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1. 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, ME-
CHANICAL, 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 ob-
ligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1992 Chrysler Corporation 20M0992
NEXT PAGE ᮣ

2. GROUP TAB LOCATOR
— Introduction
0 Lubrication and Maintenance
2 Front Suspension and Drive Shaft
3 Rear Suspension and Driveline
5 Brakes
6 Manual Transaxle Clutch
7 Cooling System
8 Electrical
9 Engines
11 Exhaust System and Intake Manifold
13 Frame and Bumpers
14 Fuel System
19 Steering
21 Transaxle
22 Wheels / Tires
23 Body
24 Heating and Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)

3. INTRODUCTION
CONTENTS
page page
BODY CODE PLATE LOCATION AND
DECODING INFORMATION . . . . . . . . . . . . . . . 2
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 5
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
METRIC THREAD AND GRADE
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . 4
VEHICLE FAMILY IDENTIFICATION . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . 3
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 num-
bers that provide specific information about the vehi-
cle (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 Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not re-
leased to the general public.
VEHICLE IDENTIFICATION NUMBER BREAKDOWN
૽ INTRODUCTION 1

4. 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 ser-
vice 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 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 Voy-
ager SE
• ASHL = 2x4-Plymouth, Voyager
• ASHP = 2x4-Plymouth, Voyager LE, Grand Voy-
ager LE
• ASPH = 4x4-Plymouth Voyager SE, Grand Voy-
ager SE
• ASPP = 4x4-Plymouth , Voyager LE, Grand Voy-
ager LE
DIGIT BOX 19—Price Class
• E = Economy
• H = High Line
• L = Low Line
• M = Maximum
• P = Premium
DIGIT BOXES 20 AND 21—Body Type
• 12 = Van/Short Wheel Base
• 13 = Van/Long Wheel Base
• 52 = Wagon/Short Wheel Base
• 53 = 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
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 Man-
ual Transaxle
• EGA = 3.3 L, V6 Gas (EFI)—Automatic Transaxle
BODY CODE PLATE LINE 1
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) para-
graph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed 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.
Fig. 1 Vehicle Identification Number (VIN Plate)
2 INTRODUCTION ૽

5. VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is at-
tached to the rear facing of the driver’s door. This la-
bel 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 manu-
facture is also included.
All communications or inquiries regarding the ve-
hicle should include the Month-Day-Hour and Vehi-
cle Identification Number.
Fig. 2 Vehicle Safety Certification Label
BODY CODE PLATE
STANDARD BODY DIMENSIONS
૽ INTRODUCTION 3

6. TORQUE REFERENCES
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations 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. Mark-
ings corresponding to two lines less than the actual
grade (Fig. 6). For Example: Grade 7 bolt will have 5
embossed lines on the bolt head.
Fig. 7 International Symbols
Fig. 3 Grade 5 and 8 Standard Torque
Specifications
4 INTRODUCTION ૽

7. 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
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 salvage-
able, a fastener of equivalent specification should be
used.
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
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. 4 Thread Notation (Metric and SAE)
Fig. 5 Metric Bolt Identification
Fig. 6 SAE Bolt Identification
૽ INTRODUCTION 5

8. CONVERSION TABLES
6 INTRODUCTION ૽

9. CONVERSION TABLES
૽ INTRODUCTION 7

10. LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . 20
DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
Classification of Lubricants . . . . . . . . . . . . . . . . . . . 1
Fuel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hoisting Recommendations . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . 2
Parts and Lubricant Recommendations . . . . . . . . . . 1
Parts Requiring No Lubrication . . . . . . . . . . . . . . . . 2
Severe Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Towing Recommendations . . . . . . . . . . . . . . . . . . . 7
Warnings and Precautions . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures 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 fre-
quently than a vehicle used for general transporta-
tion.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation rec-
ommends that only Mopar௡ brand parts, lubricants
and chemicals be used. Mopar provides the best engi-
neered 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 en-
gine to warm to operating temperatures.
• Police or taxi usage.
FUEL USAGE
All Chrysler Corporation engines require the use of
unleaded fuel to reduce exhaust emissions. See En-
gine section of this group for Fuel Recommendations.
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 crank-
case lubricant designed for use in most naturally
aspirated gasoline or diesel engines.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear lubri-
cants. In addition, API classification defines the lubri-
cants usage.
૽ LUBRICATION AND MAINTENANCE 0 - 1

11. 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 qual-
ity identification letters. Wheel bearing lubricant is
identified by the letter ‘‘G’’. Chassis lubricant is iden-
tified by the latter ‘‘L’’. The letter following the us-
age letter indicates the quality of the lubricant. The
following symbols indicate the highest quality.
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysler Corporation vehi-
cle require no periodic maintenance. Some compo-
nents 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/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDICA-
TOR 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. PER-
SONAL INJURY OR DAMAGE TO ELECTRICAL SYS-
TEM 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 in-
spect 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 dis-
abled 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 op-
erate 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).
NLGI SYMBOL
0 - 2 LUBRICATION AND MAINTENANCE ૽

12. LUBRICATIONANDMAINTENANCESCHEDULES
૽ LUBRICATION AND MAINTENANCE 0 - 3

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14. 0 - 4 LUBRICATION AND MAINTENANCE ૽

15. ૽ LUBRICATION AND MAINTENANCE 0 - 5

16. (4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at oppo-
site 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 over-
heat 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 sec-
onds, 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. Discon-
nect 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.
FLUID CAPACITIES
Fig. 1 Jumper Cable Clamp Connections
0 - 6 LUBRICATION AND MAINTENANCE ૽