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

The service manual provides mechanical repair procedures; the diagnostic publications supply symptom-based tests, fault isolation, and repair-verification routines. The GS supplements distinguish international engine, manual-transaxle, and LHD/RHD configurations from the core NS material.

Diagnostic scope: The separate Chassis Diagnostic Procedures and standalone Transmission Diagnostic Procedures volumes are not included. The main service chapters provide chassis and transaxle diagnosis, but specifically refer complete electronic ABS diagnosis to the Chassis Diagnostic Procedures manual.

PDF Search, Bookmarks, and File Layout

Search and diagram detail: Service text and diagnostic test charts support text search, while many wiring diagrams and schematic labels do not. Embedded bookmarks are present in the service chapters and gasoline diagnostic manual; the body and diesel diagnostic volumes have none. Small wiring labels require zooming. Text search is also unreliable on some welcome pages.

The ZIP contains 71 printable PDFs totaling 3,763 pages: 65 service-manual files and two files for each diagnostic publication. The total includes four one-page welcome files, a one-page group locator, and 35 blank pages within the service material.

Engine, Driveline, and Electronic Fault Diagnosis

These selected coverage highlights summarize the principal repair areas rather than reproduce the complete contents. Other documented subjects include heated-seat testing and compass calibration.

• Engine repair: Step-by-step procedures cover engine removal, cylinder-head and valvetrain repair, timing-system service, internal inspection, lubrication, cooling, fuel, exhaust, turbocharger, and emissions systems.

• Automatic transaxles: 31TH and 41TE coverage includes road and hydraulic testing, clutch air tests, pump, servo, valve-body, geartrain, and differential repair.

• Manual transaxles and AWD: A-598/A-558 service includes teardown, synchronizer inspection, bearing setup, and shift-cable adjustment, alongside power transfer unit and rear driveline repair.

• Brakes and chassis: Suspension diagnosis, alignment, power-steering pressure testing, base-brake overhaul and bleeding, and Mark 20i ABS component service with or without traction control.

• Body and climate control: Sliding-door, liftgate, stationary-glass, seat, trim, and sheet-metal procedures accompany front/rear HVAC diagnosis and R-134a recovery, evacuation, leak testing, and charging.

• Electronic diagnostics: DRB III test paths address active and stored DTCs, intermittent and no-code faults, no-start conditions, charging, fuel delivery, ignition, EGR/EVAP, SKIS, and post-repair verification.

• Wiring references: The 486-page wiring section provides system diagrams, connector pinouts, component indexes, circuit identification, splice information, ground locations, and terminal-repair procedures.

This material is suited to technicians familiar with electrical fault tracing and mechanical overhaul, with access to DRB III diagnostic equipment and the specified workshop tools.

Engine Repair and Configuration Differences

Engine chapters cover the 2.0L SOHC, 2.4L DOHC, 3.0L, 3.3L, 3.3L E85, and 3.8L gasoline families, plus the 2.5L VM turbo diesel. Mechanical and performance diagnosis extends to compression and leakage testing, oil-pump service, crankshaft, piston, and bearing inspection, and sealing.

The diesel material adds injection-pump timing, glow-plug checks, boost-pressure sensor calibration, and turbocharger testing. Factory identification tables distinguish FWD/AWD, short/long wheelbase, passenger/commercial van, and lowline, highline, premium, sport, and special configurations.

The 2.0L SOHC has a non-freewheeling valvetrain: a broken timing belt or incorrect valve timing can allow piston-to-valve contact.

Transaxle Overhaul and AWD Components

Automatic-transaxle procedures extend to cooler flushing, internal clutch and differential work, Quick Learn, pinion-factor settings, and final adjustment. Manual-transaxle chapters distinguish input- and intermediate-shaft bearings, synchronizer assemblies, differential inspection, and bearing-preload procedures.

Driveline coverage includes front driveshafts and CV joints, the rear driveline module, viscous coupler, and power transfer unit. Hydraulic schematics for the 31TH and 41TE and AWD vacuum schematics support system diagnosis.

Body Electronics and CCD Communication

The body diagnostic charts address airbag squib circuits, audio and Infinity speaker faults, chimes, compass/mini-trip functions, door-ajar inputs, lighting, information-center warnings, instrument-cluster gauges, manual A/C sensor faults, power locks and RKE, folding mirrors, VTSS/SKIS, and front/rear wipers.

CCD tests distinguish shorts to power or ground, bus wires shorted together, opens, missing termination, bias faults, and incorrect messages. No-response tests cover the ACM, BCM, instrument cluster, PCM/ECM, TCM, CAB, CMTC, and HVAC module.

These communication tests help distinguish a network fault from an individual controller problem before replacement is considered. Programming sections address PCM/ECM, BCM, SKIM, ignition keys, and RKE transmitters.

Disconnecting control modules with the ignition on can damage electronics; piercing wire insulation during testing can cause later corrosion faults. Airbag and multiplex-network testing should follow the manual’s isolation and probing precautions exactly.

Circuit References and Workshop Specifications

Representative diagrams include anti-lock brakes, BCM circuits, power door locks, CCD vehicle communication, and gasoline engine-control schematics for the 2.0/2.4L, 3.0L, and 3.3/3.8L families. Separate diesel schematics accompany the diagnostic tests.

The 8W material explains connector and splice identification, electrostatic-discharge precautions, intermittent-connection diagnosis, wiring repair, Molex and Augat terminal service, and diode replacement. Connector tables identify module cavities, circuit functions, wire colors, grounds, and splices.

Related service chapters provide torque tables, hydraulic and fuel-pressure specifications, refrigerant and fluid data, wheel-alignment settings, wear limits, clearances, and special-tool listings.

A Sample of VM Diesel Bearing and Endplay Data

For the 2.5L VM diesel, rear crankshaft journal-to-bearing clearance is specified as 0.050–0.080 mm, with a 0.200 mm wear limit.

Crankshaft endplay is 0.08–0.21 mm. The adjoining specification tables list the thrust-washer sizes used for adjustment.