🏷️ Basic Information

Make:

Dodge

Model:

Grand Caravan

Model Years Covered:

1996, 1997

Platform:

NS Platform

👋 Introduction

Segment:

Minivan

Positioning:

The Dodge Grand Caravan was a popular and practical family vehicle, known for its spacious interior, versatility, and affordability in the North American market.

Key Competitors:

Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Honda Odyssey, Toyota Previa.

Notable Features:

Available Stow 'n Go seating (later generations), flexible cargo space, front-wheel drive, optional all-wheel drive (in some markets/years), and a range of powerful V6 engines.

Value For Buyers:

Essential for owners and independent repair shops seeking to maintain, diagnose, and repair the 1996-1997 Grand Caravan. Provides in-depth technical knowledge crucial for proper servicing.

📋 Manual Details

General Coverage:

Repair and overhaul of Dodge Grand Caravan 1996-1997 models.

Target Audience:

Professional technicians and advanced DIY enthusiasts familiar with general automotive practices.

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for engine removal, disassembly, inspection, repair, and reassembly for all applicable engine variants.

Engine Electrical:

Diagnosis and repair of ignition system, starting system, charging system, fuel injection system, and onboard diagnostics (OBD-I).

Transmission Automatic:

Service and repair of the automatic transmission (e.g., 41TE, 42LE) including fluid changes, component replacement, and diagnostic procedures.

Drivetrain:

Repair and overhaul of front-wheel drive axle shafts, differential, and related components.

Suspension:

Front and rear suspension component diagnosis, replacement (struts, shocks, control arms, ball joints, bushings), and alignment specifications.

Steering:

Power steering system diagnosis and repair, steering gear replacement, and steering column service.

Brakes:

Front and rear brake system service (disc/drum), including hydraulic system repair, brake pad/shoe replacement, rotor/drum service, and ABS system diagnosis (if equipped).

Electrical Body:

Wiring diagrams, lighting systems, power windows, power locks, interior and exterior trim, and body panel repair procedures.

HVAC:

Heating, ventilation, and air conditioning system service, including refrigerant handling, component replacement (compressor, evaporator, heater core), and diagnosis.

Fuel System:

Fuel pump, fuel filter, fuel injectors, and fuel tank service and diagnostics.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, and pipe replacement procedures.

Scheduled Maintenance:

Detailed guidance on routine maintenance tasks and recommended service intervals.

Troubleshooting:

Systematic diagnostic charts and procedures for identifying and resolving common and uncommon problems.

Repair Overhaul:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.

Component Replacement:

Explicit instructions for replacing various parts and assemblies, including torque specifications.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, aiding in diagnosis and repair.

Diagnostic Codes:

Explanation of diagnostic trouble codes (DTCs) and their associated symptoms and repair actions.

Depth:

Comprehensive, covering everything from basic fluid checks and filter replacements to complete engine and transmission overhauls, and complex electrical system diagnostics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing quick access to specific information.

Printability:

Designed for printing, allowing users to create physical copies of relevant sections.

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Option 1 Displacement:

3.0 L (181 cu in) Mitsubishi V6

Engine Option 1 Code:

6G72 (SOHC)

Engine Option 1 Horsepower:

142 hp @ 4800 rpm

Engine Option 1 Torque:

170 lb-ft @ 3000 rpm

Engine Option 2 Displacement:

3.3 L (203 cu in) Chrysler V6

Engine Option 2 Code:

EGA (OHV)

Engine Option 2 Horsepower:

156 hp @ 4800 rpm

Engine Option 2 Torque:

189 lb-ft @ 3200 rpm

Engine Option 3 Displacement:

3.8 L (231 cu in) Chrysler V6

Engine Option 3 Code:

ECL (OHV)

Engine Option 3 Horsepower:

168 hp @ 4400 rpm

Engine Option 3 Torque:

227 lb-ft @ 3200 rpm

Emissions Control:

OBD-I compliant, with catalytic converters and EGR systems.

Injection Type:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle

Transmission Availability:

Standard on most models; specific transmission model varied by engine.

Transmission Models:

Likely 41TE or 42LE depending on engine and year.

Fluid Type:

ATF+4 (Mopar)

Fluid Capacity:

Approx. 7.5 quarts (7.1 liters) for dry fill.

📐 Dimensions

Length:

Approx. 179.0 - 181.7 inches (454.7 - 461.5 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 68.3 inches (1735 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm)

Cargo Volume Rear Seats Up:

Approx. 140.4 cu ft (3976 L)

Cargo Volume Rear Seats Down:

Approx. 177.3 cu ft (5020 L) for SWB, much larger for LWB models (LWB not specified for 96-97, but a common variant).

Curb Weight:

Approx. 3700 - 4100 lbs (1678 - 1860 kg), depending on engine and configuration.

🛡️ Safety Features

NHTSA Frontal Impact Driver:

Four stars (1996 models, for the driver).

NHTSA Frontal Impact Passenger:

Four stars (1996 models, for the passenger).

ABS:

Anti-lock Braking System (ABS) available as an option on some trims.

Airbags:

Driver and front passenger airbags.

Seat Belts:

Three-point front and rear seat belts.

💡 Technology Features

Audio System:

Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations (e.g., 4 or 6 speakers).

Cruise Control:

Standard on most models.

Trailer Tow Prep:

Optional trailer tow package available, including wiring harness and possibly upgraded cooling.

🔧 Maintenance

Oil Change Interval:

Every 3,000 to 7,500 miles (5,000 to 12,000 km) or 6 months, depending on driving conditions and oil type. Refer to manual for specifics.

Tire Rotation:

Every 6,000 to 7,500 miles (10,000 to 12,000 km).

Spark Plug Replacement:

Approximately every 100,000 miles for platinum-tipped plugs (check manual for specific engine).

Engine Oil Type:

API Certified SAE 5W-30 or 10W-30 (refer to owner's manual for climate-specific recommendations).

Coolant Type:

Chrysler/Mopar Antifreeze/Coolant (green ethylene glycol based) or equivalent, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3.

Power Steering Fluid:

ATF+4 (Mopar) or equivalent.

Common Problems 1:

Transmission issues (solenoid packs, torque converter clutch shudder), A/C system leaks, power window regulator failure, front suspension wear (ball joints, tie rods), rear axle bearing failure.

Common Problems 2:

Ignition coil failure, exhaust manifold leaks, coolant leaks (especially intake manifold gaskets on some engines).

📚 Vehicle History

Dodge Legacy:

Dodge, a division of Chrysler (later FCA, now Stellantis), has a long history of producing robust and versatile vehicles, particularly trucks and minivans.

Generation:

This manual covers the second generation (NS) of the Dodge Caravan/Grand Caravan, introduced for the 1996 model year, featuring a significant redesign including improved aerodynamics and safety features.

Assembly Locations:

Primarily Windsor, Ontario, Canada.

🏆 Awards & Recognition

Car And Driver 10Best:

While the Grand Caravan itself may not have been on the '10 Best' list, the minivan segment it helped define was revolutionized by Chrysler's original minivan concept.