1996-2000 Dodge Grand Caravan Service & Repair Manual

CHRYSLER INTERNATIONAL SERVICE MANUAL 1998 CHRYSLER VOYAGER NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER INTERNATIONAL. Chrysler International reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli- gations upon itself to install them on its products previously manufactured. Litho in U.S.A. Copyright © 1976 Chrysler Corporation

FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo- nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR Introduction 0 Lubrication and Maintenance 2 Suspension 5 Brakes 6 Clutch 7 Cooling System 8A Battery 8B Starting System 8E Instrument Panel and Systems 8H Vehicle Speed Control System 8K Wiper and Washer Systems 8L Lamps 8Q Vehicle Theft/Security Systems 8U Chime Warning/Reminder System 8W Wiring Diagrams 9 Engine 13 Frame and Bumpers 14 Fuel System—2.5L Diesel Engine/2.0L Gas Engine 19 Steering 21 A—598 Manual Transaxle 23 Body 24 Heating and Air Conditioning 25 Emission Control System

INTRODUCTION CONTENTS page page GENERAL INFORMATION BODY CODE PLATE ...................... 1 FASTENER IDENTIFICATION ................ 4 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS ..................... 4 METRIC SYSTEM ........................ 7 TORQUE REFERENCES ................... 7 VEHICLE IDENTIFICATION NUMBER .......... 1 VEHICLE SAFETY CERTIFICATION LABEL ..... 1 VIN CHECK DIGIT ........................ 1 GENERAL INFORMATION VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 1) is located on the rear shut face of the driver’s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rat- ing (GAWR) rear and the Vehicle Identification Num- ber (VIN). The Month, Day and Hour of manufacture is also included. When it is necessary to contact the manufacturer regarding service or warranty, the information on the Vehicle Safety Certification Label would be required. VEHICLE IDENTIFICATION NUMBER 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. 2). The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. VIN CHECK DIGIT 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 Iden- tification 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. BODY CODE PLATE LOCATION AND DECODING The Body Code Plate (Fig. 3) 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. Fig. 1 Vehicle Safety Certification Label Fig. 2 Vehicle Identification Number (VIN Plate) NS INTRODUCTION 1

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 • NS DIGIT 20 Carline FWD • H = Plymouth • K = Dodge • S = Chrysler AWD • C = Chrysler • D = Dodge • P = Plymouth VIN CODE BREAKDOWN CHART POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = United States 2 = Canada 2 Make B = Dodge C = Chrysler P = Plymouth 3 Vehicle Type 4 = Multipurpose Pass. Vehicle 4 Gross Vehicle Weight Rating G = 2268 - 2721 kg (5001 - 6000 lbs) 5 Car Line P = Chrysler, Town & Country P = Dodge, Caravan/Grand Caravan P = Plymouth, Voyager/Grand Voyager T = AWD Chrysler, Town & Country T = AWD Dodge, Grand Caravan T = AWD Plymouth, Grand Voyager 6 Series 2 = FWD Caravan/Grand Caravan, Voyager/ Grand Voyager 4 = Caravan SE/Grand Caravan SE, Voyager SE/Grand Voyager SE 5 = Caravan LE or ES/Grand Caravan LE or ES, Voyager LE/Grand Voyager LE, Town & Country LX 6 = Town & Country LXI 7 Body Style 4 = Long Wheel Base 5 = Short Wheel Base 8 Engine B = 2.4 L 4 cyl. MPI 16-VALVE DOHC 3 = 3.0 L 6 cyl. gas MPI R = 3.3L 6 cyl. gas MPI L = 3.8 L 6 cyl. gas MPI 9 Check Digit See explanation in this section. 10 Model Year V = 1997 11 Assembly Plant B = St. Louis South R = Windsor 12 thru 17 Sequence Number 6 digit number assigned by assembly plant. 2 INTRODUCTION NS GENERAL INFORMATION (Continued)

DIGIT 21 Price Class • H = Highline • L = Lowline • P = Premium • S = Luxury 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 8 Primary paint See Group 23, Body for color codes. DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 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. DOHC Gasoline • EFA = 3.0L 6 cyl. Gasoline • EGA = 3.3L 6 cyl. Gasoline • EGH = 3.8L 6 cyl. Gasoline BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGB = 31TH 3-Speed Automatic Transaxle • DGL = 41TE 4-speed Electronic Automatic Tran- saxle • DGM = 31TH 3-Speed Automatic 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. Fig. 3 Body Code Plate NS INTRODUCTION 3 GENERAL INFORMATION (Continued)

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the following chart (Fig. 4) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. FASTENER IDENTIFICATION FASTENER IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt/nut threads are not the same. The difference is described in the Thread Notation chart (Fig. 5). GRADE/CLASS IDENTIFICATION 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 12.9. 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. INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 4 Fig. 5 Thread Notation—SAE and Metric 4 INTRODUCTION NS GENERAL INFORMATION (Continued)

FASTENER IDENTIFICATION NS INTRODUCTION 5 GENERAL INFORMATION (Continued)

FASTENER STRENGTH 6 INTRODUCTION NS GENERAL INFORMATION (Continued)

METRIC SYSTEM WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvage- able, a fastener of equivalent specification should be used. The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. 6). The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. Refer to the 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.) TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- cations Chart for torque references not listed in the individual torque charts. Fig. 6 Metric Prefixes CONVERSION FORMULAS AND EQUIVALENT VALUES NS INTRODUCTION 7 GENERAL INFORMATION (Continued)

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1996-2000 Dodge Grand Caravan Service & Repair Manual

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