2001 dodge caravan factory service manual




















The use of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality reg- ular gasoline, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine.

However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage result- ing from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experi- ence these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications the Worldwide Fuel Charter, WWFC to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle.

We rec- ommend the use of gasolines that meet the WWFC specifications if they are available. Reformulated gasoline contain oxygen- ates, and are specifically blended to reduce vehicle emissions and improve air quality.

We strongly supports the use of reformulated gas- oline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. Gasoline containing methanol may damage critical fuel system components. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles.

We recommend that gasolines free of MMT be used in your vehicle. MMT is prohibited in Federal and California refor- mulated gasoline. If such fuels are not available in states adopting California emission standards, your vehicles will operate satis- factorily on fuels meeting federal specifications, but emission control system performance may be adversely affected.

We recommend that you try a dif- ferent brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. Use of additional detergents or other additives is not needed under normal conditions.

Using leaded gasoline can impair engine perfor- mance, damage the emission control system, and could result in loss of warranty coverage. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. If spark knock persists, lighten the load, or engine piston damage may result. Most of these products contain high concentrations of methanol.

Fuel system damage or vehicle perfor- mance problems resulting from the use of such fuels or additives is not the responsibility of Daimler- Chrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible.

Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporation vehicle. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. DaimlerChrysler Corporation only recommends multiple grade engine oils. At the bottom NLGI symbol is the usage and quality identification letters.

First is Schedule — A. Second is Schedule — B. Add fluid as required. These, and all other maintenance services included in this manual, should be done to provide the best vehicle performance and reliability. More frequent mainte- nance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving. This maintenance is not required if the belt was previously replaced. Not required if previously changed. Not required if replaced at 75,, 90, or , miles.

NOTE: Inspection and service should also be per- formed anytime a malfunction is observed or sus- pected. Retain all receipts. Replace as necessary. See the note at the end of Schedule — B. This maintenance is not required if belt was previously replaced. Per- form these services if vehicle usually operates under these conditions. This main- tenance is not required if belt was previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected.

This main- tenance is not required if the belt was previously replaced. Perform these services if vehicle usually operate under these con- ditions. CAUTION: Do not position hoisting device on any suspension component, including the front suspen- sion crossmember, the rear leaf springs, and the rear axle.

Do not hoist on the front and rear bumpers, the lower liftgate crossmember, the lower radiator crossmember, the down standing flanges on the sill or the front engine mount. The hoisting points are identified by S. The front hoisting points are at the bottom of the font rail below the hoisting symbol approximately mm behind the front suspension crossmember. When using outboard lift hoists, verify that the hoist lift pads have been properly adjusted to eliminate con- tact between the hoist arm and the down standing flange on the sill.

The rear hoisting points are the leaf spring front mounting brackets. The hoist pad must be positioned to pick up the flanges on the bracket, not the leaf spring. When servicing the leaf springs or the leaf spring mounting brackets, special provisions are required to support the rear of the vehicle. Place a soft pad between the hoist and the painted surface on the sill to avoid scratching the fin- ish.

Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual Fig. Turn off all accesso- ries. BLACK clamp to neg- ative terminal -. DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. If engine does not start within 15 sec- onds, stop cranking engine and allow starter to cool 15 minutes , before cranking again. Disconnect RED cable clamp from battery positive terminal.

CAUTION: Do not damage brake lines, exhaust sys- tem, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle.

Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. When using a wheel lift towing device, be sure the disabled vehicle has at least mm 4 in.

If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.

A towed vehicle should be raised until the lifted wheels are a minimum mm 4 in. Be sure there is at least mm 4 in. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the rear of the vehicle.

Install lug nuts on wheel attaching studs to retain brake drums or rotors. The steering col- umn must be unlocked and gear selector in neutral. The steering column must be unlocked and gear selector in neutral. The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails, behind the front wheels.

The two pair of rear slots on the bottom of the rail between the bumper extension bolts and on the bottom of the rail just rearward of the jounce bumper. Vehicles equipped with a rear sway bar have brackets at this location. Use towing dollies at unlifted end of vehicle. Fuel Tank Diesel 75 L 20 gal. Manual Transaxle T 5-speed 2.

AWD Rear Carrier 0. Only lubricants bearing designations defined by the following organization should be used. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans Fig.

Use Mopar or an equivalent oil meeting the specification MS In addition, API classification defines the lubri- cants usage. Con- sult the appropriate sections in this manual for the correct application of these lubricants.

If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion. Use good quality diesel fuel from a reputable sup- plier. For most year-round service, number 2 diesel fuel meeting ASTM specification D will provide good performance. This will provide better protection from fuel gelling or wax plugging of the fuel filters.

Diesel fuel is seldom completely free of water. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle.

Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. SAE 15W—40 specifies a multiple viscosity engine oil.

When choosing an engine oil, consider the range of temperatures the vehicle will be operated in before the next oil change. For diesel engines, refer to Fig. Production Year: Step by Step Instructions. Comprehensive Diagrams. Diagnostic Procedures. Wiring Diagrams. Here is what you'll get.

Step-by-step factory recommended repair instructions. Unlimited access to personal support reps who are always available to assist you. We can answer your questions about using the software or help you find the specific information you need for your Dodge Grand Caravan.

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