2001-2007 Chrysler Town & Country & Voyager / Dodge Caravan (RS/RG) OEM Service & Repair Manual

GROUP TAB LOCATOR IN Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 7a Cooling - 2.5L Turbo Diesel 8A Audio 8B Chime/Buzzer 8E Electronic Control Modules 8Ea Electronic Control Modules 8F Engine Systems 8Fa Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8Ia Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 9a Engine 11 Exhaust System 11a Exhaust System and Turbocharger 13 Frame & Bumpers 14 Fuel System 14a Fuel System 19 Steering 21 Transmission 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control 25a Emissions Control 2.5L Turbo Diesel Service Manual Comment Forms

INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE DESCRIPTION .......................... 1 FASTENER IDENTIFICATION DESCRIPTION .......................... 2 FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE ........ 5 DESCRIPTION - THREADED HOLE REPAIR ..5 INTERNATIONAL SYMBOLS DESCRIPTION .......................... 5 METRIC SYSTEM DESCRIPTION .......................... 6 TORQUE REFERENCES DESCRIPTION .......................... 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION ......................... 11 E-MARK LABEL DESCRIPTION ......................... 11 VECI LABEL DESCRIPTION ......................... 11 MANUFACTURER PLATE DESCRIPTION ......................... 11 BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 1) is located in the engine compartment on the radiator closure panel crossmember. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate. BODY CODE PLATE – LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 THROUGH 17 Open Space DIGITS 18 AND 19 Vehicle Shell Line • RS DIGIT 20 Carline FWD • K = Dodge • Y = Chrysler AWD • C = Chrysler • D = Dodge Fig. 1 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN RS INTRODUCTION 1

DIGIT 21 Price Class • H = Highline • L = Lowline • P = Premium • S = Luxury • X = Premium DIGITS 22 AND 23 Body Type • 52 = Short Wheel Base • 53 = Long Wheel Base BODY CODE PLATE LINE 2 DIGITS 1, 2 AND 3 Paint Procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary Paint (Refer to 23 - BODY/PAINT - SPEC- IFICATIONS). DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint DIGIT 13 AND 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline (MPI) • EGA = 3.3L 6 cyl. Gasoline (SMPI) • EGH = 3.8L 6 cyl. Gasoline (SMPI) • EGM = 3.3L 6 cyl. Ethanol Flexible Fuel • ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel DIGIT 23 Open Space BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGC = 31TH 3-Speed Automatic Transaxle • DGL = 41AE/TE 4-Speed Electronic Automatic • DDR = T850 5-Speed Manual Transaxle DIGIT 4 Open Space DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code. IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be fol- lowed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates. FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3). 2 INTRODUCTION RS BODY CODE PLATE (Continued)

Fig. 2 FASTENER IDENTIFICATION RS INTRODUCTION 3 FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH 4 INTRODUCTION RS FASTENER IDENTIFICATION (Continued)

FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures. INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 4) are used to identify various instrument controls. The symbols correspond to the controls and dis- plays that are located on the instrument panel. Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter RS INTRODUCTION 5

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 5). 6 INTRODUCTION RS

Fig. 5 METRIC CONVERSION CHART RS INTRODUCTION 7 METRIC SYSTEM (Continued)

TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- tions Chart for torque references not listed in the individual torque charts (Fig. 6). Fig. 6 TORQUE SPECIFICATIONS 8 INTRODUCTION RS

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left cor- ner of the instrument panel, near the left windshield pillar (Fig. 7). The VIN consists of 17 characters in a combination of letters and numbers that provide spe- cific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the vehicle identification number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. VIN CODE BREAKDOWN CHART POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Built in the United States by DaimlerChrysler 2 = Built in Canada by DaimlerChrysler Canada Inc. 2 Make B = Dodge C = Chrysler 3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags 8 = Multipurpose Pass. Vehicle With Side Air Bags 4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.) 5 Car Line P = Chrysler, Town & Country - FWD P = Dodge, Caravan/Grand Caravan - FWD T = Chrysler, Town & Country -AWD T = Dodge, Grand Caravan - AWD J = Chrysler, Voyager/Grand Voyager - FWD Y = Voyager/Grand Voyager - FWD Left Hand Drive C = Voyager/Grand Voyager - AWD Left Hand Drive H = Voyager/Grand Voyager - FWD Right Hand Drive K = Voyager/Grand Voyager - AWD Left Hand Drive Fig. 7 VEHICLE IDENTIFICATION NUMBER (VIN) 1 - DEFROSTER OUTLET 2 - VEHICLE IDENTIFICATION NUMBER 3 - HEATED WINDSHIELD GRID RS INTRODUCTION 9

2001-2007 Chrysler Town & Country & Voyager / Dodge Caravan (RS/RG) OEM Service & Repair Manual

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