Dodge Caravan, Plymouth Voyager, Chrysler Town & Country Repair Manual 1984-1995

COOLANT RESERVOIR | REMOVAL AND INSTALLATION
(Refer to illustration 6.2)

1. Detach the overflow hose at the radiator filler neck. Plug the hose so you don't spill any coolant out of the reservoir during removal.



2. Remove the mounting screws (see illustration) and lift the reservoir straight up. On earlier models, it will be necessary to first remove the battery.



3. Installation is the reverse of the removal.

WATER PUMP | CHECK

1. A failure in the water pump can cause serious damage due to overheating.
   
   
2. There are three ways to check the operation of the water pump while it's installed on the engine. If the pump is defective, it should be replaced with a new or rebuilt unit.



3. With the engine running at normal operating temperature, squeeze the upper radiator hose. If the water pump is working properly, a pressure surge should be felt as the hose is released.
   
   WARNING: Keep your hands away from the fan blades!



4. Water pumps are equipped with weep or vent holes. If a failure occurs in the pump seal, coolant will leak from the hole. In most cases you'll need a flashlight to find the hole on the water pump from underneath to check for leaks.



5. If the water pump shaft bearings fail there may be a howling sound at the front of the engine while it's running. Shaft wear can be felt if the water pump pulley is rocked up-and-down. Don't mistake drive belt slippage, which causes a squealing sound, for water pump bearing failure.

STRUT | REPLACEMENT
(Refer to illustrations 3.4, 3.5 and 3.6)

NOTE: You'll need a spring compressor for this procedure. Spring compressors are available on a daily rental basis at most auto parts stores or equipment yards.

1. If the struts or coil springs exhibit the telltale signs of wear (leaking fluid, loss of damping capability, chipped, sagging or cracked coil springs) explore all options before beginning any work.
   
   The strut insert assemblies are not serviceable and must be replaced if a problem develops. However, strut assemblies complete with springs may be available on an exchange basis, which eliminates much time and work.
   
   Whichever route you choose to take, check on the cost and availability of parts before disassembling your vehicle.
   
   WARNING: Disassembling a strut assembly is a potentially dangerous undertaking and utmost attention must be directed to the job at hand, or serious bodily injury may result. Use only a high-quality spring compressor and carefully follow the manufacturer's instructions furnished with the tool.
   
   After removing the coil spring from the strut assembly, set it aside in a safe, isolated area (a steel cabinet is preferred).



2. Remove the strut and spring assembly (see Section 2).



3. Mount the strut assembly in a vise. Line the vise jaws with wood or rags to prevent damage to the unit and don't tighten the vise excessively.



4. Install the spring compressor in accordance with the manufacturer's instructions (see illustration). Compress the spring until you can wiggle the mount assembly and spring seat.



5. To loosen the damper shaft nut, hold the shaft with a box-end wrench while loosening the shaft nut with another box-end wrench (see illustration).

• Introduction: Vehicle identification numbers. Buying parts. Safety. Maintenance techniques. Chemical and lubricants, and more.
• Tune-up and routine maintenance
• 2.2L and 2.5L four-cylinder engines
• 2.6L four-cylinder engine
• 3.0L V6 engine
• 3.3L and 3.8L V6 engines
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams