Chrysler Town Country 1996 Factory Service Repair Manual
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Basic Information Identification Make: Chrysler Model: Town & Country Year: 1996 Codes Platform: NS Introduction Market Position Segment: Minivan / Full-size Van Target Audience: Families seeking versatile and spacious transportation. Competitive Analysis Competitors 1996: Ford Aerostar, Chevrolet Venture (introduced later), Dodge Caravan/Plymouth Voyager. Key Features Versatility: Known for its flexible interior seating and cargo configurations. Comfort: Emphasis on passenger comfort for long journeys. Practicality: Designed for everyday family use and hauling capability. Manual Details Coverage Areas Diagnostic Procedures: Comprehensive diagnostic procedures for all major systems. Repair Instructions: Detailed step-by-step repair instructions for all components. Maintenance Schedules: Scheduled maintenance intervals and procedures. Electrical Schematics: Complete electrical system diagrams and wiring schematics. Troubleshooting Guides: Extensive troubleshooting charts for common and uncommon issues. Component Identification: Identification and location of all major vehicle components. Specifications: Detailed technical specifications for all vehicle systems. Torque Specifications: Precise torque values for all fasteners. Engine Overhaul: Complete engine overhaul and rebuild procedures. Transmission Repair: Detailed repair and overhaul procedures for the transmission. Brake Systems: Service and repair procedures for ABS and standard brake systems. Suspension Steering: Repair and alignment procedures for suspension and steering. Body And Frame: Information on body panel repair, corrosion protection, and frame straightening. HVAC System: Service and repair of the heating, ventilation, and air conditioning system. Fuel System: Diagnosis and repair of the fuel delivery and injection system. Exhaust System: Repair and replacement of exhaust components. Cooling System: Service and repair of the engine cooling system. Ignition System: Diagnosis and repair of the ignition system, including spark plugs and coils. Emissions Control: Information on emission control systems and their service. Interior Trim: Procedures for removing and installing interior trim components. Lighting System: Service and repair of all exterior and interior lighting. Audio System: Information on the factory audio system, including troubleshooting. Security System: Details on the factory anti-theft system. Safety Restraints: Information on airbags and seatbelt systems. Wheels Tires: Specifications and service for wheels and tires. Paint Finish: Information on paint codes and minor body repair. Fluid Capacities: Complete list of all fluid capacities and types. Diagnostic Trouble Codes: List and interpretation of all DTCs. Factory Procedures: Adherence to factory-specified procedures for optimal results. Page Count Pages: Hundreds of pages (specific count not provided in description, but implies comprehensive coverage). Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Management: Includes diagnosis and repair of fuel injection, ignition, and emissions control systems. Powertrain: Covers engine mechanical, transmission, and drivetrain components extensively. Chassis Systems: Detailed information on suspension, steering, brakes (including ABS), and wheel bearings. Electrical And Electronics: Comprehensive coverage of body and powertrain electrical systems, including wiring diagrams and component testing. Body And Accessories: Instructions for interior and exterior trim, doors, windows, seats, and power accessories. Procedures Included Preventative Maintenance: Detailed maintenance schedules and procedures for fluid changes, filter replacements, and inspections. Diagnostic Troubleshooting: Systematic diagnostic approach for identifying and resolving malfunctions, including symptom-based troubleshooting. Component Replacement: Step-by-step guides for removing, replacing, and installing all major and minor vehicle components. Rebuilding And Overhaul: Detailed instructions for overhauling engines, transmissions, and other complex assemblies. Alignment And Adjustment: Procedures for wheel alignment, steering system adjustments, and brake adjustments. Special Tools Usage: Identification and usage instructions for specialized tools required for specific repairs. Technical Depth Depth: Comprehensive coverage from basic maintenance to complex engine and transmission rebuilds. Diagnostic Level: Advanced diagnostic capabilities, including interpretation of sensor data and troubleshooting electronic modules. Repair Accuracy: Ensures repairs are performed to factory specifications, maintaining vehicle integrity and performance. Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick access to information. Print Quality Resolution: High-resolution digital reproduction for clear text and diagrams. Printability: Printable in its entirety or specific sections as needed. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Engine Specifications Primary Engine Engine Code: 3.3L V6 (EGA) Displacement: 3.3 Liters (201.6 cubic inches) Configuration: Overhead Valve (OHV) V6 Horsepower: Approx. 158 hp @ 4800 rpm Torque: Approx. 190 lb-ft @ 3000 rpm Fuel System Induction: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management Ignition System: Distributorless Ignition System (DIS) - often utilizing coil packs Emissions Control: Catalytic Converter, EGR (Exhaust Gas Recirculation) Transmission Standard Type: 4-speed Automatic Transaxle (A604/41TE) Optional Type: N/A (4-speed automatic was standard) Features Control System: Electronically controlled with overdrive. Fluid Type Fluid Specification: ATF+4 (Chrysler's recommendation, though ATF+3 was common in '96) Fluid Capacity Capacity: Approx. 6.0 quarts (5.7 liters) for pan drop and refill. Dimensions Exterior Wheelbase: Approx. 112.3 inches Length: Approx. 190.1 inches Width: Approx. 72.1 inches Height: Approx. 67.6 inches Weights Curb Weight: Approx. 4000-4300 lbs (depending on configuration) Gross Vehicle Weight Rating: Approx. 5700 lbs Cargo Max Cargo Volume: Varies with seating configuration, but significantly large, often exceeding 100 cu ft with...
Families seeking versatile and spacious transportation.
Competitive Analysis
Competitors 1996:
Ford Aerostar, Chevrolet Venture (introduced later), Dodge Caravan/Plymouth Voyager.
Key Features
Versatility:
Known for its flexible interior seating and cargo configurations.
Comfort:
Emphasis on passenger comfort for long journeys.
Practicality:
Designed for everyday family use and hauling capability.
Manual Details
Coverage Areas
Diagnostic Procedures:
Comprehensive diagnostic procedures for all major systems.
Repair Instructions:
Detailed step-by-step repair instructions for all components.
Maintenance Schedules:
Scheduled maintenance intervals and procedures.
Electrical Schematics:
Complete electrical system diagrams and wiring schematics.
Troubleshooting Guides:
Extensive troubleshooting charts for common and uncommon issues.
Component Identification:
Identification and location of all major vehicle components.
Specifications:
Detailed technical specifications for all vehicle systems.
Torque Specifications:
Precise torque values for all fasteners.
Engine Overhaul:
Complete engine overhaul and rebuild procedures.
Transmission Repair:
Detailed repair and overhaul procedures for the transmission.
Brake Systems:
Service and repair procedures for ABS and standard brake systems.
Suspension Steering:
Repair and alignment procedures for suspension and steering.
Body And Frame:
Information on body panel repair, corrosion protection, and frame straightening.
HVAC System:
Service and repair of the heating, ventilation, and air conditioning system.
Fuel System:
Diagnosis and repair of the fuel delivery and injection system.
Exhaust System:
Repair and replacement of exhaust components.
Cooling System:
Service and repair of the engine cooling system.
Ignition System:
Diagnosis and repair of the ignition system, including spark plugs and coils.
Emissions Control:
Information on emission control systems and their service.
Interior Trim:
Procedures for removing and installing interior trim components.
Lighting System:
Service and repair of all exterior and interior lighting.
Audio System:
Information on the factory audio system, including troubleshooting.
Security System:
Details on the factory anti-theft system.
Safety Restraints:
Information on airbags and seatbelt systems.
Wheels Tires:
Specifications and service for wheels and tires.
Paint Finish:
Information on paint codes and minor body repair.
Fluid Capacities:
Complete list of all fluid capacities and types.
Diagnostic Trouble Codes:
List and interpretation of all DTCs.
Factory Procedures:
Adherence to factory-specified procedures for optimal results.
Page Count
Pages:
Hundreds of pages (specific count not provided in description, but implies comprehensive coverage).
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
Manual Coverage
Systems Covered
Engine Management:
Includes diagnosis and repair of fuel injection, ignition, and emissions control systems.
Powertrain:
Covers engine mechanical, transmission, and drivetrain components extensively.
Chassis Systems:
Detailed information on suspension, steering, brakes (including ABS), and wheel bearings.
Electrical And Electronics:
Comprehensive coverage of body and powertrain electrical systems, including wiring diagrams and component testing.
Body And Accessories:
Instructions for interior and exterior trim, doors, windows, seats, and power accessories.
Procedures Included
Preventative Maintenance:
Detailed maintenance schedules and procedures for fluid changes, filter replacements, and inspections.
Diagnostic Troubleshooting:
Systematic diagnostic approach for identifying and resolving malfunctions, including symptom-based troubleshooting.
Component Replacement:
Step-by-step guides for removing, replacing, and installing all major and minor vehicle components.
Rebuilding And Overhaul:
Detailed instructions for overhauling engines, transmissions, and other complex assemblies.
Alignment And Adjustment:
Procedures for wheel alignment, steering system adjustments, and brake adjustments.
Special Tools Usage:
Identification and usage instructions for specialized tools required for specific repairs.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complex engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostic capabilities, including interpretation of sensor data and troubleshooting electronic modules.
Repair Accuracy:
Ensures repairs are performed to factory specifications, maintaining vehicle integrity and performance.
Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick access to information.
Print Quality
Resolution:
High-resolution digital reproduction for clear text and diagrams.
Printability:
Printable in its entirety or specific sections as needed.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Engine Specifications
Primary Engine
Engine Code:
3.3L V6 (EGA)
Displacement:
3.3 Liters (201.6 cubic inches)
Configuration:
Overhead Valve (OHV) V6
Horsepower:
Approx. 158 hp @ 4800 rpm
Torque:
Approx. 190 lb-ft @ 3000 rpm
Fuel System
Induction:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition System:
Distributorless Ignition System (DIS) - often utilizing coil packs
Emissions Control:
Catalytic Converter, EGR (Exhaust Gas Recirculation)
Transmission
Standard
Type:
4-speed Automatic Transaxle (A604/41TE)
Optional
Type:
N/A (4-speed automatic was standard)
Features
Control System:
Electronically controlled with overdrive.
Fluid Type
Fluid Specification:
ATF+4 (Chrysler's recommendation, though ATF+3 was common in '96)
Fluid Capacity
Capacity:
Approx. 6.0 quarts (5.7 liters) for pan drop and refill.
Dimensions
Exterior
Wheelbase:
Approx. 112.3 inches
Length:
Approx. 190.1 inches
Width:
Approx. 72.1 inches
Height:
Approx. 67.6 inches
Weights
Curb Weight:
Approx. 4000-4300 lbs (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 5700 lbs
Cargo
Max Cargo Volume:
Varies with seating configuration, but significantly large, often exceeding 100 cu ft with rear seats removed.
Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not rated or poor (typical for vehicles of this era without advanced safety features).
NHTSA Frontal Impact Passenger:
Not rated or poor.
Active Features
ABS:
Anti-lock Braking System (ABS) available, often standard on higher trims or optional.
Passive Features
Airbags:
Driver and Passenger airbags standard.
Seatbelts:
Front seat pretensioners, three-point seatbelts for all occupants.
Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or optional CD player.
Speakers:
Typically 4-6 speakers depending on trim level.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
N A:
No advanced connectivity features (e.g., Bluetooth, USB) were available in 1996.
Maintenance
Service Intervals
Oil Change:
Every 3,000 - 7,500 miles, depending on oil type and driving conditions (refer to manual for specific recommendations).
Transmission Fluid:
Every 30,000 - 60,000 miles (check manual for specific interval and procedure).
Spark Plugs:
Around 100,000 miles (depending on plug type, e.g., platinum).
Fluid Specifications
Engine Oil:
API Service SG or SH, SAE 5W-30 or 10W-30 (check dipstick and manual for exact grade).
Coolant:
Chrysler Recommended Antifreeze/Coolant (ethylene glycol based, 50/50 mix with distilled water).
Brake Fluid:
DOT 3.
Power Steering Fluid:
ATF+3 or ATF+4 compatible fluid.
Known Issues
Transmission Issues:
Early 41TE transmissions could experience solenoid issues, harsh shifting, or torque converter clutch problems.
Engine Mounts:
Engine mounts can wear over time, leading to vibrations.
Cooling System:
Water pump leaks and radiator issues are common on higher mileage vehicles.
Rear Suspension:
Rear shock absorbers and leaf spring bushings can wear, affecting ride quality.
Part Numbers
Oil Filter Example:
Fram PH8A or equivalent (refer to manual for specific Chrysler part number).
Vehicle History
Brand Heritage
Manufacturer:
Chrysler Corporation.
Model Evolution
Generation Ns:
Part of the NS platform, representing Chrysler's second generation of minivans, known for improvements in styling and engineering over the original T115 platform.
Introduction Year:
The NS platform was introduced for the 1996 model year, replacing the original 'mini-van' Chrysler designs.
Production
Manufacturing Plant:
Primarily Windsor, Ontario, Canada.
Awards & Recognition
Recognitions
N A:
While specific awards for the 1996 model year are not widely documented, the Chrysler minivans in this era consistently received praise for their class-leading interior space and versatility.