Chrysler Town & Country / Voyager / Caravan 2001–2005 Service Manual (P/N 81-370-05037, 81-370-05036)

This 21-file PDF set combines DaimlerChrysler diagnostic books for Chrysler Town & Country, Chrysler Voyager/Grand Voyager, and Dodge Caravan/Grand Caravan applications with 2003 and 2005 RG diesel service-manual supplements. It is suited to professional automotive technicians and experienced repairers with access to a DRBIII scan tool, electrical test equipment, and the specified special tools. Coverage is year- and system-specific: 2001 appears only in the gasoline powertrain diagnostic book, and no 2004-specific manual is included.

• Factory six-step diagnostics: complaint verification, related-symptom verification, symptom analysis, problem isolation, repair of the isolated fault, and verification of proper operation, with DRBIII paths for DTCs, no-code complaints, module communication faults, and final verification tests.
• 2002 and 2005 body systems: PCI-bus communication, Body and Front Control Modules, restraint diagnostics, ATC/MTC, instrument cluster, memory system, TPMS, power doors and liftgate, exterior lighting, DCHA, and theft security. The 2005 book adds Park Assist, Occupant Classification, and hands-free phone systems. Both body books expressly cover LHD and RHD vehicles.
• Gasoline and diesel powertrain diagnosis: 2001-2002 2.4L and 3.3L/3.8L gasoline engines, 2005 RS 2.4L and 3.3L/3.8L engines, 2002-2003 RG 2.5L diesels, and 2005 RG 2.5L/2.8L common-rail diesels. Coverage includes PCM/ECM circuits, no-start tests, sensor calibration, SKIS/SKREES faults, and controller/key programming.
• Chassis and transmission fault isolation: Teves Mark 20/20e ABS, traction control, adjustable pedals, the 2002 41TE/AE transaxle, and 2005 electronic transaxles with separate EATX diesel and NGC gasoline logic. Quick Learn, clutch-volume data, pinion-factor programming, pressure-switch faults, event data, and verification tests are covered.
• Diesel mechanical repair procedures: 2.5L/2.8L cooling-system service, engine removal and installation, cylinder-head and valve service, timing-belt work, turbocharger service, common-rail fuel testing and air purging, plus 2005 power-transfer-unit, rear driveline, half-shaft, and T850 manual-transaxle disassembly and assembly.
• Electrical and workshop reference: component-location views, connector pinout tables, system schematics, lab-scope patterns, torque tables, capacities, pressure tests, inspection limits, adjustment data, and electrical test specifications. Tools include the Miller #3638 Terminal Removal Pick, #8815 Pinout Box, #8333 Transmission Simulator with #8333-1/#8333-1A adapters, and VM1052/VM1053/VM1055/VM1074 diesel timing tools.

System Scope and Diagnostics

The body books map the RS/RG module network across the PCI bus and organize fault finding around active codes, stored codes, and customer-complaint tests. The chassis, powertrain, and transmission volumes follow the same pattern: system operation, DTC logic, required equipment, symptom-based charts, locations, pinouts, schematics, and verification procedures. DRBIII error-message and blank-screen checks separate scan-tool communication problems from module or vehicle-circuit faults.

Electrical Reference and System Operation

Representative electrical drawings include the Occupant Restraint Controller high-line/low-line and Occupant Classification System schematics; front LHD/RHD and rear three-zone ATC diagrams; PCM-NGC and diesel ECM/DCHA communication diagrams; power liftgate and left/right power sliding-door circuits; Teves Mark 20/20e ABS schematics; and PCM-NGC gasoline versus TCM-EATX diesel transmission diagrams. KDB and PCI-bus lab-scope patterns, transmission range-sensor states, pressure-switch states, and solenoid-application charts provide baseline references for circuit testing.

Diesel Mechanical Service

The diesel supplements add mechanical repair procedures not found in the diagnostic books. They cover cooling-system leak, flow, aeration, and pressure-cap testing; ECM programming; charging, starting, and glow-plug systems; internal engine inspection and assembly; turbocharger and EGR service; fuel-supply and transfer-pump tests; injector return testing; and fuel-system air purging. The 2005 supplement also contains rear driveline service, PTU seal and shim work, and T850 transaxle teardown, end-play adjustment, synchronizer service, and reassembly.

The diesel engine chapters warn that disturbing the cylinder-head cover or timing system without the prescribed post-TDC service position can cause valve or piston damage during reassembly. They also treat common-rail high-pressure lines as replacement items after disassembly and prohibit straightening, welding, or routing them against adjacent lines or components.

Included Files and Page Count

The archive totals 5,651 PDF pages as supplied; 5,264 pages are in the non-duplicated core manuals.

• 2002 RS/RG set - 2,027 pages: Body Diagnostics 1,168; Chassis Diagnostics 78; Diesel Powertrain Diagnostics 264; Gasoline Powertrain Diagnostics 332; Transmission Diagnostics 182; cover/menu files 3.
• 2003 RG 2.5L diesel set - 435 pages: Service Manual Supplement 149; Diesel Powertrain Diagnostics 282; supplement front matter 4.
• 2005 set - 3,186 pages: Body Diagnostics 1,402; Chassis Diagnostics 84; Diesel Powertrain Diagnostics 288; 2.5L/2.8L Diesel Service Manual Supplement 333; Gasoline Powertrain Diagnostics 368; Transmission Diagnostics 334; duplicate Gasoline Powertrain version 370; cover/menu files 7.
• Separate DTC reference - 3 pages: a general Dodge/Chrysler/Jeep P-code list, not a model-specific factory diagnostic book.

Scope Limits and Service Cautions

The body, chassis, gasoline powertrain, diesel powertrain, and automatic-transmission books are diagnostic references; after a test isolates a failed part, they direct the technician to separate service information for removal and repair. Mechanical service coverage in this set is limited to the 2003 2.5L and 2005 2.5L/2.8L RG diesel supplements. The two supplied 2005 gasoline powertrain PDFs contain the same RS 2.4L and 3.3L/3.8L diagnostic content; the longer copy adds two feedback pages and does not provide separate RG gasoline coverage. The 2005 diesel diagnostic book states 2.5L/2.8L coverage, but its two ending schematic pages are labeled 2003 RG 2.5L.

Follow the manual's restraint-system depowering, high-pressure diesel fuel, refrigerant, lifting, and road-test precautions. Airbag circuits and common-rail fuel components require the specified isolation and test equipment before diagnosis or repair.