Repair manual
Chrysler Town & Country IV рестайлинг Repair Manual
Step-by-step repair and maintenance instructions for the Chrysler Town & Country IV рестайлинг (2004–2007): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
63sections
591articles
ENManual language
- DESCRIPTION - VEHICLE IDENTIFICATION
- SAFETY PRECAUTIONS AND WARNINGS
- WATER LEAKS
- VISUAL INSPECTION BEFORE WATER LEAK TESTS
- WATER LEAK TESTS
- WATER LEAK DETECTION
- MIRROR INSPECTION METHOD
- BRIGHT LIGHT LEAK TEST METHOD
- PRESSURIZED LEAK TEST METHOD
- WIND NOISE
- VISUAL INSPECTION BEFORE TESTS
- ROAD TESTING WIND NOISE
- POSSIBLE CAUSE OF WIND NOISE
- STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR
- Rigid Plastics
- Semi-Rigid Plastics
- Flexible Plastics
- Repair Procedure
- Adhesion Promoter/Surface Modifier
- SAFETY PRECAUTION AND WARNINGS
- RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
- PANEL SECTIONING
- PANEL REINFORCEMENT
- VISUAL INSPECTION
- PANEL SURFACE PREPARATION
- PATCHING PANELS
- PANEL PATCH FABRICATIONS
- PATCHED PANEL SURFACING
- STANDARD PROCEDURE - HEAT STAKING
- TORQUE
- LUBRICATION REQUIREMENTS
- DOOR LOCK CYLINDERS
- ALL OTHER BODY MECHANISMS
- LUBRICANT USAGE
- REMOVAL
- INSTALLATION
- REMOVAL - A-PILLAR-HEADER, OR B-PILLAR
- INSTALLATION - A-PILLAR-HEADER, OR B-PILLAR
- SLIDING DOOR ADJUSTMENTS
- PRELIMINARY CHECKS
- DOOR FLUSHNESS ADJUSTMENT
- DOOR GAP ADJUSTMENT - FORE/AFT
- DOOR SEAL COMPRESSION
- STABILIZER ADJUSTMENT - UPPER/LOWER
- REMOVAL - BODY SIDE
- REMOVAL - LIFTGATE SIDE
- INSTALLATION - BODY SIDE
- INSTALLATION - LIFTGATE SIDE
- DESCRIPTION
- LONG WHEELBASE
- SHORT WHEELBASE
- TYPE ONE
- TYPE TWO
- SPECIFICATIONS - COLOR CODE CHARTS
- PAINT CODE
- PAINTED TOUCH-UP
- TOUCH UP PROCEDURE
- SYNCHRONIZING CABLE ADJUSTMENT
- BENCH SEAT & 50/50 SPLIT
- QUAD BUCKET
- 3-PASS BENCH SEAT
- 50/50 SPLIT BENCH SEAT
- WINDSHIELD SAFETY PRECAUTIONS
- WINDSHIELD REMOVAL - EXTERIOR METHOD
- WINDSHIELD REMOVAL - INTERIOR METHOD
- REAR WINDOW REMOVAL - EXTERIOR METHOD
- SPECIFICATIONS - GAP AND FLUSH MEASUREMENTS
- SPECIFICATIONS - BODY OPENING DIMENSIONS
- SPECIFICATIONS - BODY SEALING LOCATIONS
- SPECIFICATIONS - BODY SEALING LOCATIONS - FOLD-IN-FLOOR ONLY
- SPECIFICATIONS - STRUCTURAL ADHESIVE LOCATIONS
- SPECIFICATIONS - STRUCTURAL ADHESIVE LOCATIONS - FOLD-IN-FLOOR ONLY
- SPECIFICATIONS - WELD LOCATIONS — Part 1
- SPECIFICATIONS - WELD LOCATIONS — Part 2
- SPECIFICATIONS - WELD LOCATIONS - FOLD-IN-FLOOR
- SUNROOF DIAGNOSIS AND TESTING
- WATER DRAINAGE AND WIND NOISE DIAGNOSIS
- FRONT HOSES
- REAR HOUSING HOSE
- SUNROOF GLASS PANEL ADJUSTMENT
- ADJUSTMENT
- DESCRIPTION - COOLING SYSTEM
- DESCRIPTION - HOSE CLAMPS
- OPERATION - COOLING SYSTEM
- OPERATION - HOSE CLAMPS
- DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST
- DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
- PREFERRED METHOD
- ALTERNATIVE METHOD
- DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION
- DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION
- STANDARD PROCEDURE - COOLING SYSTEM DRAINING
- STANDARD PROCEDURE - COOLING SYSTEM FILLING
- STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
- STANDARD PROCEDURE - COOLANT LEVEL CHECK
- CLEANING
- REVERSE FLUSHING
- REVERSE FLUSHING RADIATOR
- REVERSE FLUSHING ENGINE
- CHEMICAL CLEANING
- ACCESSORY DRIVE BELT TENSION
- TORQUE
- DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
- INSPECTION
- STANDARD PROCEDURE - CHECKING POWER STEERING BELT TENSION
- GENERATOR AND AIR CONDITIONING BELT
- POWER STEERING PUMP
- ADJUSTMENTS
- REMOVAL
- INSTALLATION
- DIAGNOSIS AND TESTING - ENGINE COOLING SYSTEM
- DRIVING TECHNIQUES
- TRAILER TOWING
- VISUAL INSPECTION
- DESCRIPTION - ENGINE COOLANT
- DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING
- STANDARD PROCEDURE - COOLANT SERVICE
- DESCRIPTION
- OPERATION
- DIAGNOSIS AND TESTING - COOLANT RECOVERY SYSTEM
- DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING
- DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT
- DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING
- DIAGNOSIS AND TESTING - RADIATOR CAP TO FILLER NECK SEAL
- DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
- DESCRIPTION
- DESCRIPTION - FFV REPLACEMENT PARTS
- OPERATION
- DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM
- STANDARD PROCEDURE - DRAINING FUEL TANK
- STANDARD PROCEDURE - FUEL PRESSURE GAUGE
- TORQUE
- REMOVAL
- DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
- STANDARD PROCEDURE - HOSES AND CLAMP
- INSTALLATION
- FUEL PUMP ELECTRICAL CONTROL
- ELECTRICAL PUMP REPLACEMENT
- REMOVAL - FOLD-IN-FLOOR
- INSTALLATION - FOLD-IN-FLOOR
- INSTALLATION - 2.4L
- INSTALLATION - 3.3/3.8L
- INLET CHECK VALVE
- TWO-TAB TYPE FITTING
- DISCONNECTION/CONNECTION
- PLASTIC RETAINER RING TYPE FITTING
- OPERATION - INJECTION SYSTEM
- OPERATION - MODES OF OPERATION
- IGNITION SWITCH ON (ZERO RPM) MODE
- ENGINE START-UP MODE
- ENGINE WARM-UP MODE
- CRUISE OR IDLE MODE
- ACCELERATION MODE
- DECELERATION MODE
- WIDE-OPEN-THROTTLE MODE
- IGNITION SWITCH OFF MODE
- REMOVAL - 2.4L
- REMOVAL - 3.3/3.8L
- Target Idle
- UPSTREAM OXYGEN SENSOR
- DOWNSTREAM OXYGEN SENSOR
- REMOVAL - UPSTREAM 1/1 - 2.4L
- INSTALLATION - UPSTREAM 1/1 - 2.4L
- INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L
- INSTALLATION DOWNSTREAM 2/1 - 2.4/3.3/3.8L
- HEATER AND AIR CONDITIONER
- MANUAL SINGLE ZONE
- MANUAL DUAL ZONE
- MANUAL THREE ZONE
- FRONT CONTROL PANEL
- REAR CONTROL PANEL
- AUTOMATIC TEMPERATURE CONTROL (ATC)
- REAR CONTROL PANEL - THREE ZONE ATC SYSTEM
- A/C COOL DOWN TEST
- MANUAL TEMPERATURE CONTROL
- AUTOMATIC TEMPERATURE CONTROL
- A/C PERFORMANCE TEST
- PERFORMANCE TEST PROCEDURE
- HEATER PERFORMANCE TEST
- MAXIMUM HEATER OUTPUT: TEST AND ACTION
- OBSTRUCTED COOLANT FLOW
- MECHANICAL PROBLEMS
- TEMPERATURE CONTROL
- HEATING-A/C SYSTEM
- DESCRIPTION
- OPERATION
- A/C COMPRESSOR CLUTCH COIL
- PRELIMINARY CHECKS
- TESTS
- A/C CLUTCH INSPECTION
- A/C CLUTCH BREAK-IN
- REMOVAL
- INSTALLATION
- A/C-HEATER CONTROL CALIBRATION
- A/C PRESSURE TRANSDUCER
- FRONT BLOWER MOTOR RESISTOR
- RG MODELS
- RS MODELS
- REAR BLOWER MOTOR RESISTOR
- DEMISTER OUTLETS
- CENTER BEZEL OUTLETS
- INSTRUMENT PANEL OUTLETS
- BLOWER MOTOR
- VIBRATION
- NOISE
- AIR DISTRIBUTION HOUSING
- AIR INLET HOUSING
- HVAC HOUSING
- WARNINGS
- CAUTIONS
- REFRIGERANT SYSTEM LEAKS
- SYSTEM EMPTY
- SYSTEM LOW
- SYSTEM CHARGE LEVEL TEST
- REFRIGERANT SYSTEM SERVICE EQUIPMENT
- RECOVERY/RECYCLING STATION
- MANIFOLD GAUGE SET
- MANIFOLD GAUGE SET CONNECTIONS
- REFRIGERANT SYSTEM RECOVERY
- REFRIGERANT SYSTEM EVACUATE
- REFRIGERANT SYSTEM CHARGE
- CHARGING PROCEDURE
- A/C COMPRESSOR
- HIGH PRESSURE RELIEF VALVE
- A/C COMPRESSOR NOISE
- A/C COMPRESSOR MOUNTING BRACKET-2.4L/2.5L/2.8L ENGINES
- 2.4L/3.3L/3.8L ENGINES
- 2.5L/2.8L ENGINES
- 2.5L/2.8L DIESEL ENGINES
- A/C EXPANSION VALVE
- FRONT HEATER CORE TUBES
- FRONT HEATER CORE
- FRONT SECTION
- REAR SECTION
- REFRIGERANT OIL LEVEL
- REAR A/C EVAPORATOR
- REAR EVAPORATOR LINE EXTENSION
- REAR HEATER CORE FILLING
- PRE-FILLING
- THERMAL CYCLING
- REAR HEATER PERFORMANCE CHECK
- UNDERBODY HEATER TUBES
- UNDERBODY REFRIGERANT LINES
- MANUAL TEMPERATURE CONTROL SYSTEM
- AUTOMATIC TEMPERATURE CONTROL SYSTEM
- WARNING
- SUPPLEMENTAL CABIN HEATER
- CLEANING
- HEATER UNIT
- DESCRIPTION - BASE BRAKES
- DESCRIPTION - BASE BRAKES (EXPORT)
- OPERATION - BASE BRAKES
- WARNING
- CAUTION
- DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM
- RED BRAKE WARNING INDICATOR LAMP
- BRAKE NOISE
- OTHER BRAKE CONDITIONS
- STANDARD PROCEDURE - BASE BRAKE BLEEDING
- MANUAL BLEEDING PROCEDURE
- PRESSURE BLEEDING PROCEDURE
- BRAKE FASTENER TORQUE
- DESCRIPTION
- OPERATION
- INSTALLATION
- REMOVAL
- DESCRIPTION - DISC BRAKES (FRONT)
- DESCRIPTION - DISC BRAKES (REAR)
- DESCRIPTION - DISC BRAKES (EXPORT)
- DESCRIPTION - DRUM BRAKES (REAR)
- OPERATION - DISC BRAKES (FRONT)
- OPERATION - DISC BRAKES (REAR)
- DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER
- DESCRIPTION - BRAKE TUBES AND HOSES
- OPERATION - BRAKE TUBES AND HOSES
- INSPECTION - BRAKE TUBES AND HOSES
- CLEANING - DISC BRAKE SHOES
- INSPECTION - DISC BRAKE SHOES
- INSTALLATION - FRONT DISC BRAKE SHOES (CONTINENTAL TEVES BRAKES)
- INSTALLATION - FRONT DISC BRAKE SHOES (TRW BRAKES)
- INSTALLATION - REAR DISC BRAKE SHOES
- INSPECTION - REAR DRUM BRAKE SHOE LINING
- ADJUSTMENT - REAR DRUM BRAKE SHOES
- REMOVAL - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES)
- REMOVAL - FRONT DISC BRAKE CALIPER (TRW BRAKES)
- DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES)
- DISASSEMBLY - CALIPER PISTON AND SEAL
- CLEANING - CALIPER
- INSPECTION - CALIPER
- ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES)
- ASSEMBLY - CALIPER PISTON AND SEAL
- INSTALLATION - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES)
- INSTALLATION - FRONT DISC BRAKE CALIPER (TRW BRAKES)
- REMOVAL - REAR DISC BRAKE CALIPER
- INSTALLATION - REAR DISC BRAKE CALIPER
- REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER
- INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER
- REMOVAL - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES)
- INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES)
- DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION
- STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING
- BRAKE FLUID
- DESCRIPTION - NON-ABS JUNCTION BLOCK
- OPERATION - NON-ABS JUNCTION BLOCK
- INSTALLATION - NON-ABS JUNCTION BLOCK
- DESCRIPTION - RHD
- STANDARD PROCEDURE - MASTER CYLINDER BLEEDING
- REMOVAL - LHD
- REMOVAL - RHD
- ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR)
- INSTALLATION - LHD
- INSTALLATION - RHD
- BASIC TEST
- VACUUM LEAK TEST
- DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING)
- OPERATION - PROPORTIONING VALVE (HEIGHT SENSING)
- DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT SENSING)
- INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING)
- DIAGNOSIS AND TESTING - BRAKE ROTOR
- BRAKING SURFACE INSPECTION
- ROTOR MINIMUM THICKNESS
- ROTOR THICKNESS VARIATION
- ROTOR RUNOUT
- STANDARD PROCEDURE - BRAKE ROTOR MACHINING
- INSTALLATION - FRONT BRAKE ROTOR
- BRAKE ROTOR
- BRAKE ROTOR - EXPORT
- INSPECTION
- DESCRIPTION - EXPORT
- STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE
- STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET
- ADJUSTMENT - PARKING BRAKE CABLES
- REMOVAL - EXPORT
- INSTALLATION - FOLD-IN-FLOOR SEATING
- INSTALLATION - EXPORT
- INSTALLATION - RIGHT REAR
- INSTALLATION - LEFT REAR
- REMOVAL - PARKING BRAKE LEVER AND FRONT CABLE
- INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE
- ADJUSTMENT - PARKING BRAKE SHOES
- DESCRIPTION - POWER STEERING SYSTEM
- OPERATION - POWER STEERING SYSTEM
- ALL ENGINES
- DIAGNOSIS AND TESTING - STEERING SYSTEM DIAGNOSIS CHARTS
- POWER STEERING NOISE
- STEERING WHEEL FEEL
- POWER STEERING FLUID
- POWER STEERING FASTENER TORQUE
- WARNINGS AND CAUTIONS
- DIAGNOSIS AND TESTING - STEERING COLUMN
- REMOVAL
- INSTALLATION
- COLUMN FASTENER TORQUE
- DESCRIPTION
- OPERATION
- INSTALLATION - RHD GEAR
- DESCRIPTION - PUMP (2.4L/3.3L/3.8L ENGINE)
- DESCRIPTION - PUMP (DIESEL)
- WARNING
- CAUTION
- STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION
- DISASSEMBLY - PUMP (PULLEY)
- ASSEMBLY - PUMP (PULLEY)
- INSTALLATION - PUMP (2.4L ENGINE)
- INSTALLATION - PUMP (3.3L/3.8L ENGINE)
- INSTALLATION - PUMP (DIESEL)
- STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING
- REMOVAL - 2.4L ENGINE
- REMOVAL - 3.3L/3.8L ENGINE
- INSTALLATION - 2.4L ENGINE
- INSTALLATION - 3.3L/3.8L ENGINE
- DESCRIPTION - 2.4L/3.3L/3.8L ENGINE
- DESCRIPTION - DIESEL
- INSTALLATION - DIESEL
- DESCRIPTION - FRONT SUSPENSION
- OPERATION - FRONT SUSPENSION
- STANDARD PROCEDURE - LUBRICATION
- FRONT SUSPENSION FASTENER TORQUE
- DESCRIPTION
- OPERATION
- DIAGNOSIS AND TESTING - HUB AND BEARING
- REMOVAL
- INSTALLATION
- INSPECTION - STEERING KNUCKLE
- DIAGNOSIS AND TESTING - LOWER BALL JOINT
- DESCRIPTION - EXPORT
- REMOVAL - EXPORT
- INSPECTION - LOWER CONTROL ARM
- ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD)
- ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO)
- INSPECTION
- DESCRIPTION - STRUT ASSEMBLY
- OPERATION - STRUT ASSEMBLY
- REMOVAL - STRUT ASSEMBLY
- DISASSEMBLY - STRUT ASSEMBLY
- ASSEMBLY - STRUT ASSEMBLY
- INSTALLATION - STRUT ASSEMBLY
- DESCRIPTION - REAR SUSPENSION
- REAR SUSPENSION FASTENER TORQUE
- FRONT-WHEEL-DRIVE VEHICLES
- REMOVAL - AWD, HEAVY DUTY, CARGO
- REMOVAL - FRONT-WHEEL-DRIVE
- INSTALLATION - AWD, HEAVY DUTY, CARGO
- INSTALLATION - FRONT-WHEEL-DRIVE
- REMOVAL - SHOCK ABSORBER
- DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING)
- ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING)
- INSTALLATION - SHOCK ABSORBER
- REMOVAL - AWD
- REMOVAL - FWD
- INSTALLATION - AWD
- INSTALLATION - FWD
- INSTALLATION - FWD - FOLD-IN-FLOOR SEATING
- DESCRIPTION - WHEEL ALIGNMENT
- CAMBER
- CROSS CAMBER
- CASTER
- CROSS CASTER
- TOE
- TOE-OUT ON TURNS
- DYNAMIC TOE PATTERN
- STEERING AXIS INCLINATION (S. A. I.)
- INCLUDED ANGLE (I. A.)
- THRUST ANGLE
- DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
- PRE-WHEEL ALIGNMENT INSPECTION
- WHEEL ALIGNMENT SETUP
- CAMBER AND CASTER
- CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
- STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT
- WHEEL ALIGNMENT