1993 DODGE CARAVAN Service Repair Manual by 16310168

CHRYSLER CORPORATION SERVICE MANUAL 1993 FRONT WHEEL DRIVE ALL WHEEL DRIVE VAN/WAGON To order the special service tools used and illustrated, please refer to the instructions on inside back cover.

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 CORPORATION.

Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

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Introduction

Lubrication and Maintenance

Front Suspension and Drive Shaft

Rear Suspension and Driveline

Brakes

Manual Transaxle Clutch

Cooling System

Electrical

Engines

Exhaust System and Intake Manifold

Frame and Bumpers

Fuel System

Steering

Transaxle

Wheels / Tires

Body

Heating and Air Conditioning

Emission Control Systems Component and System Index

Service Manual Comment Forms

(Rear of Manual)

INTRODUCTION

INTRODUCTION CONTENTS page

BODY CODE PLATE LOCATION AND DECODING INFORMATION . . . . . . . . . . . . . . . INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . METRIC THREAD AND GRADE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . .

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TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . VEHICLE FAMILY IDENTIFICATION . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL . . . . .

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VEHICLE FAMILY IDENTIFICATION Throughout this service manual references are made to Vehicle Family, Body Codes. The letters AS is a body code that is assigned to a individual vehicle family. Digit boxes 16 and 17 on the Body Code Plate indicate the Vehicle family.

VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left windshield pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle (Fig. 1). Refer to VIN Code Breakdown Chart.

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 Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

VEHICLE IDENTIFICATION NUMBER BREAKDOWN

INTRODUCTION • L = Low Line • M = Maximum • P = Premium DIGIT • 12 • 13 • 52 • 53

BOXES 20 AND 21—Body Type = Van/Short Wheel Base = Van/Long Wheel Base = Wagon/Short Wheel Base = Wagon/Long Wheel Base

BODY CODE PLATE LINE 2 DIGIT BOXES 22,23, AND 24—Paint Procedure DIGIT BOXES 25 THROUGH 28—Primary Paint See Group 23, Body for color codes

Fig. 1 Vehicle Identification Number (VIN Plate)

BODY CODE PLATE LOCATION AND DECODING INFORMATION The Body Code Plate is attached to the top of the radiator closure panel in the engine compartment. 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.

BODY CODE PLATE LINE 3

DIGIT BOXES 29 THROUGH 32—Secondary Paint DIGIT BOXES 33 THROUGH 36—Interior Trim Code DIGIT BOXES 37, 38, AND 39—Engine Code • EDM = 2.5 L, 4 cylinder EFI Gas—Automatic or Manual Transaxle • EFA = 3.0 L, V6 Gas (EFI)—Automatic or Manual Transaxle • EGA = 3.3 L, V6 Gas (EFI)—Automatic Transaxle

BODY CODE PLATE LINE 1 DIGIT BOXES 1 THROUGH 12—Vehicle Order Number DIGIT BOXES 13, 14, AND 15—Vinyl Roof Code DIGIT BOXES 16, 17, 18, AND 19—Vehicle Shell Car Line • ASYP = 2x4-Chrysler Town & Country • ASCP = 4x4-Chrysler Town & Country • ASKE = 2x4-Dodge Caravan C/V • ASKH = 2x4-Dodge Caravan SE, Grand Caravan SE • ASKL = 2x4-Dodge Caravan • ASDE = 4x4-Dodge Caravan CV • ASDH = 4x4-Dodge Caravan SE, Grand Caravan SE • ASDP = 4x4-Dodge Caravan LE • ASHH = 2x4-Plymouth, Voyager SE, Grand Voyager SE • ASHL = 2x4-Plymouth, Voyager • ASHP = 2x4-Plymouth, Voyager LE, Grand Voyager LE • ASPH = 4x4-Plymouth Voyager SE, Grand Voyager SE • ASPP = 4x4-Plymouth , Voyager LE, Grand Voyager LE DIGIT BOX 19—Price Class • E = Economy • H = High Line

DIGIT BOXES 40, 41, AND 42—Transaxle Codes • DDM = 5-speed Manual Transaxle • DGM = 3-speed Automatic Transaxle • DGC = 3-speed Automatic Transaxle • DGL = 4-speed Electronic Automatic Transaxle DIGIT BOX 43—Market Code • U = United States • C = Canada • B = International • M = Mexico DIGIT BOXES 44 THROUGH 60—Vehicle Identification Number (VIN) 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 followed by END. When two plates are required, the last code space on the first plate will show CTD (for continued). When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

INTRODUCTION

BODY CODE PLATE

VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 2) is attached to the rear facing of the driverâ&#x20AC;&#x2122;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

Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included. All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification Number.

Fig. 2 Vehicle Safety Certification Label STANDARD BODY DIMENSIONS

INTRODUCTION

Fig. 7 International Symbols

TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifications and Bolt Identification Chart in this Group for torques not listed in the individual torque charts (Fig. 3). Torque specifications on the Bolt Torque chart are based on the use of clean and dry threads. Reduce the torque by 10% when the threads are lubricated with engine oil and by 20% if new plated bolts are used. Various sizes of Torx head fasteners are used to secure numerous components to assemblies. Due to ever changing usage of fasteners, Torx head fasteners may not be identified in art or text.

METRIC THREAD AND GRADE IDENTIFICATION Metric and SAE thread notations differ slightly. The difference is illustrated in Figure 4. Common metric fastener strength classes are 9.8 and 12.9 with the class identification embossed on the head of each bolt (Fig. 5). Some metric nuts will be marked with a single digit strength number on the nut face. SAE strength classes range from grade 2 to 8 with line identification embossed on each bolt head. Markings corresponding to two lines less than the actual

Fig. 3 Grade 5 and 8 Standard Torque Specifications grade (Fig. 6). For Example: Grade 7 bolt will have 5 embossed lines on the bolt head.

INTRODUCTION

INTERNATIONAL SYMBOLS Some International Symbols are used to identify controls and displays in this vehicle. These symbols are applicable to those controls which are displayed on the instrument panel or in the immediate vicinity of the driver (Fig. 7).

METRIC SYSTEM Fig. 4 Thread Notation (Metric and SAE)

Figure art, specifications, and tightening references in this Service Manual are identified in the metric system and in the SAE system. During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification should be used. WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY.

Fig. 5 Metric Bolt Identification

The metric system is based on quantities of one, ten, one hundred, one thousand, and one million (Fig. 8). The following Tables will assist you in conversion procedures.

Fig. 8 Metric Prefixes

Fig. 6 SAE Bolt Identification

INTRODUCTION CONVERSION TABLES

LUBRICATION AND MAINTENANCE

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LUBRICATION AND MAINTENANCE CONTENTS page

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CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . 20 DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION INDEX page Classification of Lubricants Fuel Usage . . . . . . . . . . . Hoisting Recommendations Introduction . . . . . . . . . . . Jump Starting Procedure .

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page Parts and Lubricant Recommendations Parts Requiring No Lubrication . . . . . Severe Service . . . . . . . . . . . . . . . . Towing Recommendations . . . . . . . . Warnings and Precautions . . . . . . . .

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INTRODUCTION

FUEL USAGE

Chrysler Corporation has compiled recommended lubrication and maintenance schedules and procedures to help reduce premature wear or failure over a broad range of operating conditions. When selecting the proper maintenance schedule, the climate and operating conditions must be considered. A vehicle subjected to severe usage requires service more frequently than a vehicle used for general transportation.

All Chrysler Corporation engines require the use of unleaded fuel to reduce exhaust emissions. See Engine section of this group for Fuel Recommendations.

PARTS AND LUBRICANT RECOMMENDATIONS When service is required, Chrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing Chrysler Corporation vehicles.

SEVERE SERVICE If a vehicle is operated under any of the following conditions, it is considered severe service. • Extremely dusty areas. • 50% or more of vehicle operation in 32°C (90°F) or higher temperatures. • Prolonged idling (such as, vehicle operation in stop and go traffic). • Frequent short running periods. Not allowing engine to warm to operating temperatures. • Police or taxi usage.

CLASSIFICATION OF LUBRICANTS Only lubricants that are endorsed by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI)

ENGINE OIL SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY • SAE 30 = single grade engine oil. • SAE 5W-30 = multiple grade engine oil. API QUALITY CLASSIFICATION. • SG service engine oil is a high quality crankcase lubricant designed for use in all naturally aspirated engines. • SG/CD service engine oil is a high quality crankcase lubricant designed for use in most naturally aspirated gasoline or diesel engines.

GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage.

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LUBRICATION AND MAINTENANCE

LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter ‘‘G’’. Chassis lubricant is identified by the latter ‘‘L’’. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality. NLGI SYMBOL

PARTS REQUIRING NO LUBRICATION Many components on a Chrysler Corporation vehicle require no periodic maintenance. Some components are sealed and permanently lubricated. Rubber bushings can deteriorate or limit damping ability if lubricated. The following list of components require no lubrication: • Air Pump • Generator Bushings • Drive Belts • Drive Belt Idler/Tensioner Pulley • Front Wheel Bearings • Rubber Bushings • Starter Bearings/Bushings • Suspension Strut Bearings • Throttle Control Cable • Throttle Linkage • Water Pump Bearings

JUMP STARTING PROCEDURE WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCHING OF BATTERY CURRENT. WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW DISABLED VEHICLE’S BATTERY TO EXCEED 16 VOLTS. PERSONAL INJURY OR DAMAGE TO ELECTRICAL SYSTEM CAN RESULT. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. • Low battery fluid level. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, turn off all accessories, place gear selector in park or neutral, set park brake or equivalent and operate engine at 1200 rpm. (3) On disabled vehicle, place gear selector in park or neutral and set park brake or equivalent. Turn OFF all accessories (Keyless Entry and Ultralight systems must be turned OFF manually).

LUBRICATION AND MAINTENANCE SCHEDULES

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LUBRICATION AND MAINTENANCE

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LUBRICATION AND MAINTENANCE FLUID CAPACITIES

(4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result (Fig. 1). Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 1).

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (6) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

HOISTING RECOMMENDATIONS Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures.

Fig. 1 Jumper Cable Clamp Connections