Dodge Caravan / Dodge Grand Caravan / Chrysler Voyager / Chrysler Town Country / Plymouth Voyager / Plymouth Grand Voyager 1995 thru 2001, repair e-manual (in Russian)

Content

Introduction

• A few words about this manual
• Introduction
• Vehicle identification numbers
• Acquisition of spare parts
• Maintenance, tools and devices
• Lifting a car with a jack and towing
• Starting the engine with an additional power source
• Working fluids and lubricants
• Safety first!
• Troubleshooting

Operation

• Instruments and controls
• Interior conditioning system

Vehicle adjustments and maintenance

• Schedule of regular maintenance of Dodge, Chrysler and Plymouth cars
• Introduction
• Adjustments - general information
• Checking the level of working fluids (every 400 km or every week)
• Checking tires and air pressure (every 400 km mileage or every week)
• Checking the hydraulic fluid level (every 400 km or weekly)
• Check the power steering fluid level (every 400 km or weekly)
• Replacement of engine oil and filter (every 5,000 km or every 3 months)
• Check, maintain and charge the battery (every 10,000 km or every 6 months)
• Checking the engine cooling system (every 10,000 km or every 6 months)
• Checking and replacing hoses in the engine compartment (every 10,000 km or every 6 months)
• Checking and replacing the wiper blades (every 10,000 km or every 6 months)
• Rearrangement of the wheels (every 10,000 km or every 6 months)
• Suspension and steering control (every 10,000 km or every 6 months)
• Checking the exhaust system (every 10,000 km or every 6 months)
• Checking the differential fluid level
• Chassis lubrication (every 24,000 km or 12 months)
• Checking the braking system (every 24,000 km or 12 months of run)
• Checking the power system (every 24,000 km or 12 months)
• Check, adjust and replace the auxiliary drive belt (every 24,000 km or 12 months)
• Replacement of the air filter (every 48,000 km or 24 months)
• Replacement of automatic transmission and filter fluid (every 48,000 km or 24 months)
• Checking the drive shaft anther (every 48,000 km or every 24 months)
• Replacing differential fluid
• Maintenance of the engine cooling system (draining, rinsing and refueling) (every 48,000 km or every 24 months)
• Checking and replacing the system for forced ventilation of crankcase gases (every 48,000 km or every 24 months)
• Checking the fuel vapor recovery system (every 48,000 km or every 24 months)
• Checking and replacing spark plugs (every 48,000 km or every 24 months)
• Checking and replacing the spark plug wires (every 48,000 km or every 24 months)
• Checking seat belts (every 48,000 km or every 24 months)
• Replacing the fuel filter (every 96,000 km or 48 months)
• Checking the exhaust gas recirculation system (every 48,000 km or every 24 months)

Four-cylinder engines

• General information
• Possible procedures for repairing the engine without removing it from the engine compartment
• Cylinder head cover - removal and installation
• Intake manifold - removal, inspection and installation
• Exhaust manifold - removal and installation
• Timing belt - removal, inspection and installation
• Crankshaft front oil seal - replacement
• Camshaft seal - replacement
• Valve springs, rusks and oil suction caps - replacement
• Camshafts - removal, inspection and installation
• Valve springs, cymbals and oil suction caps - replacement
• Cylinder head - removal and installation
• Crankcase - removal and installation
• Oil pump - removal, inspection and installation
• Drive clutch plate - removal and installation
• Crankshaft rear crankshaft rear seal - replacement
• Engine supports - checking and replacing

V6 3.0 liter engines

• General information
• Possible procedures for repairing the engine without removing it from the engine compartment
• Cylinder head covers - removal and installation
• Intake manifold - removal and installation
• Exhaust manifolds - removal and installation
• Crankshaft pulley / torsional vibration damper - removing and installing
• Timing belt - removal, installation and adjustment
• Crankshaft front oil seal - replacement
• Camshaft seal - replacement
• Rockers and hydraulic lifters - removal, inspection and installation
• Camshafts - removal, inspection and installation
• Valve springs, cymbals and oil suction caps - replacement
• Cylinder heads - removing and installing
• Crankcase - removal and installation
• Oil pump - removal, inspection and installation
• Drive clutch plate - removal and installation
• Crankshaft rear crankshaft rear seal - replacement
• Engine supports - checking and replacing

V6 3.3 and 3.8 liter engines

• General information
• Possible procedures for repairing the engine without removing it from the engine compartment
• Cylinder head covers - removal and installation
• Intake manifold - removal and installation
• Exhaust manifolds - removal and installation
• Crankshaft pulley - removing and installing
• Timing chain cover - removing and installing
• Chain of drive timing - removal, inspection and installation
• Crankshaft front oil seal - replacement
• Rockers and pushers - removal, check and installation
• Hydrocompensators - removal, inspection and installation
• Valve springs, cymbals and oil suction caps - replacement
• Cylinder heads - removing and installing
• Crankcase - removal and installation
• Oil pump - removal, inspection and installation
• Oil cooler - removal and installation (car models released in 2001 and later)
• Drive clutch plate - removal and installation
• Crankshaft rear crankshaft rear seal - replacement
• Engine supports - checking and replacing

Engine overhaul procedures

• General information
• Major engine repairs - general information
• The top dead center of the piston of the first cylinder
• Compression check in cylinder
• Diagnostic checks with a vacuum gauge
• Engine removal - procedures and precautions
• Engine - removal and installation
• Alternative engine replacement
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head - cleaning and checking
• Valves - maintenance
• Cylinder head - assembly
• Camshafts and bearings (models of cars equipped with 3.3 and 3.8 liter V6 engines) - removal and inspection
• Pistons / connecting rods - removal
• Balancing shafts (only four-cylinder engines) - removal, inspection and installation
• Crankshaft removal
• Cylinder block - cleaning
• Cylinder block - check
• Honing cylinders
• Pistons and connecting rods - check
• Crankshaft check
• Crankshaft bearings - check
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation and inspection of the oil clearance of the main bearing
• Camshaft (models of cars equipped with 3.3 and 3.8 liter engines) - installation
• Rear main packing - installation
• Pistons and connecting rods - installation and check of the oil clearance of connecting rod bearings
• Engine starting and running-in period after engine overhaul

Cooling system, heater and air conditioning

• General information
• Coolant / antifreeze - general information
• Thermostat - check and replace
• Engine cooling fans and electric circuit - check and replace
• Radiator / cooler for automatic transmission fluid - removing and installing
• Coolant expansion tank - removing and installing
• Water pump - check
• Water pump - removal and installation
• Coolant temperature sensor - check and replace
• The fan motor of the heater / air conditioning system (front) - removal and installation
• Heater core - replacement
• Control panel for air conditioning and heater - removal and installation
• Air conditioning and heating system - check and maintenance
• Air conditioning compressor - removal and installation
• Air conditioning filter / drier - Removing and installing
• Air conditioning condenser - Removing and installing
• Auxiliary (rear) air conditioning and heater - general information
• Components of the auxiliary air conditioning and heating system - removal and installation

Power and exhaust systems

• General information
• Fuel pressure relief procedure
• Fuel pump / fuel pressure check
• Fuel lines and fittings - general information
• Fuel pump / fuel pressure regulator and filter - removal and installation
• Fuel level sensor - check and replace
• Fuel tank - removal and installation
• Fuel tank cleaning and repair - general information
• Air filter assembly - removing and installing
• Accelerator cable - replacement
• Fuel injection system - general information
• Fuel injection system - inspection
• Throttle body - check, removal and installation
• Fuel rail and injectors - check, remove and install
• Idle air control valve - check and replace
• Inlet air chamber or upper intake manifold (V6 engines) - removal and installation
• Maintenance of the exhaust system - General information

Electric engine system

• General information
• Battery - emergency starting of the engine from an additional
• power source
• Battery wires - check and replace
• Battery - removal and installation
• Ignition system - general
• Ignition system - check
• Ignition coil - check and replace
• Distributor (only V6 3.0-liter engines) - removal, inspection and installation
• Charge system - general information and precautions
• Charge system - check
• Generator - removal and installation
• Voltage regulator - general information
• Start-up system - general information and precautions
• Starter - check
• Starter - removal and installation

Engine control and emission control systems

• General information
• The sequential fuel injection system (MPI) and information sensors
• The electronic block of management of the engine and transmission - removal and installation
• On-board diagnostic system and DTCs
• Information sensors - general data, verification and replacement
• Crankcase ventilation system
• Exhaust gas recirculation system
• Fuel vapor recovery system
• Catalytic converter

Automatic transmission

• General information
• Diagnostics - general information
• Oil seals - replacement
• Transmission supports - check and replace
• Switching cable - check and adjustment
• Throttle cable of gearbox (3-speed gearbox 31TH) - check and adjustment
• Neutral lock switch / reverse light switch - check and replace
• Automatic gearbox - removal and installation
• Adjustment of automatic transmission clamps (3-speed gearbox 31TH)

Power shafts

• Drive shafts - general information and verification
• Drive shaft - removal and installation
• Replacement of an anther of a power shaft and SHRUS check

Brake system

• General information
• Anti-lock system - general information
• Disc brake pads - replacement
• Disc brake caliper - removal and installation
• Brake disc - check, remove and install
• Brake shoe pads - replacement
• The working cylinder - removal and installation
• Master cylinder - removal and installation
• Pressure limiters - check and replace
• Brake hoses and lines - check and replace
• Bleeding the brake system
• Brake amplifier - checking, removing and installing
• The parking brake pedal assembly - removal, installation and adjustment
• Parking brake cables - replacement
• Parking brake shoes (car models equipped with rear disc brakes) - replacement
• Stop light switch - check, replace and adjust

Suspension and steering

• General information
• Bushings of stabilizers of lateral stability (front) - removal, check and installation
• The rack in gathering (forward) - removal, check and installation
• Rack / coil springs - disassembly, inspection and assembly
• Suspension levers - removal, inspection and installation
• Ball bearings - replacement
• Hub and bearing assembly (front) - removing and installing
• Rotary Fist - removing and installing
• Stabilizer of transverse stability (rear) - removal, inspection and installation
• Cross-section reactive rod and support - removal and installation
• Leaf spring supports - removal and installation
• Leaf spring - removal and installation
• Shock absorbers (rear) - removal and installation
• Rear axle assembly - removal and installation
• The hub and the bearing in gathering (back) - removal and installation
• Steering system - general information
• Steering wheel - removal and installation
• The ends of the transverse steering rods - removal and installation
• Steering gear - removal and installation
• Power steering pump - removal and installation
• Power steering fluid cooler - removing and installing
• Power steering system - pumping
• Wheels and tires - general information
• Adjusting the angles of installing the front wheels - general information

Body

• General information
• Body care
• Vinyl facing - care
• Interior upholstery and floor covering - care
• Body repair - minor damage
• Body repair - Serious Damage
• Locks and hinges - maintenance
• Windshield and fixed glass - replacement
• Hood - removal, installation and adjustment
• Hood retainer and cable - removal and installation
• Radiator grille - removal and installation
• Front wing - removal and installation
• Bumpers - removal and installation
• Door trim panels - removal and installation
• Lock, lock and door handle - removal and installation
• Front door - removal and installation
• Sliding door - removal and installation
• The luggage compartment door - removal, installation and adjustment
• Trunk doors rack - replacement
• Front door glass - removal and installation
• Rear side window - removal and installation
• Lifters - removal and installation
• Lower console - removal and installation
• Top console - removal and installation
• Dashboard trim - removal and installation
• Dashboard panel trim - removal and installation
• Internal lining panels - removal and installation
• Mirrors - removal and installation
• Mudguards of wheel arches - removal and installation
• Hood cover - removing and installing
• Seats - removal and installation
• Seat belt inspection
• Frame and body dimensions

Chassis electrical system

• General information
• Elimination of faults in the electrical system - general information
• Fuses - general information
• Fusible jumpers - general information
• Breakers - general information
• Relay - general information and verification
• Control unit for direction indicators / light alarms - check and replace
• Ignition lock and lock cylinder - replacement
• Multifunction switch - check and replace
• Lamps for head lighting - replacement
• Headlamps - adjustment
• Headlight housing - removal and installation
• Lamp replacement
• Headlight switch - check and replace
• Audio system and speakers - removal and installation
• Antenna - removal and installation
• Windscreen wiper motor - check and replace
• Rear window heating switch - removal and installation
• Rear window heating - inspection and repair
• Instrument panel - removal and installation
• Audible signal - check and replace
• External mirrors with servo drive - description and verification
• Cruise control system - description and verification
• Central locking - description and verification
• Power window system - description and verification
• Servo seats - description and verification
• Airbags - general information
• Wiring diagrams

Glossary

Customers reviews