2000 Dodge Caravan / Town & Country / Voyager Service Manual (P/N 81-370-0005)

• The set contains 3,763 PDF pages: Electronic Service Manual, Publication No. 81-370-0005 (2,270 pages); Body Diagnostic Procedures (691 pages); gasoline Powertrain Diagnostic Manual (365 pages); and 2.5L VM Diesel Powertrain Diagnostic Procedures (437 pages).
• Vehicle coverage includes 2000 Chrysler Town & Country, Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager, and GS-market Chrysler/Dodge Voyager models. Factory identification tables separate FWD and AWD, short- and long-wheelbase, LHD and RHD, passenger and commercial-van, lowline/highline/premium/sport builds, and base/midline/highline BCM configurations.
• Engine repair chapters cover 2.0L SOHC, 2.4L DOHC, 3.0L, 3.3L, 3.3L E85, and 3.8L gasoline engines plus the 2.5L VM turbo diesel. Procedures address engine removal, cylinder-head and valvetrain repair, timing-system service, internal inspection, lubrication, cooling, fuel, exhaust, turbocharger, and emissions systems.
• Transmission and AWD sections address the 31TH and 41TE automatics, A-598/A-558 manual-transaxle applications, power transfer unit, front driveshafts, rear driveline module, and viscous coupler. Coverage includes road and hydraulic testing, internal disassembly, clutch, servo, valve-body, synchronizer, and differential repair, bearing setup, and shift-cable adjustment.
• Chassis, brake, body, and HVAC procedures include suspension diagnosis and alignment, power-steering pressure testing, base brakes and Mark 20i ABS with or without traction control, brake bleeding and component overhaul, sliding-door and liftgate service, stationary glass, seats, trim, sheet-metal adjustment, and R-134a recovery, evacuation, leak testing, and charging.
• Dedicated diagnostic books provide DRB III fault-isolation paths for PCM/ECM, BCM, ACM, SKIM, TCM, CAB, and HVAC functions. They cover active and stored DTCs, intermittent and no-code conditions, no-start complaints, charging, fuel delivery, ignition, EGR/EVAP, SKIS, body electronics, controller programming, and post-repair verification.
• A 486-page wiring-diagram section supplies system schematics, connector pinouts, component indexes, splice data, ground locations, circuit identification, and terminal-repair information. Separate diagnostic schematics and component-location views support gasoline, diesel, body-control, airbag, lighting, door-lock, and CCD-bus work.

Factory Repair Coverage

The service material combines the core 2000 NS factory groups with GS-specific international supplements. Those supplements add the 2.0L gasoline and 2.5L VM diesel systems, manual-transaxle applications, and international LHD/RHD configurations rather than treating every vehicle as one identical build.

Engine chapters move from mechanical and performance diagnosis into compression and leakage testing, cylinder-head and valvetrain repair, timing-system service, oil-pump work, crankshaft, piston, and bearing inspection, sealing, and complete engine removal and installation. The automatic-transaxle sections carry 31TH and 41TE work through cooler flushing, clutch air tests, pump and valve-body service, internal clutch, geartrain, and differential repair, Quick Learn and pinion-factor procedures, and final adjustment. A-598/A-558 coverage includes teardown, synchronizer and differential inspection, reassembly, shift-cable adjustment, and bearing preload.

Brake repair is divided between the base hydraulic system and Mark 20i ABS. The manual also provides factory procedures for steering, suspension, wheel alignment, CV joints and driveshafts, AWD rear driveline components, body panels and glass, and air-conditioning service. Related chapters include torque data, inspection limits, adjustments, diagnostic specifications, and special-tool listings instead of stopping at component descriptions.

Diagnostic and Network Coverage

The body diagnostic publication explains base, midline, and highline BCM operation for both LHD and RHD vehicles. Its symptom charts address airbag squib circuits, audio and Infinity speaker faults, chimes, compass/mini-trip functions, door-ajar inputs, exterior and interior lighting, information-center warnings, instrument-cluster gauges, manual A/C sensor faults, power locks and RKE, folding mirrors, VTSS/SKIS, and front and rear wipers.

Dedicated CCD tests isolate bus shorts to power or ground, bus wires shorted together, opens, missing termination, bias faults, incorrect messages, and no-response conditions from the ACM, BCM, instrument cluster, PCM/ECM, TCM, CAB, CMTC, and HVAC module. The gasoline and diesel diagnostic books add controller operating theory, DTC set conditions, no-start and driveability paths, connector views, and replacement-module programming for PCM/ECM, BCM, SKIM, ignition keys, and RKE transmitters.

Two manual-specific cautions directly affect repair outcome. The 2.0L SOHC is identified as a non-freewheeling engine, so incorrect timing-belt indexing can result in valve-to-piston contact. The body diagnostic book also warns that disconnecting control modules with the ignition on can damage electronics, while piercing wire insulation during testing can create later corrosion faults. Airbag and multiplex-network testing should follow the manual’s isolation and probing precautions exactly.

Wiring, Specifications, and Scope

Representative references include 31TH and 41TE hydraulic schematics, anti-lock brake wiring, BCM and power-door-lock circuits, CCD vehicle-communication schematics, AWD vacuum schematics, and engine-control diagrams for the 2.0/2.4L, 3.0L, and 3.3/3.8L gasoline families. The 8W material also explains connector and splice identification, electrostatic-discharge precautions, intermittent-connection diagnosis, wiring and terminal repair, Molex and Augat terminal service, and diode replacement.

Connector tables identify module cavities, circuit functions, wire colors, grounds, splices, and component locations. Specifications cover component torque, hydraulic and fuel-pressure testing, electrical values, refrigerant and fluid data, wheel alignment, wear limits, clearances, and system-specific adjustment information.

The dedicated diagnostic volumes supplied in this set cover body systems, gasoline powertrain, and 2.5L VM diesel powertrain. The separately issued Chassis Diagnostic Procedures and standalone Transmission Diagnostic Procedures volumes are not included; chassis and transaxle diagnosis remains available within the main service-manual chapters.