Dodge Caravan / Mini Ram Van / Grand Voyager 1994 Service Manual (P/N 81-370-4105)

This factory electronic service manual covers the 1994 AS-body Chrysler Town & Country, Dodge Caravan and Grand Caravan (including Caravan C/V), and Plymouth Voyager and Grand Voyager. It addresses front-wheel-drive and all-wheel-drive configurations, short- and long-wheelbase bodies, and the 2.5L, 3.0L, 3.3L, and 3.8L gasoline engines. Chrysler wrote it for professional automotive technicians involved in daily repair operations; it assumes shop knowledge and equipment, while CNG fuel-system repair is specifically reserved for qualified technicians.

• Document set: 1,434 PDF pages in 56 files - 1,334 pages for the primary service manual, 86 pages for the CNG supplement, and 14 pages of CD navigation, cover, and support material. The primary manual is Chrysler Publication No. 81-370-4105, with incorporated TSB pages dated through June 1995.
• Engine repair: Covers engine removal and installation, cylinder-head and valve work, crankshaft, piston/ring, and bearing inspection, timing-belt or timing-chain procedures, oil-pump service, and engine-specific specification tables.
• Transaxles and AWD driveline: Details the A-523 five-speed manual, three-speed TorqueFlite automatic, 41TE four-speed electronic automatic, power transfer unit, rear drive-line module, viscous coupler, overrunning clutch, propeller shaft, and half-shaft repair procedures.
• Chassis and brakes: Includes strut disassembly, wheel alignment, control-arm and ball-joint work, hub and CV-joint service, steering pressure testing, disc and drum brake repair, and Bendix Antilock 4 diagnosis, modulator service, and bleeding.
• Electrical systems: Provides battery, starter, and charging tests; distributor and direct-ignition diagnosis; airbag, instrument-cluster, and body-electrical service; plus connector, splice, and component-location references.
• Body and HVAC: Documents water- and wind-leak diagnosis, windshield and sliding-door service, seat and interior-component work, frame dimensions, and R-134a front and auxiliary rear HVAC testing, evacuation, charging, and component repair.
• Dedicated CNG coverage: Applies only to short-wheelbase FWD passenger or cargo vans with the 3.3L MFI engine, four-speed electronic automatic, and J in the eighth VIN position. It covers purging, leak and pressure testing, fuel-cylinder service, regulator and shutoff-valve work, injector-driver diagnosis, and CNG wiring.

Engine Management and Factory Service Data

Gasoline fuel-management coverage is separated by configuration: 2.5L single-point throttle-body injection, 3.0L multi-port injection, and 3.3L/3.8L sequential multi-port injection. The diagnosis sections identify PCM inputs and outputs, explain on-board trouble-code retrieval, and cover State Display and Circuit Actuation test modes. Component work includes throttle bodies, injector rails, pressure regulators, MAP/TPS, oxygen sensors, and camshaft/crankshaft sensors where fitted. Fuel-delivery procedures distinguish FWD and AWD tanks, pump modules, level sensors, filters, and lines, with engine-specific pressure release before the system is opened.

Group 0 supplies the factory maintenance schedule with severe-service criteria, lubricant requirements, fluid-capacity tables, and inspection points. Repair sections add torque charts, pressure-test specifications, electrical values, wear limits, clearances, shim charts, and adjustment data. Factory tool callouts include strut spring compressor C-4838, lower-control-arm bushing remover/installer 6602, power-steering gauge C-3309-E, and CNG fuel-line tool FIH 9055-2. PCM, Bendix ABS, and 41TE procedures also call for the DRB scan tool.

Wiring Diagrams and Diagnostic Scope

The 240-page Group 8W wiring section includes circuit identification, power-distribution and relay-bank information, connector views, splice locations, terminal repair, and troubleshooting guidance. Representative factory sheets include Fuel Injection/Ignition System (2.5L), Fuel Injection/Ignition System with Transmission Control (3.0L), Fuel Injection/Ignition System (3.3L and 3.8L), Transmission Control and AWD System, Anti-Lock Brake System, and Airbag System. The supplement adds dedicated CNG fuel-injection, injector-driver, shutoff-solenoid, pressure-sensor, and PCM connector schematics.

The manual contains code descriptions, system tests, hydraulic schematics, and DRB procedures, but Chrysler directs complete 41TE fault isolation to separate transmission diagnostic manuals and Bendix ABS electronic diagnosis to the 1994 Bendix Antilock 4 Diagnostic Manual. Some powertrain circuit tests likewise require the appropriate Powertrain Diagnostic Procedures manual; those companion publications are not included.

Repair Cautions and Scope Boundaries

In the A-523 chapter, the longer No. 2 case bolt must not be installed in the No. 3 position because it can damage the selector-shaft housing. The steering section also warns that hammering the power-steering pump pulley can damage both the pulley and the pump.

The CNG package deletes the conventional fuel pump, EVAP and EGR systems, and rear-seat HVAC; it substitutes CNG-specific valves, seats, seals, controls, injectors, and storage hardware. Gasoline fuel pressure must be released before fuel-system repair. The CNG system remains pressurized with the engine off, so its isolation and purging procedures are central to safe service. The publication also carries precautions for Bendix ABS, airbags, and R-134a work.

This is a factory repair reference, not a theory or vehicle-operation guide. Chrysler assigns theory of operation to service-training material and standard/optional equipment use to the owner's manual.