This Haynes DIY repair manual, covers 1996 to 2002 Dodge Caravan, Plymouth Voyager, and Chrysler Town and Country minivans. Note: this manual DOES NOT include info on All-Wheel Drive (AWD) and alternative-fuel models.
Book Excerpt: 1996-2002 Dodge Caravan, Plymouth Voyager, Chrysler Town and Country Repair Manual FOUR-CYLINDER ENGINE

CAMSHAFT(S) - REMOVAL, INSPECTION AND INSTALLATION INSPECTION (Refer to illustration 10.9)

8. Clean the camshaft(s) and the gasket surface. Inspect the camshaft for wear and/or damage to the lobe surfaces, bearing journals, and seal contact surfaces. Inspect the camshaft bearing surfaces in the cylinder head and bearing caps for scoring and other damage.
9. Measure the camshaft bearing journal diameters (see illustration). Measure the inside diameter of the camshaft bearing surfaces in the cylinder head, using a telescoping gauge (temporarily install the bearing caps). Subtract the journal measurement from the bearing measurement to obtain the camshaft bearing oil clearance. Compare this clearance with the value listed in this Chapter's Specifications. Replace worn components as required.
10. Replace the camshaft if it fails any of the above inspections. Note: If the lobes are worn, replace the rocker arms and lash adjusters along with the camshaft. The cylinder head may need to be replaced, if the camshaft bearing surfaces in the head are damaged or excessively worn.
11. Clean and inspect the cylinder head (see Chapter 2D).
CAMSHAFT END PLAY MEASUREMENT
(Refer to illustration 10.14)
12. Lubricate the camshaft(s) and cylinder head bearing journals with clean engine oil.
13. Place the camshaft in its original location in the cylinder head. Note: Do not install the rocker arms for this check. Install the rear bearing cap and tighten the bolts to the torque listed in this Chapter's Specifications.
14. Install a dial indicator on the cylinder head and place the indicator tip on the camshaft at the sprocket end (see illustration).
15. Use a screwdriver to carefully pry the camshaft to the fully to the rear (toward the camshaft position sensor) until it stops. Zero the dial indicator and pry the camshaft fully to the front (toward the dial indicator end). The amount of indicator travel is the camshaft endplay. Compare the endplay with the tolerance given in this Chapter's Specifications. If the endplay is excessive, check the camshaft and cylinder head bearing journals for wear. Replace as necessary.

FUEL AND EXHAUST SYSTEMS

IDLE AIR CONTROL (IAC) VALVE | CHECK AND REPLACEMENT
(Refer to illustrations 15.1a, 15.1b, 15.1c, 15.4 and 15.6)

1. The idle speed is controlled by the IAC valve located on the throttle body (see illustrations). The IAC valve controls idle speed by changing the amount of air that will bypass the throttle plate and flow into the intake manifold. The IAC valve controls idle speed by changing the amount of air that will bypass the throttle plate and flow into the intake manifold. The IAC valve has a pintle valve that protrudes into the air bypass passage and regulates air flow, as controlled by the PCM. The IAC valve is opened and closed depending upon the running conditions of the engine (TPS, crankshaft position, camshaft position, engine coolant temperature, air conditioning system, power steering, cold and warm running, etc.). Sudden release of the accelerator pedal by the driver can cause an engine to stall, so the IAC system is also designed to slow the engine deceleration by increasing bypass airflow when the throttle is closed quickly after driving at speed.

Subject: 1996, 1997, 1998, 1999, 2000, 2001, 2002 Dodge Caravan, Plymouth Voyager, Chrysler Town and Country service, maintenance, repair. ISBN-10: 1563924692 | ISBN-13: 9781563924699 | Haynes 30011