Repair manual
Chrysler Town & Country IV Repair Manual
Step-by-step repair and maintenance instructions for the Chrysler Town & Country IV (2000–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
72sections
449articles
ENManual language
- INTRODUCTION
- COMPONENT LOCATIONS
- SELF-DIAGNOSTIC SYSTEM
- ON-BOARD DIAGNOSTICS
- Monitored Circuits
- Non-Monitored Circuits
- Hard Failures
- Intermittent Failures
- SERVICE PRECAUTIONS
- DIAGNOSTIC PROCEDURE
- VISUAL INSPECTION
- RETRIEVING DIAGNOSTIC TROUBLE CODES
- Using Scan Tool
- Using Odometer Display
- CLEARING DIAGNOSTIC TROUBLE CODES
- POWERTRAIN CONTROL MODULE LOCATION
- POWERTRAIN CONTROL MODULE
- Programming Powertrain Control Module
- Updating Secret Key Data
- SUMMARY
- FUEL SYSTEM PRESSURE RELEASE
- DIAGNOSTIC TROUBLE CODE DEFINITIONS
- CONNECTOR IDENTIFICATION
- DIAGNOSTIC TESTS
- DTC P0071: AMBIENT AIR TEMP SENSOR PERFORMANCE
- Monitored & Set Conditions
- Testing
- DTC P0106: BAROMETRIC PRESSURE OUT OF RANGE
- DTC P0107: MAP SENSOR VOLTAGE TOO LOW
- DTC P0108: MAP SENSOR VOLTAGE TOO HIGH
- DTC P0111: INTAKE AIR TEMP SENSOR PERFORMANCE
- DTC P0117: ECT SENSOR VOLTAGE TOO LOW
- DTC P0118: ECT SENSOR VOLTAGE TOO HIGH
- DTC P0121: TPS VOLTAGE DOES NOT AGREE WITH MAP
- DTC P0122: THROTTLE POSITION SENSOR VOLTAGE LOW
- DTC P0123: THROTTLE POSITION SENSOR VOLTAGE HIGH
- DTC P0125: CLOSED LOOP TEMP NOT REACHED
- DTC P0131: 1/1 O2 SENSOR SHORTED TO GROUND
- DTC P0132: 1/1 O2 SENSOR SHORTED TO VOLTAGE
- DTC P0133: 1/1 O2 SENSOR SLOW RESPONSE
- DTC P0134: 1/1 O2 SENSOR STAYS AT CENTER
- DTC P0135: 1/1 O2 SENSOR HEATER FAILURE
- DTC P0137: 1/2 O2 SENSOR SHORTED TO GROUND
- DTC P0138: 1/2 O2 SENSOR SHORTED TO VOLTAGE
- DTC P0139: 1/2 O2 SENSOR SLOW RESPONSE
- DTC P0140: 1/2 O2 SENSOR STAYS AT CENTER
- DTC P0141: 1/2 O2 SENSOR HEATER FAILURE
- DTC P0171: 1/1 FUEL SYSTEM LEAN
- DTC P0172: 1/1 FUEL SYSTEM RICH
- DTC P0201: INJECTOR #1 CONTROL CIRCUIT
- DTC P0202: INJECTOR #2 CONTROL CIRCUIT
- DTC P0203: INJECTOR #3 CONTROL CIRCUIT
- DTC P0204: INJECTOR #4 CONTROL CIRCUIT
- DTC P0205: INJECTOR #5 CONTROL CIRCUIT (3.3L & 3.8L)
- DTC P0206: INJECTOR #6 CONTROL CIRCUIT (3.3L & 3.8L)
- DTC P0300: MULTIPLE CYLINDER MISFIRE, DTC P0301: CYLINDER #1 MISFIRE, DTC P0302: CYLINDER #2 MISFIRE, DTC P0303: CYLINDER #3 MISFIRE, DTC P0304: CYLINDER #4 MISFIRE, DTC P0305: CYL
- DTC P0320: NO CRANK REFERENCE SIGNAL AT PCM
- DTC P0325: KNOCK SENSOR #1 CIRCUIT
- DTC P0340: NO CAM SIGNAL AT PCM
- DTC P0351: IGNITION COIL #1 PRIMARY CIRCUIT
- DTC P0352: IGNITION COIL #2 PRIMARY CIRCUIT
- DTC P0353: IGNITION COIL #3 PRIMARY CIRCUIT (3.3L & 3.8L)
- DTC P0401: EGR SYSTEM FAILURE
- DTC P0403: EGR SOLENOID CIRCUIT
- DTC P0420: 1/1 CATALYTIC CONVERTER EFFICIENCY
- DTC P0441: EVAP PURGE FLOW MONITOR
- DTC P0442: EVAP LEAK MONITOR MEDIUM (.040") LEAK DETECTED, DTC P0455: EVAP LEAK MONITOR LARGE LEAK DETECTED OR DTC P0456: EVAP LEAK MONITOR (.020") SMALL LEAK DETECTED
- DTC P0443: EVAP PURGE SOLENOID CIRCUIT
- DTC P0460: FUEL LEVEL UNIT NO CHANGE OVER MILES
- DTC P0462: FUEL LEVEL SENDING UNIT VOLTS TOO LOW
- DTC P0463: FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
- DTC P0500: NO VEHICLE SPEED SENSOR SIGNAL (3SP AUTO TRANS)
- DTC P0500: NO VEHICLE SPEED SENSOR SIGNAL (4SP AUTO TRANS)
- DTC P0505: IDLE AIR CONTROL MOTOR CIRCUITS (2.4L)
- DTC P0508: IAC MOTOR SENSE CIRCUIT LOW (3.3L & 3.8L)
- DTC P0509: IAC MOTOR SENSE CIRCUIT HIGH (3.3L & 3.8L)
- DTC P0600: PCM FAILURE SPI COMMUNICATIONS
- DTC P0601: INTERNAL CONTROLLER FAILURE
- DTC P0645: A/C CLUTCH RELAY CIRCUIT
- DTC P0703: BRAKE SWITCH SENSE CIRCUIT
- DTC P0740: TORQUE CONVERTER CLU, NO RPM DROP AT LOCKUP (3SP AUTO TRANS)
- DTC P0743: TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS (3SP AUTO TRANS)
- DTC P1192: INLET AIR TEMP SENSOR VOLTAGE LOW
- DTC P1193: INLET AIR TEMP SENSOR VOLTAGE HIGH
- DTC P1195: 1/1 O2 SENSOR SLOW DURING CATALYST MONITOR
- DTC P1281: ENGINE IS COLD TOO LONG
- DTC P1282: FUEL PUMP RELAY CONTROL CIRCUIT
- DTC P1294: TARGET IDLE NOT REACHED (2.4L)
- DTC P1294: TARGET IDLE NOT REACHED (3.3L & 3.8L)
- DTC P1297: NO CHANGE IN MAP FROM START TO RUN
- DTC P1299: VACUUM LEAK FOUND (IAC FULLY SEATED)
- DTC P1388: AUTO SHUTDOWN RELAY CONTROL CIRCUIT
- DTC P1389: NO ASD RELAY OUTPUT VOLTAGE AT PCM
- DTC P1391: INTERMITTENT LOSS OF CMP OR CKP (2.4L)
- DTC P1391: INTERMITTENT LOSS OF CMP OR CKP (3.3L & 3.8L)
- DTC P1398: MISFIRE ADAPTIVE NUMERATOR AT LIMIT (2.4L)
- DTC P1398: MISFIRE ADAPTIVE NUMERATOR AT LIMIT (3.3L & 3.8L)
- DTC P1486: EVAP LEAK MONITOR PINCHED HOSE FOUND
- DTC P1491: RAD FAN CONTROL RELAY CIRCUIT
- DTC P1494: LEAK DETECT PUMP SW OR MECHANICAL FAULT
- DTC P1495: LEAK DETECTION PUMP SOLENOID CIRCUIT
- DTC P1496: 5 VOLT SUPPLY, OUTPUT TOO LOW
- DTC P1598: A/C PRESSURE SENSOR VOLTS TOO HIGH
- DTC P1599: A/C PRESSURE SENSOR VOLTS TOO LOW
- DTC P1685: WRONG OR INVALID KEY MSG RECEIVED FROM SKIM
- DTC P1686: NO SKIM BUS MESSAGE RECEIVED
- DTC P1695: NO CCD/J1850 MESSAGE FROM BODY CONTROL MODULE
- DTC P1696: PCM FAILURE EEPROM WRITE DENIED OR DTC P1697: PCM FAILURE SRI MILE NOT STORED
- DTC P1698: NO BUS MESSAGE FROM TRANS CONTROL MODULE (3.3L & 3.8L)
- DTC P1899: P/N SWITCH STUCK IN PARK OR IN GEAR (3SP AUTO TRANS)
- DTC P1899: P/N SWITCH STUCK IN PARK OR IN GEAR (4SP AUTO TRANS)
- VERIFICATION TESTS
- POWERTRAIN VERIFICATION TEST VER-1
- POWERTRAIN VERIFICATION TEST VER-2
- POWERTRAIN VERIFICATION TEST VER-4
- POWERTRAIN VERIFICATION TEST VER-5
- POWERTRAIN VERIFICATION TEST VER-6
- SKIS VERIFICATION TEST
- 31TH TRANSMISSION VERIFICATION TEST
- 41TE TRANSMISSION VERIFICATION TEST
- DESCRIPTION
- TRANSAXLE IDENTIFICATION
- NEUTRAL
- 1ST GEAR
- 2ND GEAR
- 3RD GEAR
- 4TH GEAR
- 5TH GEAR
- REVERSE GEAR
- DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES
- HARD SHIFTING
- NOISY OPERATION
- SLIPS OUT OF GEAR
- LOW LUBRICANT LEVEL
- CLUTCH PROBLEMS
- ASSEMBLY
- SPECIFICATIONS - T850 MANUAL TRANSAXLE
- OPERATION
- ADJUSTMENT - DIFFERENTIAL TURNING TORQUE
- ADJUSTMENT - DIFFERENTIAL SIDE GEAR END PLAY
- STANDARD PROCEDURE - FLUID LEVEL CHECK
- STANDARD PROCEDURE - FLUID DRAIN AND FILL
- DISASSEMBLY
- CLEAN
- INSPECT
- FORD FS-10 10-CYLINDER
- Removal
- Installation
- SHAFT SEAL
- COMPRESSOR CLUTCH PLATE & HUB ASSEMBLY
- COMPRESSOR CONTROL VALVE (VARIABLE DISPLACEMENT COMPRESSORS ONLY)
- COMPRESSOR PRESSURE RELIEF VALVE
- Removal & Installation
- CLUTCH ROTOR/BEARING
- HIGH PRESSURE SWITCH
- MITSUBISHI ASTT
- MITSUBISHI SCROLL
- CLUTCH ASSEMBLY
- Removal (All Models Except Grand Cherokee)
- Installation (All Models Except Grand Cherokee)
- Removal (Grand Cherokee)
- Installation (Grand Cherokee)
- Removal & Installation (General Motors)
- SANDEN SD-7H15 7-CYLINDER
- Removal (All Models)
- Installation (Cherokee)
- Installation (Dakota, Durango & Ram Pickup)
- Removal ("S" Series)
- Installation ("S" Series)
- Removal ("L" Series)
- Installation ("L" Series)
- Removal (VUE)
- Installation (VUE)
- PRESSURE RELIEF VALVE
- HANDLING/SAFETY PRECAUTIONS
- IDENTIFYING R-134a SYSTEMS & COMPONENTS
- Fittings & "O" Rings
- Underhood A/C Specification Labels
- REFRIGERANT OILS
- SCHRADER-TYPE VALVES
- SPECIAL VALVE CONNECTORS
- R-134a SERVICE VALVES/PORTS
- SERVICE VALVE LOCATIONS
- SERVICE EQUIPMENT
- MANIFOLD GAUGE SET
- CONNECTING GAUGE SET
- STABILIZING A/C SYSTEM
- PRESSURE-TEMPERATURE RELATIONSHIP
- PRESSURE GAUGE READINGS
- DAIMLERCHRYSLER CORP.
- Refrigerant System Service Equipment
- Manifold Gauge Set Connections
- Refrigerant Recovery
- Refrigerant System Evacuate
- Refrigerant System Charge
- FORD MOTOR CO.
- Refrigerant System Recovery
- Refrigerant System Evacuation
- Refrigerant System Charging
- GENERAL MOTORS
- JEEP
- A/C SYSTEM FILTERING (FOCUS)
- A/C SYSTEM FILTERING (VILLAGER)
- A/C SYSTEM FILTERING (EXCEPT FOCUS & VILLAGER)
- LEAK TESTING
- Bubble Solution Detector
- Dye Solution
- Fluorescent Leak Detection
- Electronic Leak Detector
- PREPARATION FOR LEAK TESTING
- BUBBLE DETECTOR LEAK TESTING PROCEDURE
- ELECTRONIC LEAK TESTING PROCEDURE
- DYE SOLUTION LEAK TESTING PROCEDURES
- FLUORESCENT DYE LEAK TESTING PROCEDURES
- DESCRIPTION
- OPERATION
- DRIVELINE MODULE ASSEMBLY NOISE
- TIRE NOISE
- GEAR NOISE (DRIVE PINION AND RING GEAR)
- BEARING NOISE (DRIVE PINION AND DIFFERENTIAL)
- ENGINE AND TRANSMISSION NOISE
- DISASSEMBLY
- STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION
- TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION
- STEADY STATE, HIGH SPEED, NO WHEEL SLIP
- STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL
- INSTALLATION
- DESCRIPTION
- TRANSAXLE IDENTIFICATION
- OPERATION
- DIAGNOSIS AND TESTING - 41TE & 41AE TRANSAXLE GENERAL DIAGNOSIS
- DIAGNOSIS AND TESTING - ROAD TEST
- DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS
- TEST ONE-SELECTOR IN LOW (1st GEAR)
- TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
- TEST TWO A-SELECTOR IN OD (4th Gear)
- TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)
- TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
- TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)
- TEST SIX-SELECTOR IN REVERSE
- DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS
- OVERDRIVE CLUTCH
- REVERSE CLUTCH
- 2/4 CLUTCH
- LOW/REVERSE CLUTCH
- UNDERDRIVE CLUTCH
- DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE
- TORQUE CONVERTER LEAKAGE
- DISASSEMBLY
- ASSEMBLY
- SPECIFICATIONS - 41TE & 41AE TRANSAXLE
- ADJUSTMENT - DIFFERENTIAL BEARING PRELOAD
- PRELOAD ADJUSTMENT W/O SHIM
- FLUID LEVEL AND CONDITION CHECK
- FLUID LEVEL CHECK
- FLUID LEVEL CHECK USING DRB
- FLUID CONDITION
- STANDARD PROCEDURE - FLUID AND FILTER SERVICE
- DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)
- VERIFICATION
- STANDARD PROCEDURE - OIL PUMP VOLUME CHECK
- DIAGNOSIS AND TESTING - BRAKE/TRANSMISSION SHIFT INTERLOCK SOLENOID
- SOLENOIDS
- PRESSURE SWITCHES
- VEHICLE SPEED SIGNAL
- IMPELLER
- TURBINE
- STATOR
- TORQUE CONVERTER CLUTCH (TCC)
- TRANSMISSION TEMPERATURE SENSOR
- CALCULATED TEMPERATURE
- REGULATOR VALVE
- SOLENOID SWITCH VALVE
- MANUAL VALVE
- CONVERTER CLUTCH SWITCH VALVE
- CONVERTER CLUTCH CONTROL VALVE
- T/C REGULATOR VALVE
- LOW/REVERSE SWITCH VALVE