Repair manual
Dodge Grand Caravan IV Repair Manual
Step-by-step repair and maintenance instructions for the Dodge Grand Caravan IV (2000–2007): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- IMPORTANT
- NGC CONTROLLER
- SYSTEM COVERAGE
- SIX - STEP TROUBLESHOOTING PROCEDURE
- IDENTIFICATION OF SYSTEM
- GENERAL DESCRIPTION
- FUNCTIONAL OPERATION
- AUTOSTICK FEATURE (IF EQUIPPED)
- TRANSMISSION OPERATION AND SHIFT SCHEDULING AT VARIOUS OIL TEMPERATURES.
- DIAGNOSTIC TROUBLE CODES
- HARD CODE
- ONE TRIP FAILURES
- INTERMITTENT CODE
- STARTS SINCE SET COUNTER
- TROUBLE CODE ERASURE
- QUICK LEARN
- CLUTCH VOLUMES
- Possible Causes
- EATX DTC EVENT DATA
- ELECTRONIC PINION FACTOR (IF APPLICABLE)
- USING THE DRBIII®
- DRBIII® ERROR MESSAGES
- DRBIII® DOES NOT POWER UP (BLANK SCREEN)
- DISPLAY IS NOT VISIBLE
- SOME DISPLAY ITEMS READ "-"
- TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND FWD ADAPTER (MILLER TOOL #8333-1A)
- DISCLAIMERS
- TECHNICIAN SAFETY INFORMATION
- VEHICLE PREPARATION FOR TESTING
- SERVICING SUB-ASSEMBLIES
- DRBIII® SAFETY INFORMATION
- VEHICLE DAMAGE WARNINGS
- ROAD TESTING A COMPLAINT VEHICLE
- ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE)
- BULLETINS AND RECALLS
- REQUIRED TOOLS AND EQUIPMENT
- ACRONYMS
- DEFINITIONS
- When Monitored and Set Condition: P0122-TPS/APPS LOW
- When Monitored and Set Condition: P0123-TPS/APPS HIGH
- When Monitored and Set Condition: P0124-TPS/APPS INTERMITTENT
- When Monitored and Set Condition: P0218-HIGH TEMPERATURE OPERATION ACTIVATED
- When Monitored and Set Condition: P0562-LOW BATTERY VOLTAGE
- When Monitored and Set Condition: P0604-INTERNAL TCM
- When Monitored and Set Condition: P0605-INTERNAL TCM
- When Monitored and Set Condition: P0613-INTERNAL TCM
- When Monitored and Set Condition: P0706-CHECK SHIFTER SIGNAL
- When Monitored and Set Condition: P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE
- When Monitored and Set Condition: P0712-TRANSMISSION TEMPERATURE SENSOR LOW
- When Monitored and Set Condition: P0713-TRANSMISSION TEMPERATURE SENSOR HIGH
- When Monitored and Set Condition: P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT
- When Monitored and Set Condition: P0715-INPUT SPEED SENSOR ERROR
- When Monitored and Set Condition: P0720-OUTPUT SPEED SENSOR ERROR
- When Monitored and Set Condition: P0725-ENGINE SPEED SENSOR CIRCUIT
- When Monitored and Set Condition: P0731-GEAR RATIO ERROR IN 1ST
- When Monitored and Set Condition: P0732-GEAR RATIO ERROR IN 2ND
- When Monitored and Set Condition: P0733-GEAR RATIO ERROR IN 3RD
- When Monitored and Set Condition: P0734-GEAR RATIO ERROR IN 4TH
- When Monitored and Set Condition: P0736-GEAR RATIO ERROR IN REVERSE
- When Monitored and Set Condition: P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT
- When Monitored and Set Condition: P0750-LR SOLENOID CIRCUIT
- When Monitored and Set Condition: P0755-2/4 SOLENOID CIRCUIT
- When Monitored and Set Condition: P0760-OD SOLENOID CIRCUIT
- When Monitored and Set Condition: P0765-UD SOLENOID CIRCUIT
- When Monitored and Set Condition: P0841-LR PRESSURE SWITCH SENSE CIRCUIT
- When Monitored and Set Condition: P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE
- When Monitored and Set Condition: P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT
- When Monitored and Set Condition: P0870-OD HYDRAULIC PRESSURE TEST FAILURE
- When Monitored and Set Condition: P0871-OD PRESSURE SWITCH SENSE CIRCUIT
- When Monitored and Set Condition: P0884-POWER UP AT SPEED
- When Monitored and Set Condition: P0888-RELAY OUTPUT ALWAYS OFF
- When Monitored and Set Condition: P0890-SWITCHED BATTERY
- When Monitored and Set Condition: P0891-TRANSMISSION RELAY ALWAYS ON
- When Monitored and Set Condition: P0897-WORN OUT/BURNT TRANSAXLE FLUID
- When Monitored and Set Condition: P0944-LOSS OF PRIME
- When Monitored and Set Condition: P0952-AUTOSTICK INPUT CIRCUIT LOW
- When Monitored and Set Condition: P0953-AUTOSTICK INPUT CIRCUIT HIGH
- When Monitored and Set Condition: P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE
- POSSIBLE CAUSE
- When Monitored and Set Condition: P1652-SERIAL COMMUNICATION LINK MALFUNCTION
- When Monitored and Set Condition: P1684-BATTERY WAS DISCONNECTED
- When Monitored and Set Condition: P1687-NO COMMUNICATION WITH THE MIC
- When Monitored and Set Condition: P1694-BUS COMMUNICATION WITH ENGINE MODULE
- When Monitored and Set Condition: P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION
- When Monitored and Set Condition: P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION
- When Monitored and Set Condition: P1790-FAULT IMMEDIATELY AFTER SHIFT
- When Monitored and Set Condition: P1793-TRD LINK COMMUNICATION ERROR
- When Monitored and Set Condition: P1794-SPEED SENSOR GROUND ERROR
- When Monitored and Set Condition: P1797-MANUAL SHIFT OVERHEAT
- When Monitored and Set Condition:P0122-THROTTLE POSITION SENSOR/APPS LOW
- When Monitored and Set Condition:P0123-THROTTLE POSITION SENSOR/APPS HIGH
- When Monitored and Set Condition:P0124-THROTTLE POSITION SENSOR/APPS INTERMITTENT
- DTC P0604: INTERNAL TCM, DTC P0605: INTERNAL TCM, DTC P0613: INTERNAL TCM
- When Monitored and Set Condition: P0891-TRANSMISSION RLY ALWAYS ON
- TRANSMISSION RANGE SENSOR STATES
- PRESSURE SWITCH STATES
- SOLENOID APPLICATION CHART
- SHIFT LEVER ERROR CODES
- TRANSMISSION TEMPERATURE SENSOR (DUAL RANGE)
- INTRODUCTION
- SYSTEM COVERAGE
- SIX-STEP TROUBLESHOOTING PROCEDURE
- IDENTIFICATION OF SYSTEM
- TEVES MARK 20e SYSTEM DESCRIPTION
- TRACTION CONTROL SYSTEM (TCS) DESCRIPTION (IF EQUIPPED)
- General
- System Features
- SYSTEM COMPONENTS
- ABS AND BRAKE WARNING INDICATORS
- CONTROLLER ANTILOCK BRAKE (CAB)
- HYDRAULIC CONTROL UNIT
- ABS SWITCHES/SENSORS
- ABS INITIALIZATION
- ABS DIAGNOSTIC MODE
- TRACTION CONTROL OPERATION (IF EQUIPPED)
- DIAGNOSTIC TROUBLE CODES
- FREEZE FRAME
- TIRE PRESSURE MONITORING SYSTEM (2003 ONLY)
- TRAINING THE EVIC
- PRESSURE THRESHOLDS
- CRITICAL AND NON-CRITICAL SYSTEM ALERTS
- SYSTEM FAULTS
- SPARE WHEEL AUTO-DETECT
- DIAGNOSING AND CLEARING SYSTEM FAULTS
- SYSTEM TEST
- DRBIII® ERROR MESSAGES AND BLANK SCREEN
- DRBIII® DOES NOT POWER UP
- DISPLAY IS NOT VISIBLE
- DISCLAIMERS
- TECHNICIAN SAFETY INFORMATION
- VEHICLE PREPARATION FOR TESTING
- SERVICING SUB-ASSEMBLIES
- DRBIII® SAFETY INFORMATION
- VEHICLE DAMAGE WARNINGS
- ROAD TESTING A COMPLAINT VEHICLE
- DIAGNOSIS
- REQUIRED TOOLS AND EQUIPMENT
- GLOSSARY OF TERMS
- DIAGNOSTIC INFORMATION AND PROCEDURES
- When Monitored and Set Condition
- POSSIBLE CAUSES
- When Monitored and Set Conditions
- Symptom List: LEFT FRONT SENSOR CIRCUIT FAILURE, LEFT REAR SENSOR CIRCUIT FAILURE, RIGHT FRONT SENSOR CIRCUIT FAILURE, RIGHT REAR SENSOR CIRCUIT FAILURE
- LEFT FRONT SENSOR CIRCUIT FAILURE
- LEFT REAR SENSOR CIRCUIT FAILURE
- RIGHT FRONT SENSOR CIRCUIT FAILURE
- RIGHT REAR SENSOR CIRCUIT FAILURE
- Symptom List: LEFT FRONT WHEEL SPEED SIGNAL FAILURE, LEFT REAR WHEEL SPEED SIGNAL FAILURE, RIGHT FRONT WHEEL SPEED SIGNAL FAILURE, RIGHT REAR WHEEL SPEED SIGNAL FAILURE
- LEFT FRONT WHEEL SPEED SIGNAL FAILURE
- LEFT REAR WHEEL SPEED SIGNAL FAILURE
- RIGHT FRONT WHEEL SPEED SIGNAL FAILURE
- RIGHT REAR WHEEL SPEED SIGNAL FAILURE
- VERIFICATION TESTS
- AIR INDUCTION SYSTEMS
- COMPUTERIZED ENGINE CONTROLS
- POWERTRAIN CONTROL MODULE
- Removal (2.4L)
- Installation (2.4L)
- Removal (3.3L & 3.8L)
- Installation (3.3L & 3.8L)
- TRANSMISSION CONTROL MODULE (3.3L & 3.8L)
- PROGRAMMING POWERTRAIN CONTROL MODULE
- Programming PCM
- Programming the SKIM
- Programming Ignition Keys To The SKIM
- Updating Secret Key Data
- A/C PRESSURE SENSOR
- BRAKE SWITCH
- CRANKSHAFT POSITION SENSOR
- ENGINE COOLANT TEMPERATURE SENSOR
- Removal & Installation (4-Speed A/T)
- INLET AIR TEMPERATURE SENSOR
- Removal & Installation
- Removal & Installation (2.4L)
- Removal & Installation (3.3L & 3.8L)
- Removal (4-Speed A/T)
- Installation (4-Speed A/T)
- Removal - Upstream 1/1 O2 Sensor (2.4L)
- Installation - Upstream 1/1 O2 Sensor (2.4L)
- Removal - Upstream 1/1 O2 Sensor (3.3L & 3.8L)
- Installation - Upstream 1/1 O2 Sensor (3.3L & 3.8L)
- Removal - Downstream 1/2 & 2/1 (All Models)
- Installation - Downstream 1/2 & 2/1 (All Models)
- EVAP PURGE SOLENOID
- COOLING SYSTEM BLEEDING
- FUEL SYSTEMS
- FUEL SYSTEM PRESSURE RELEASE
- FUEL LINE DISCONNECT FITTINGS
- Removal & Installation (Dual Tab)
- Removal & Installation (Plastic Retainer Ring)
- FUEL LEVEL SENSOR
- FUEL PUMP
- FUEL PUMP MODULE
- OXYGEN SENSOR
- THROTTLE BODY
- THROTTLE POSITION SENSOR
- CAMSHAFT POSITION SENSOR
- KNOCK SENSOR
- SPARK PLUG
- EVAP CANISTERS
- TORQUE SPECIFICATIONS
- DESCRIPTION
- OPERATION
- DRIVELINE MODULE ASSEMBLY NOISE
- TIRE NOISE
- GEAR NOISE (DRIVE PINION AND RING GEAR)
- BEARING NOISE (DRIVE PINION AND DIFFERENTIAL)
- ENGINE AND TRANSMISSION NOISE
- DISASSEMBLY
- STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION
- TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION
- STEADY STATE, HIGH SPEED, NO WHEEL SLIP
- STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID CHANGE
- INSTALLATION
- DESCRIPTION
- TRANSAXLE IDENTIFICATION
- OPERATION
- DIAGNOSIS AND TESTING - 41TE & 41AE TRANSAXLE GENERAL DIAGNOSIS
- DIAGNOSIS AND TESTING - ROAD TEST
- DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS
- TEST ONE-SELECTOR IN LOW (1st GEAR)
- TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
- TEST TWO A-SELECTOR IN OD (4th Gear)
- TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)
- TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
- TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)
- TEST SIX-SELECTOR IN REVERSE
- TEST RESULT INDICATIONS
- DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS
- OVERDRIVE CLUTCH
- REVERSE CLUTCH
- 2/4 CLUTCH
- LOW/REVERSE CLUTCH
- UNDERDRIVE CLUTCH
- DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE
- TORQUE CONVERTER LEAKAGE
- DISASSEMBLY
- ASSEMBLY
- SPECIFICATIONS - 41TE & 41AE TRANSAXLE
- ADJUSTMENT - DIFFERENTIAL BEARING PRELOAD
- PRELOAD ADJUSTMENT W/O SHIM
- FLUID LEVEL AND CONDITION CHECK
- FLUID LEVEL CHECK
- FLUID LEVEL CHECK USING DRB
- FLUID CONDITION
- STANDARD PROCEDURE - FLUID AND FILTER SERVICE
- DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)
- VERIFICATION
- DIAGNOSIS AND TESTING - BRAKE/ TRANSMISSION SHIFT INTERLOCK SOLENOID
- SOLENOIDS
- PRESSURE SWITCHES
- VEHICLE SPEED SIGNAL
- IMPELLER
- TURBINE
- STATOR
- TORQUE CONVERTER CLUTCH (TCC)
- TRANSMISSION TEMPERATURE SENSOR
- CALCULATED TEMPERATURE
- REGULATOR VALVE
- SOLENOID SWITCH VALVE
- MANUAL VALVE
- CONVERTER CLUTCH SWITCH VALVE
- CONVERTER CLUTCH CONTROL VALVE
- T/C REGULATOR VALVE
- LOW/REVERSE SWITCH VALVE
- DESCRIPTION
- TRANSAXLE IDENTIFICATION
- NEUTRAL
- 1ST GEAR
- 2ND GEAR
- 3RD GEAR
- 4TH GEAR
- 5TH GEAR
- REVERSE GEAR
- DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES
- HARD SHIFTING
- NOISY OPERATION
- SLIPS OUT OF GEAR
- LOW LUBRICANT LEVEL
- CLUTCH PROBLEMS
- ASSEMBLY
- SPECIFICATIONS - T850 MANUAL TRANSAXLE
- OPERATION
- ADJUSTMENT - DIFFERENTIAL TURNING TORQUE
- ADJUSTMENT - DIFFERENTIAL SIDE GEAR END PLAY
- STANDARD PROCEDURE - FLUID LEVEL CHECK
- STANDARD PROCEDURE - FLUID DRAIN AND FILL
- DISASSEMBLY
- CLEANING
- INSPECTION