Safety:

Anti-lock Braking System (ABS) - standard on most later models and optional on earlier ones.

Passive Safety:

Driver and front passenger airbags, front seatbelt pre-tensioners.

💡 Technology Features

Audio System:

Basic AM/FM radio with cassette and/or CD player, optional premium sound systems.

Driver Assistance Features:

Limited by era; ABS was the primary advanced system. Cruise control was common.

Connectivity Options:

No modern connectivity features like Bluetooth or USB ports. Auxiliary inputs may be present on later models.

🔧 Maintenance

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.

📚 Vehicle History

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.

🏆 Awards & Recognition

Car And Driver Ten Best:

The Chrysler Minivan platform (including Grand Caravan) was a frequent recipient of Car and Driver's 'Ten Best' list during this period, particularly in its earlier iterations.