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

Content

Introduction

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

Operation

• Instruments and controls
• Interior conditioning system
• Maintenance

Vehicle adjustments and maintenance

• Schedule of regular maintenance
• Introduction
• Adjustments - general information
• Checking the level of working fluids
• Checking tires and air pressure
• Replacement of engine oil and filter
• Checking and replacing the wiper blades
• Check, maintain and charge the battery
• Rearrangement of wheels
• Seat belt inspection
• Check and replace engine compartment hoses
• Checking the engine cooling system
• Checking and replacing the air filter
• Checking the brake system
• Check of a suspension bracket, a steering and anther of a semiaxis
• Exhaust system check
• Power system check
• Replacement of the particle filter
• Checking, adjusting and replacing the auxiliary drive belt
• Brake fluid replacement
• Checking and replacing spark plugs
• Check and replacement of wires of spark plugs
• Check and replace the crankcase ventilation valve
• Maintenance of the engine cooling system (draining, rinsing and filling)
• Replacing filter and automatic transmission fluid

Four-cylinder engines

• General information
• Possible repair procedures without removing the engine from the engine compartment
• The top dead center of the piston of the first cylinder
• Cylinder head cover - removal and installation
• Intake manifold - removal, inspection and installation
• Exhaust manifold - removal and installation
• Timing belt cover and covers - removal, inspection and installation
• Crankshaft front oil seal - replacement
• Camshaft seal - replacement
• Rockers and hydraulic lifters - removal, inspection and installation
• Camshafts - removal, inspection and installation
• 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

Engines V6 in volume 3,3 and 3,8 l

• General information
• Possible repair procedures without removing the engine from the engine compartment
• The top dead center of the piston of the first cylinder
• Cylinder head covers - removal and installation
• Rockers and pushers - removal, check and installation
• Intake manifold - removal and installation
• Exhaust manifolds - removal and installation
• Crankshaft pulley - removing and installing
• Crankshaft front oil seal - replacement
• Chain of drive timing - removal, inspection and installation
• Hydrocompensators - removal, inspection and installation
• Cylinder heads - removing and installing
• Crankcase - removal and installation
• Oil pump - removal, inspection and installation
• Oil cooler - removal and installation
• Drive clutch plate - removal and installation
• Crankshaft rear crankshaft rear seal - replacement
• Engine supports - checking and replacing

Engine overhaul procedures

• General information - engine overhaul
• Checking engine oil pressure
• Compression check in cylinder
• Diagnostic checks with a vacuum gauge
• Alternative engine replacement
• Engine removal - procedures and precautions
• Engine - removal and installation
• Engine overhauling - sequence of disassembly
• Camshaft and bearings (models of cars equipped with engines 3,3 and 3,8 l) - removal, check and installation
• Balancing shafts (models of cars equipped with 2.4 L engines) - removal, inspection and installation
• Pistons / connecting rods - removal and installation
• Crankshaft - removal and installation
• Engine overhaul - assembly sequence
• Engine starting and running-in period after engine overhaul
• Analysis of the state of the engine bearings
• General terms relating to the engine overhaul procedure

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
• Coolant expansion tank - removing and installing
• Radiator - removal and installation
• Water pump - check
• Water Pump - replacement
• Intake water line - removal and installation
• Motor fan resistor / power supply and motor fan assembly - replacement
• 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 handling system dryer-removing and installing
• Condenser air conditioning / cooler working fluid automatic gearbox - removing and installing
• Control valve - removal and installation
• Rear air conditioning and heater housing - removing and installing
• Air conditioning pressure sensor - removing and installing

Power and exhaust systems

• General information
• Fuel pressure relief procedure
• Fuel pump / fuel pressure check
• Fuel lines and fittings - general information
• Fuel tank - removal and installation
• Fuel tank cleaning and repair - general information
• The fuel filter (only models of cars of 2003) - replacement
• Fuel pump / fuel pressure regulator / fuel level sensor assembly - removing and installing
• Fuel pressure regulator - replacement
• Fuel pump / fuel level sensor assembly - component replacement
• Air filter housing - removing and installing
• Accelerator cable - removal and installation
• Electronic distributed fuel injection (MPI) - general information
• Fuel injection system - inspection
• Throttle body - check, removal and installation
• Fuel rail and injectors - removal and installation
• Maintenance of the exhaust system - general information

Electric engine system

• General information, precautions and disconnection of the negative battery terminal
• Battery - emergency start of the engine from an additional power source
• Battery - check, remove and install
• Battery wires - replacement
• Ignition system - general information and precautions
• Ignition system - check
• Ignition coil - replacement
• Charge system - general information and precautions
• Charge system - check
• Generator - removal and installation
• Start-up system - general information and precautions
• Starter and chain check
• Starter - removal and installation

Engine control and emission control systems

• General information
• On-board diagnostic system and DTCs
• Battery temperature sensor - replacement
• Camshaft position sensor - replacement
• Crankshaft position sensor - replacement
• Coolant temperature sensor - replacement
• Intake air temperature sensor - replacement
• Detonation sensor - replacement
• Manifold absolute pressure sensor - replacement
• Oxygen sensors - general information and replacement
• Throttle position sensor - replacement
• Sensor of selected gearbox mode and gearbox temperature sensors - replacement
• Gearbox speed sensors - replacement
• The electronic block of management of the engine and transmission - removal and installation
• No-load system motor replacement
• Catalytic converter - description, verification and replacement
• Fuel vapor recovery system - general information and component replacement
• Exhaust gas recirculation system - general information and component replacement
• Crankcase ventilation system

Automatic transmission

• General information
• Diagnostics - general information
• Drive shaft seals - replacement
• Switching cable - removal, installation and adjustment
• Shift selector lever lock (BTSI) - description, check and replacement of components
• Electronic gearbox control unit (TCM) (2003-2005 models with four-cylinder engines) - removal and installation
• Transmission oil cooler - removing and installing
• Automatic gearbox - removal and installation
• Overhaul of an automatic transmission - general information

Power shafts

• Drive shafts - general information and verification
• Drive shaft - removal and installation
• Drive shaft replacement

Brake system

• General information
• Anti-lock braking system (ABS) - 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
• Braking system - pumping
• Brake amplifier - checking, removing and installing
• 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 cross-section stability (forward) - removal and installation
• The rack in gathering (forward) - removal, check and installation
• Rack / helical spring - replacement
• Suspension levers - removal, inspection and installation
• Ball bearings - replacement
• Hub and bearing assembly (front) - removing and installing
• Rotary fist - removing and installing
• Stabilizer of lateral stability (rear) - removal and installation
• Transverse reactive rod - 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
• The subframe carrier plate - removal and installation
• Steering wheel - removal and installation
• The ends of the transverse steering rods - removal and installation
• Steering column - 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 awnings - maintenance
• Windshield and fixed glass - replacement
• Hood - removal, installation and adjustment
• Hood retainer and cable - removal and installation
• Radiator grille - removal and installation
• Bumper covers - removal and installation
• Front wing - removal and installation
• Hood cover - removing and installing
• Door trim panels - removal and installation
• Door - removal and installation
• Trunk doors rack - replacement
• Lock, lock and door handle - removal and installation
• Front door glass - removal and installation
• Rear side window - removal and installation
• Lifters - removal and installation
• Mirrors - removal and installation
• Top console - removal and installation
• Panels of a steering column - removal and installation
• Panels for facing the dashboard - removal and installation
• Rear facing panels - removal and installation
• Seats - removal and installation

Chassis electrical system

• General information
• Troubleshooting the electrical system - general information
• Fuses and fusible links - general information
• Breakers - general information and verification
• Relay - general information
• Multifunction switch - replacement
• Ignition lock and lock cylinder - Replacement
• Switches on the dashboard - replacement
• Instrument panel - removal and installation
• Wiper motor - replacement
• Audio system and speakers - removal and installation
• Antenna and wires are replacement
• Rear window heating - inspection and repair
• Headlight headlight housing - replacement
• Headlight lamp - replacement
• Headlights - adjustment
• Lamp replacement
• Acoustic signal - replacement
• Sliding door servomotor - removal and installation
• Rear-view mirrors with servo drive - general information
• Cruise control system - general information
• Electric window system - general information
• Central locking - general information
• Daylighting system - general information
• Airbags - general information
• Wiring diagrams - general information

Glossary

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