1994 DODGE INTREPID Service Repair Manual by 163101

CHRYSLER CORPORATION SERVICE MANUAL and SUPPLEMENT 1994 NEW YORKER, LHS CONCORDE, INTREPID AND VISION To order the special service tools used and illustrated, please refer to the instructions on inside back cover.

NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION.

Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

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FOREWORD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Ownerâ&#x20AC;&#x2122;s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation. NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in this manual may have changed from prior publications. These new terms are in compliance with S.A.E. recommended practice J1930.

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GROUP TAB LOCATOR PAGE NOTE: Groups with the suffix “-S” are supplements to the original service manual publication.

IN IN-S 0 2 5 7 7-S 8 8-S 9 11 13 14 14-S 19 21 22 23 23-S 24 24-S 25 25-S

Introduction Introduction Lubrication and Maintenance Front Suspension and Axle Brakes Cooling System Cooling System Electrical Electrical Engines Exhaust System and Intake Manifold Frame and Bumpers Fuel System Fuel System Steering Transaxle Wheels and Tires Body Components Body Components Heating and Air Conditioning Heating and Air Conditioning Emission Control Systems Emission Control Systems Index Index Supplement

Service Manual Comment Forms

(Rear of Manual)

INTRODUCTION

INTRODUCTION CONTENTS page

BODY CODE PLATE LOCATION AND DECODING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 4 METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3

page

METRIC THREAD AND GRADE IDENTIFICATION . . . TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL . . . . . VIN CODE BREAKDOWN

VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left windshield pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle (Fig. 1). Refer to VIN Code Breakdown Chart. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

3 3 1 1

POSITION—INTERPRETATION . . .CODE = DESCRIPTION 1

—Country of Origin. . 2 = Canada

—Make . . . . . . . . . B = Dodge C = Chrysler E = Eagle

—Vehicle Type. . . . . 3 = Pass Car

—Pass. Safety. . . . . B = Manual Belts E = Active Restraint, Passenger Air Bag X = Driver Air Bag, Passenger Manual Belts

—Car Line . . . . . . . L = Chrysler, Concorde D = Chrysler, New Yorker/ LHS D = Dodge, Intrepid D = Eagle, Vision

—Series . . . . . . . . . 4 = High Line 5 = Premium 6 = Sport

—Body Style . . . . . . 6 = 4dr. Sedan

—Engine . . . . . . . . T = 3.3L 6 Cyl. Gasoline F = 3.5L 6 Cyl. Gasoline 24V

—Check Digit . . . . . See preceding paragraph

—Model Year . . . . . R = 1994

—Assembly Plant . . . H = Bramelea

12THRU17

—Vehicle Build Sequence 94IN-5

Fig. 1 Vehicle Identification Number (VIN Plate)

VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label is attached to the rear facing of the driver’s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included.

All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification Number.

BODY CODE PLATE LOCATION AND DECODING INFORMATION The Body Code Plate is located in the engine compartment. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.

INTRODUCTION BODY CODE PLATE

DIGITS 5 THROUGH 8— Primary Paint See Group 23, Body for color codes DIGIT 9— Open Space DIGITS 10 THROUGH 13— Secondary Paint DIGIT 14— Open Space DIGITS 15 THROUGH 18— Interior Trim Code DIGIT 19— Open Space

BODY CODE PLATE LINE 3 DIGITS 1 THROUGH 12— Vehicle Order Number DIGITS 13, 14, AND 15— Vinyl Roof Code DIGITS 16, 17, AND 18— Vehicle Shell Car Line • LHXP = Eagle, Vision ESI • LHXS = Eagle, Vision TSI • LHDH = Dodge, Intrepid • LHDP = Dodge, Intrepid ES • LHLP = Chrysler, Concorde • LHCH = Chrysler, New Yorker • LHCP = Chrysler, New Yorker LHS DIGIT 19— Price Class • E = Economy • H = High Line • L = Low Line • M = Mid Line • P = Premium • S = Special/Sport • X = Performance Image DIGITS 20 AND 21— Body Type • 41 = Four Door Sedan

BODY CODE PLATE LINE 2 DIGITS 1,2, AND 3— Paint Procedure DIGIT 4— Open Space

DIGITS 20, 21, AND 22— Engine Code • EGB = 3.3L Six Cylinder Gasoline • EGE = 3.5L Six Cylinder Gasoline 24 Valve

BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3— Transaxle Codes • DGX = 42LE 4-speed Electronic Automatic Transaxle DIGIT 4— Open Space DIGIT 5— Market Code • U = United States • C = Canada • B = International • M = Mexico DIGIT 6— Open Space DIGITS 7 THROUGH 23— Vehicle Identification Number (VIN) Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate continued (CTD). When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

INTRODUCTION

STANDARD BODY DIMENSIONS INTERIOR DIMENSIONS VEHICLE BODY HEAD ROOM FAMILY STYLE FRONT REAR 975 mm 945 mm LH DP-41 38.4 in. 37.2 in. 975 mm 945 mm LH DP-41 38.4 in. 37.2 in. 975 mm 945 mm LH LP-41 38.4 in. 37.2 in. 975 mm 945 mm LH XP-41 38.4 in. 37.2 in. 975 mm 945 mm LH XS-41 38.4 in. 37.2 in. 998 mm 959 mm LH CH-41 39.3 in. 37.7 in. 998 mm 959 mm LH CP-41 39.3 in. 37.7 in. EXTERIOR DIMENSIONS WHEELBASE VEHICLE BODY FAMILY STYLE mm / in. LH DP-41 2870/113 LH DH-41 2870/113 LH LP-41 2870/113 LH XP-41 2870/113 LH XS-41 2870/113 LH CH-41 2870/113 LH CP-41 2870/113

LEG ROOM FRONT REAR 1077 mm 954 mm 42.4 in. 37.6 in. 1077 mm 954 mm 42.4 in. 37.6 in. 1077 mm 954 mm 42.4 in. 37.6 in. 1077 mm 954 mm 42.4 in. 37.6 in. 1077 mm 954 mm 42.4 in. 37.6 in. 1077 mm 1031 mm 42.4 in. 40.6 in. 1077 mm 1031 mm 42.4 in. 40.6 in.

SHOULDER ROOM FRONT REAR 1499 mm 1499 mm 59.0 in. 59.0 in. 1499 mm 1499 mm 59.0 in. 59.0 in. 1499 mm 1499 mm 59.0 in. 59.0 in. 1499 mm 1499 mm 59.0 in. 59.0 in. 1499 mm 1499 mm 59.0 in. 59.0 in. 1499 mm 1479 mm 59.0 in. 58.2 in. 1499 mm 1479 mm 59.0 in. 58.2 in.

TRACK FRONT mm / in. 1574/62 1574/62 1574/62 1574/62 1574/62 1574/62 1574/62

REAR mm / in. 1574/62 1574/62 1574/62 1574/62 1574/62 1574/62 1574/62

LENGTH mm / in. 5085/200.2 5085/200.2 5085/200.2 5085/200.2 5085/200.2 5268/207.4 5268/207.4

HIP ROOM FRONT REAR 1432 mm 1475 mm 56.3 in. 58.0 in. 1432 mm 1475 mm 58.3 in. 58.0 in. 1432 mm 1475 mm 56.3 in. 58.0 in. 1432 mm 1475 mm 56.3 in. 58.0 in. 1432 mm 1475 mm 56.3 in. 58.0 in. 1444 mm 1554 mm 56.9 in. 61.2 in. 1444 mm 1554 mm 56.9 in. 61.2 in.

OVERALL WIDTH mm / in. 1890/74.4 1890/74.4 1890/74.4 1890/74.4 1890/74.4 1890/74.4 1890/74.4

HEIGHT mm / in. 1417/55.2 1417/55.2 1417/55.2 1417/55.2 1417/55.2 1417/55.2 1417/55.2 94IN-4

TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifications and Bolt Identification Chart in this Group for torques not listed in the individual torque charts (Fig. 2). Torque specifications on the Bolt Torque chart are based on the use of clean and dry threads. Reduce the torque by 10% when the threads are lubricated with engine oil and by 20% if new plated bolts are used. Various sizes of Torx head fasteners are used to secure numerous components to assemblies. Due to ever changing usage of fasteners, Torx head fasteners may not be identified in art or text.

the head of each bolt (Fig. 4). Some metric nuts will be marked with a single digit strength number on the nut face. SAE strength classes range from grade 2 to 8 with line identification embossed on each bolt head. Markings corresponding to two lines less than the actual grade (Fig. 5). For Example: Grade 7 bolt will have 5 embossed lines on the bolt head.

METRIC SYSTEM

METRIC THREAD AND GRADE IDENTIFICATION

Figure art, specifications, and tightening references in this Service Manual are identified in the metric system and in the SAE system. During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification should be used.

Metric and SAE thread notations differ slightly. The difference is illustrated in Figure 3. Common metric fastener strength classes are 9.8 and 12.9 with the class identification embossed on

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY.

INTRODUCTION

Fig. 2 Grade 5 and 8 Standard Torque Specifications

Fig. 5 SAE Bolt Identification

Fig. 6 Metric Prefixes

INTERNATIONAL SYMBOLS Fig. 3 Thread Notation (Metric and SAE)

Fig. 4 Metric Bolt Identification The metric system is based on quantities of one, ten, one hundred, one thousand, and one million (Fig. 6).

Some International Symbols are used to identify controls and displays in this vehicle. These symbols are applicable to those controls which are displayed on the instrument panel or in the immediate vicinity of the driver.

INTRODUCTION CONVERSION TABLES

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

INTRODUCTION

INTRODUCTION VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left windshield pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle (Fig. 1). Refer to VIN Code Breakdown Chart. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

Fig. 1 Vehicle Identification Number (VIN Plate)

LUBRICATION AND MAINTENANCE

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LUBRICATION AND MAINTENANCE CONTENTS page

page

CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . 15 DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 JUMP STARTING, HOISTING AND TOWING . . . 5 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 2

GENERAL INFORMATION PARTS AND LUBRICANT RECOMMENDATIONS When service is required, Chrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing Chrysler Corporation vehicles.

SEVERE SERVICE If a vehicle is operated under any of the following conditions, it is considered severe service. • Extremely dusty areas. • 50% or more of vehicle operation in 32°C (90°F) or higher temperatures. • Prolonged idling (such as, vehicle operation in stop and go traffic). • Frequent short running periods. Not allowing engine to warm to operating temperatures. • Police or taxi usage.

FUEL USAGE All Chrysler Corporation engines require the use of unleaded fuel to reduce exhaust emissions. See Engine section of this group and Group 14, Fuel for fuel recommendations.

API QUALITY CLASSIFICATION. • SG service engine oil is a high quality crankcase lubricant designed for use in all naturally aspirated engines. • SG/CD service engine oil is a high performance crankcase lubricant designed for use in all gasoline or diesel engines.

GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage. LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter ‘‘G’’. Chassis lubricant is identified by the letter ‘‘L’’. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality. NLGI SYMBOL

CLASSIFICATION OF LUBRICANTS Only lubricants that are endorsed by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI)

ENGINE OIL SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY • SAE 30 = single grade engine oil. • SAE 5W-30 = multiple grade engine oil.

PARTS REQUIRING NO LUBRICATION Many components on a Chrysler Corporation vehicle require no periodic maintenance. Some components are sealed and permanently lubricated. Rubber bushings can deteriorate or limit damping ability if lubricated. The following list of components require no lubrication:

0-2 • • • • • • • • • • •

LUBRICATION AND MAINTENANCE FLUID CAPACITIES

Air Pump Generator Bushings Drive Belts Drive Belt Idler/Tensioner Pulley Wheel Bearings Rubber Bushings Starter Bearings/Bushings Suspension Strut Bearings Throttle Control Cable Throttle Linkage Water Pump Bearings

Fuel Tank..............................................68 L (18 gal.) Engine Oil 3.3L ...........................................................4.7L (5 qts.) 3.5L ........................................................5.2L (5.5 qts.) Cooling System 3.3L ................................................10.74L (10.17 qts.) 3.5L.................................................12.46L (11.80 qts.) Includes heater and coolant pressure bottle Transmission.......................................9.4L (9.9 qts.) Differential..............................................0.95L (1 qt)

MAINTENANCE SCHEDULES INTRODUCTION Chrysler Corporation has compiled recommended lubrication and maintenance schedules and procedures to help reduce premature wear or failure over a broad range of operating conditions. When selecting the proper maintenance schedule, the climate and operating conditions must be considered. A vehicle subjected to severe usage requires service more frequently than a vehicle used for general transportation.

GENERAL SERVICE MAINTENANCE AT EACH STOP FOR GASOLINE CHECK • Engine oil level and add as required. • Windshield washer solvent and add if required. ONCE A MONTH • Check tire pressure and look for unusual wear or damage. • Inspect battery and clean and tighten terminals as required. • Check fluid levels of coolant pressure bottle, brake master cylinder, power steering and transmission. Add fluid as needed. • Check all lights and all other electrical items for correct operation. 7,500 MILES (12 000 KM) OR AT 6 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • If it has been 12 months since your last oil filter change, replace the filter at this mileage. • Rotate tires. • Check exhaust system.

15,000 MILES (24 000 KM) OR AT 12 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • Replace engine oil filter. • Adjust the belt tension of non-automatic tensioning drive belts. • Rotate tires. • Check exhaust system. 22,500 MILES (36 000 KM) OR AT 18 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • If it has been 12 months since your last oil filter change, replace the filter at this mileage. • Rotate tires. • Check exhaust system. 30,000 MILES (48 000 KM) OR AT 24 MONTHS • Replace air cleaner filter. • Replace spark plugs. • Check engine coolant level, hoses and clamps. • Change engine oil. • Replace engine oil filter. • Replace the PCV filter (if equipped). • Adjust the belt tension of non-automatic tensioning drive belts. • Rotate tires. • Check exhaust system. 37,500 MILES (60 000 KM) OR AT 30 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • If it has been 12 months since your last oil filter change, replace the filter at this mileage. • Rotate tires. • Check exhaust system.

LUBRICATION AND MAINTENANCE 45,000 MILES (72 500 KM) OR AT 36 MONTHS • Flush and replace engine coolant at 36 months, regardless of mileage. • Flush and replace engine coolant. • Check engine coolant hoses and clamps. • Change engine oil. • Replace engine oil filter. • Adjust the belt tension of non-automatic tensioning drive belts. • Rotate tires. • Check exhaust system. 52,500 MILES (84 500 KM) OR AT 42 MONTHS • Flush and replace engine coolant if not done at 36 months. • Check engine coolant system hoses and clamps. • Change engine oil. • If it has been 12 months since your last oil filter change, replace the filter at this mileage. • Rotate tires. • Check exhaust system. 60,000 MILES (96 500 KM) OR AT 48 MONTHS • Replace air cleaner filter. • Replace ignition cables. • Replace spark plugs. • Check and replace the PCV valve if necessary (see note 1 at the end of this chart). • Replace the PCV filter (if equipped). • Check engine coolant level, hoses and clamps. • Change engine oil. • Replace engine oil filter. • Replace non-automatic tensioning drive belts. • Check and replace as needed all automatic tensioning drive belts. • Rotate tires. • Check exhaust system. 67,500 MILES (108 500 KM) OR AT 54 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • If it has been 12 months since the oil filter was changed, replace the filter at this mileage. • Rotate tires. • Check exhaust system. 75,000 MILES (120 500 KM) OR AT 60 MONTHS • Flush and replace engine coolant if it has been 30,000 miles or 24 months since last change. • Check engine coolant hoses and clamps. • Change engine oil. • Replace engine oil filter. • Adjust the belt tension of non-automatic tensioning drive belts.

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• Check and replace as needed all automatic tensioning drive belts (see note 2 at the end of this chart). • Rotate tires. • Check exhaust system.

82,500 MILES (133 000 KM) OR AT 66 MONTHS • Flush and replace engine coolant if it has been 30,000 miles or 24 months since last change. • Check engine coolant system hoses and clamps. • Change engine oil. • If it has been 12 months since the engine oil filter was changed, replace the filter at this mileage. • Rotate tires. • Check exhaust system. 90,000 MILES (145 000 KM) OR AT 72 MONTHS • Replace air cleaner filter. • Replace spark plugs. • Check and replace the PCV valve if necessary (see note 1 at the end of this chart). • Check engine coolant level, hoses and clamps. • Change engine oil. • Replace engine oil filter. • Adjust the belt tension of non-automatic tensioning drive belts. • Check and replace as needed all automatic tensioning drive belts (see note 2 at the end of this chart). • Rotate tires. • Check exhaust system. 97,500 MILES (157 000 KM) OR AT 78 MONTHS • Check engine coolant level, hoses and clamps. • Change engine oil. • If it has been more than 12 months since the engine oil filter was changed, replace the filter at this mileage. • Rotate tires. • Check exhaust system.

NOTE 1 On a California vehicle, this maintenance is recommended by Chrysler to the owner but is not required to maintain the warranty on the timing belt or the PCV valve.

NOTE 2 This maintenance is not required if the belt was previously replaced.

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LUBRICATION AND MAINTENANCE

SEVERE SERVICE MAINTENANCE Follow the Severe Service recommendations if you operate your vehicle under ANY of the following conditions • Stop and go driving • Extensive idling • Driving in dusty conditions • Frequent short trips • Trailer towing • Operating at sustained high speeds during hot weather above 90°F (32°C).

3,000 MILES(5 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. 6,000 MILES (12 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. 9,000 MILES (14 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. • Inspect front and rear brake linings. 12,000 MILES (19 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. 15,000 MILES (24 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. • Change automatic transmission fluid and filter. Adjust bands (if equipped). • Replace air cleaner air filter. 18,000 MILES (29 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. • Inspect front and rear brake linings. 21,000 MILES (34 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints.

24,000 MILES (38 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. 27,000 MILES (43 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. • Inspect front and rear brake linings. 30,000 MILES (48 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. • Change automatic transmission fluid and filter. Adjust bands (if equipped). • Inspect the PCV valve and replace, if necessary. 33,000 MILES (53 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. 36,000 MILES (58 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. • Inspect front and rear brake linings. 39,000 MILES (62 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. 42,000 MILES (67 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints. 45,000 MILES (72 000KM) • Change engine oil. • Inspect CV joints and front suspension ball joints. • Inspect front and rear brake linings. • Replace automatic transmission fluid and filter. Adjust bands (if equipped). • Replace air cleaner air filter. 48,000 MILES (77 000KM) • Change engine oil. • Replace engine oil filter. • Inspect CV joints and front suspension ball joints.

LUBRICATION AND MAINTENANCE

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JUMP STARTING, HOISTING AND TOWING JUMP STARTING PROCEDURE WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCHING OF BATTERY CURRENT. WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW DISABLED VEHICLE’S BATTERY TO EXCEED 16 VOLTS. PERSONAL INJURY OR DAMAGE TO ELECTRICAL SYSTEM CAN RESULT. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. • Low battery fluid level. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, turn off all accessories, place gear selector in park or neutral, set park brake or equivalent and operate engine at 1200 rpm. (3) On disabled vehicle, place gear selector in park or neutral and set park brake or equivalent. Turn OFF all accessories (Keyless Entry system must be turned OFF manually). (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result (Fig. 1). Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK

jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 1).

Fig. 1 Jumper Cable Clamp Connections CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (6) Allow battery in disabled vehicle least 12.4 volts (75% charge) before start engine. If engine does not start onds, stop cranking engine and allow (15 min.), before cranking again.

to charge to at attempting to within 15 secstarter to cool

DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

HOISTING RECOMMENDATIONS Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

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LUBRICATION AND MAINTENANCE

CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.

TO HOIST OR JACK VEHICLE SEE FIG. 2

Fig. 2 Hoisting and Jacking Points

TOWING RECOMMENDATIONS RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a wheel lift or flat bed towing device (Fig. 3) is recommended. When using a wheel lift towing device, be sure the rear end of disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.

A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain braking discs.

SAFETY PRECAUTIONS The following safety precautions must be considered when preparing for and during a vehicle towing operation: • Do NOT tow vehicle with front wheels on the ground. The transaxle can be damaged. • Secure loose and protruding parts from a disabled vehicle. • Always use a safety chain system that is independent of the lifting and towing equipment. • Do not allow any of the towing equipment to contact the fuel tank of the vehicle being towed. • Do not go under the vehicle while it is lifted by the towing equipment. • Do not allow passengers to ride in a vehicle being towed. • Always observe all state and local laws pertaining to warning signals, night illumination, speed, etc. • Do not attempt a towing operation that could jeopardize the operator, bystanders or other motorists. • Do not exceed a towing speed of 48 km/h (30mph). • Avoid towing distances of more than 24 km (15 miles), whenever possible. • Never attach tow chains or a tow sling to the bumper, steering linkage, or constant velocity joints. TIE DOWN LOCATIONS FOR FLAT BED TOWING There are three reinforced elongated holes on each side of the vehicle designed to serve as hold down locations. These locations can safely hold the vehicle to the towing device using T or R-hooks. • Bottom of the front frame rail forward of the engine cradle. • Bottom of the forward torque box between the front frame rail and the rocker panel. • Bottom of the rearward torque box forward of the rear wheel. FRONT TOWING PROCEDURES

Fig. 3 Recommended Towing Devices GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.

CAUTION: Do Not tow vehicle from the front with sling type towing device. Damage to bumper fascia will result. Always tow vehicle with front wheels off the ground as shown (Fig. 4).

LUBRICATION AND MAINTENANCE

0-7

Use a flat bed towing device when wheel lift towing device is not available.

REAR TOWING PROCEDURES CAUTION: Do not tow vehicle with the rear end lifted. If damage to the vehicle prevents front towing, use a flat bed towing device.

Fig. 4 Towing

CAUTION: Do not push the vehicle with another vehicle as damage to the bumper fascia and transaxle can result.

ENGINE INDEX page

page

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Crankcase Ventilation System . . . . . . . . . . . . . . . . 11 Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emission Control System . . . . . . . . . . . . . . . . . . . 12 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 9 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Frequency of Engine Oil and Filter Changes . . . . . . 7 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel Recommendations . . . . . . . . . . . . . . . . . . . . 11 Ignition Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rubber and Plastic Component Inspection . . . . . . 13 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FREQUENCY OF ENGINE OIL AND FILTER CHANGES

FLEXIBLE FUEL VEHICLES Flexible fuel is corrosive and contributes to engine oil contamination. When flexible fuel is being used, the engine oil should be changed every 8 000 kilometers (5,000 miles) or 6 months, whichever comes first.

ENGINE OIL Road conditions as well as your kind of driving affect the interval at which your oil should be changed. Check the following to determine if any apply to you: • Frequent short trip driving less than 8 kilometers (5 miles) • Frequent driving in dusty conditions • Frequent trailer towing • Extensive idling (such as vehicle operation in stop and go traffic) • More than 50% of your driving is at sustained high speeds during hot weather, above 32°C (90°F) If any of these apply to you then change your engine oil every 4 800 kilometers (3,000 miles) or 3 months, whichever comes first. If none of these apply to you then change your oil every 12 000 kilometers (7,500 miles) or 6 months, whichever comes first. If none of these apply and the vehicle is in commercial type service such as, Police, Taxi or Limousine used for highway driving of 40 kilometers (25 miles) or more between stations, the engine oil should be changed every 8 000 kilometers (5,000 miles) or 6 months.

OIL FILTER The engine oil filter should be replaced with a new filter at every second oil change.

ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

0-8

LUBRICATION AND MAINTENANCE

BREAK-IN PERIOD CAUTION: Wide open throttle operation in low gears, before engine break-in period is complete, can damage engine. On a Chrysler Corporation vehicle an extended break-in period is not required. Driving speeds of not over 80-90 km/h (50-55 mph) for the first 100 km (60 miles) is recommended. Hard acceleration and high engine rpm in lower gears should be avoided.

SELECTING ENGINE OIL

Fig. 1 API Symbol FLEXIBLE FUEL VEHICLES

CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine or Turbocharger failure can result. The factory fill engine oil is a high quality, energy conserving, crankcase lubricant. The Recommended SAE Viscosity Grades chart defines the viscosity grades that must be used based on temperature in the region where vehicle is operated and optional equipment. NON-FLEXIBLE FUEL VEHICLES Chrysler Corporation recommends that Mopar motor oil, or equivalent, be used when adding or changing crankcase lubricant. The API symbol (Fig. 1) on the container indicates the viscosity grade, quality and fuel economy ratings of the lubricant it contains. Use ENERGY CONSERVING II motor oil with API SERVICE SG or SG/CD classification. • SAE 5W-30 engine oil is recommended for use in 3.3L engines in temperatures below 38°C (100°F) to reduce low temperature cranking effort. SAE 5W-30 is recommended for use in 3.5L engines in temperatures below 0°C (32°F). SAE 5W-30 engine oil is NOT recommended for use in 3.5L engines in temperatures above 0°C (32°F). • SAE 10W-30 engine oil is recommended for use in 3.5L engine in temperatures above -18°C (0°F).

RECOMMENDED VISCOSITY GRADES

CAUTION: If motor oils that DO NOT meet or exceed MS-9214 are used in engines operated on M85 fuel, premature engine failure can result. Vehicles operated using Flexible Fuel (M85) require engine oil that meet or exceed Chrysler Standard MS-9214. Mopar Flexible Fuel engine oil or equivalent should be used when adding or changing crankcase lubricant. The API symbol (Fig. 1) on the container indicates the viscosity grade, quality and fuel economy ratings of the lubricant it contains. Equivalent commercial flexible-fuel motor oils may be labeled as Multi-fuel, Variable-fuel or Flexible-fuel. Refer to Recommended Viscosity Grades chart to determine proper motor oil viscosity based on temperature.

ENGINE OIL ADDITIVES Chrysler Corporation recommends that Mopar Engine Oil Supplement or equivalent be used when friction and corrosion reducing materials added to the crankcase lubricant is desired. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Position vehicle on level surface. With engine OFF, allow enough time for oil to settle to bottom of crankcase, remove engine oil level indicator (dipstick) and wipe clean. Install dipstick and verify it is seated in the tube. Remove dipstick, with handle above tip, take oil level reading (Fig. 2). Add oil only if level is below MIN or ADD mark on dipstick.

ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedules. TO CHANGE ENGINE OIL: (1) Position the vehicle on a level surface.

LUBRICATION AND MAINTENANCE

0-9

Fig. 2 Oil Level Indicator Dipstickâ&#x20AC;&#x201D;Typical (2) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations in this group. (3) Place a suitable 3.8 liter (4 qt.) drain pan under crankcase drain. (4) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. (5) Install drain plug in crankcase. (6) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section. (7) Start engine and inspect for leaks. (8) Stop engine and inspect oil level.

ENGINE OIL FILTER SELECTING OIL FILTER Chrysler Corporation recommends a Mopar or equivalent oil filter be used when replacement is required. A replacement filter must be designed to withstand 1756 kPa (256 psi) of internal pressure. OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench (Fig. 3) loosen filter. (3) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. (4) With a wiping cloth, clean the gasket sealing surface (Fig. 4) of oil and grime. Wipe off oil residue from below oil filter adapter. OIL FILTER INSTALLATION: (1) Lightly lubricate oil filter gasket with engine oil or chassis grease. (2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, tighten filter one full turn. If necessary use a filter wrench, do not over tighten. (3) Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.

Fig. 3 Remove Oil Filter

Fig. 4 Install Oil Filter

ENGINE COOLING SYSTEM WARNINGS AND PRECAUTIONS WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result.

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LUBRICATION AND MAINTENANCE

The engine cooling system will develop internal pressure of 97 to 123 kPa (14 to 18 psi) at normal operating temperature. Allow the vehicle approximately one half hour to cool off before opening the cooling system. As an indicator of pressure, squeeze the upper radiator hose between index finger and thumb. If it collapses with little effort the system would have low internal pressure and should be safe to open to the first safety notch of the coolant pressure bottle cap. Refer to Group 7, Cooling System.

COOLING SYSTEM INSPECTION Coolant level (Fig. 5) should be inspected when other engine compartment service is performed or when coolant leak is suspected. Coolant pressure bottle level should be inspected when the engine is cold. The COLD FILL LEVEL mark is located on the side of the coolant pressure bottle. Cooling system freeze protection should be tested at the onset of the winter season or every 12 months. Service is required if coolant is low, contaminated, rusty or freeze protection is inadequate. To properly test cooling system, see Group 7, Cooling System.

adequate protection. A mix table on the coolant container indicates the amount of antifreeze required to winterize the cooling system based on the capacity, see Capacity Chart in General Information section of this group.

SELECTING ANTIFREEZE Chrysler Corporation recommends Mopar Antifreeze/Summer Coolant, or equivalent be used to winterize and protect cooling system. PRESSURE CAP The pressure cap must be secure for the engine cooling system to perform properly. Inspect and test pressure cap when cooling system service is performed or when a problem is suspected. COOLING SYSTEM SERVICE The cooling system should be drained, flushed and filled with the proper coolant mixture at the intervals described in the Lubrication and Maintenance Schedules. Refer to General Information section of this group. For proper service instructions see Group 7, Cooling System.

ENGINE AIR CLEANER The engine air cleaner should be serviced at the intervals described in the Lubrication and Maintenance Schedules. Refer to General Information section of this group. Additional information can be found in Group 14, Fuel System and Group 25, Emission System. Inspect all air cleaner hoses or tubes for damage or leaks when other engine compartment service is performed. Replace faulty components.

AIR CLEANER SERVICE CAUTION: The air cleaner cover must be installed properly for the emissions system and engine controller to function correctly. Do not immerse paper air filter element or temperature sensor in cleaning solvents, damage can result.

Fig. 5 Coolant Pressure Bottle The cooling system factory fill is a mixture of 50% Glycol base antifreeze with silicate inhibitor and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the coolant pressure bottle when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37째C (-35째F). If the freeze protection is above -28째C (-20째F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve

TO SERVICE AIR CLEANER (1) Raise hood of vehicle and inspect all air cleaner components for damage or improper attachment. (2) Remove air cleaner lid (Fig. 6). (3) Remove paper air filter element from air cleaner body. Hold a shop light on throttle body side of element. Inspect air intake side of element. If light is visible through element, blow dust from element (Fig. 7) and reuse. If element is saturated with oil or light is not visible, replace filter. If element is saturated with oil, perform crankcase ventilation system tests. Refer to Group 25, Emission Control Systems for proper procedure.

LUBRICATION AND MAINTENANCE (4) Clean inside of air cleaner lid and body with vacuum or compressed air. If oily, wash with solvent. To Install, reverse the preceding operation.

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circuit. PCV system should be inspected at every oil change. Service PCV system if engine oil is discharged into air cleaner.

PCV SYSTEM TEST Refer to group 25, Emission Control System for proper procedures to test PCV system.

Fig. 8 PCV Systemâ&#x20AC;&#x201D;3.3L Engine Fig. 6 Air Cleaner

Fig. 7 Cleaning Air Filter Element

CRANKCASE VENTILATION SYSTEM Engine crankcase pressure and emissions are vented into combustion chambers through the positive crankcase ventilation (PCV) system (Fig. 8 or 9). The PCV system should have enough volume to overcome crankcase pressure created by piston backwash. If a PCV system becomes plugged, the crankcase pressure will increase and force engine oil past the piston rings creating oil consumption. Blockage of PCV system can occur at the vacuum source coupling, PCV valve or a collapsed hose. Chrysler Corporation recommends that a PCV valve not be cleaned. A new Mopar or equivalent PCV valve should be installed when servicing is required. Over a period of time, depending on the environment where vehicle is used, deposits build up in the PCV vacuum

Fig. 9 PCV Systemâ&#x20AC;&#x201D;3.5L Engine

FUEL RECOMMENDATIONS Chrysler Corporation recommends that only fuel purchased from a reputable retailer be used. Use high quality, unleaded gasoline to provide satisfactory driveability and highest fuel economy. Gasoline containing detergent and corrosion control additives are desireable. If the engine develops spark knock (audible ping), poor performance, hard starting or stalling, purchase fuel from another source. Engine performance can vary when using different brands of gasoline with the same octane rating. Occasional light engine spark knock under heavy acceleration, at low speed or when vehicle is heavily loaded is not harmful. Extended periods of spark knock under moderate acceleration or at cruising speed can dam-

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LUBRICATION AND MAINTENANCE

age the engine. The cause of excessive spark knock condition must be diagnosed and corrected. For diagnostic proedures refer to Group 14, Fuel System and Powertrain Diagnostic Procedures manual. 3.3 L ENGINES Use only unleaded gasoline having a minimum octane rating of 87. 3.5 L ENGINES Use of mid-grade unleaded fuel with minimum octane rating of 89 is recommended. Regular unleaded gasoline having a minimum octane rating of 87 can be used. Regular fuel can reduce engine performance and fuel mileage. Premium unleaded gasoline having a minimum octane rating of 91 can be used if desired. Refer to Group, 14 for additional information. FLEXIBLE FUEL ENGINES CAUTION: Do not use 100% methanol, damage to fuel system can result. Use unleaded regular gasoline having a minimum octane rating of 87 (R=M)/2 and M85 fuel that is 85% methanol and 15% unleaded gasoline, or a mixture of these two.

SELECTING GASOLINE CAUTION: Do not use fuel containing METHANOL (methyl or wood alcohol) in non-flexible fuel engines, damage to fuel system will result. Do not use leaded gasoline, damage to catalytic converter will result and vehicle will not conform to emission control standards. ETHANOL, MTBE OR ETBE BLENDS All Chrysler Corporation vehicles are designed to use unleaded gasoline ONLY. Gasohol blends, containing 10% Ethanol (ethyl or grain alcohol) 90% unleaded gasoline can be used provided it has adequate octane rating. Fuel blends containing up to 15% MTBE (Methyl Tertiary Butyl Ether) and 85% unleaded gasoline can be used. Fuel blends containing up to 17% ETBE (Ethyl Tertiary Butyl Ether) and 83% unleaded gasoline can also be used. Fuel blended with ethanol, MTBE or ETBE are also referred to as reformulated or clean air gasoline. These fuels contribute less emissions to the atmosphere. Chrysler Corporation recommends that blended fuels be used when available. METHANOL BLENDS Using gasoline blended with methanol in nonflexible fuel engines can result in starting and driveability problems. Deterioration of fuel system compo-

nents will result. Methanol induced problems are not the responsibility of Chrysler Corporation and may not be covered by the vehicle warranty.

FUEL FILTER The fuel filter requires service only when a fuel contamination problem is suspected. For proper diagnostic and service procedures refer to Group 14, Fuel System.

IGNITION CABLES Inspect and test ignition cables when the spark plugs are replaced. Oil and grime should be cleaned from the ignition cables and coil to avoid possible spark plug fouling. Mopar Foamy Engine Degreaser, or equivalent is recommended for cleaning the engine compartment. For proper service and diagnostic procedures refer to Group 8D, Ignition Systems.

SPARK PLUGS Ignition spark plugs should be replaced at the mileage interval described in the Lubrication and Maintenance Schedules. Refer to the General Information section of this group. For proper service procedures refer to Group 8D, Ignition Systems.

DRIVE BELTS Inspect and adjust drive belts at the interval described in the Lubrication and Maintenance Schedules. Refer to General Information section of this group. For proper inspection and adjustment procedures refer to Group 7, Cooling System.

EMISSION CONTROL SYSTEM Inspect all emission control components and hoses when other under hood service is performed. Refer to emission system Vacuum Hose Label located on the inside of the hood in the engine compartment and Group 25, Emission Control Systems for proper service procedures.

BATTERY Inspect battery tray, hold down and terminal connections when other under hood service is performed. For proper diagnostic procedures refer to Group 8A, Battery/Starting/Charging System Diagnostics. For service and cleaning procedures refer to Group 8B, Battery/Starter Service.

LUBRICATION AND MAINTENANCE RUBBER AND PLASTIC COMPONENT INSPECTION CAUTION: Plastic hoses or wire harness covers will melt or deform when exposed to heat from exhaust system or engine manifolds. Position plastic or rubber components away from moving parts in engine compartment or under vehicle, or damage will result. Do not allow rubber engine mounts or other components to become oil contaminated, repair cause of oil contamination and clean area. All rubber and plastic components should be inspected when engine compartment or under vehicle service is performed. When evidence of deterioration exists, replacement is required. To reduce deteriora-

0 - 13

tion of rubber components, Chrysler Corporation recommends Mopar Foamy Engine Degreaser or equivalent be used to clean engine compartment of oil and road grime.

EXHAUST SYSTEM ISOLATOR AND HANGER The exhaust system should be inspected when under vehicle service is performed. The exhaust system should not make contact with under body, brake cables, brake/fuel lines, fuel tank or suspension components. Slight cracking in rubber isolator or hanger is acceptable. Severely cracked or broken rubber components must be replaced. For proper service procedures see Group 11, Exhaust System and Intake Manifold.

DRIVETRAIN INDEX page

page

Automatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . 13 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Drive Shaft Boots . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 14

AUTOMATIC TRANSAXLE

level, transaxle can be considered hot and reading should be above the WARM mark. If vehicle has run for less than 15 minutes and more than 60 seconds transaxle can be considered warm and reading should be above ADD mark. Add fluid only if level is below ADD mark on dipstick when transaxle is warm. The automatic transaxle does not require periodic maintenance when used for general transportation. If the vehicle is subjected to severe service conditions, the automatic transaxle will require fluid/filter change and band adjustments every 24 000 km (15,000 miles). For additional information, refer to Severe Service paragraph and Lubrication and Maintenance Schedules in General Information section of this group. The fluid and filter should be changed when water contamination is suspected. If fluid has foamy or milky appearance, it is probably contaminated. If the fluid appears brown or dark and a foul odor is apparent, the fluid is burned, transaxle requires maintenance or service. A circular magnet located in the transaxle pan, collects metallic particles circulating in the oil. For proper diagnostic and service procedures, refer to Group 21, Automatic Transaxle.

The automatic transaxle should be inspected for fluid leaks and proper fluid level when other under hood service is performed. CAUTION: To minimize fluid contamination, verify that dipstick is seated in the fill tube after fluid level reading is taken. TO INSPECT THE TRANSAXLE FLUID LEVEL: (1) Position the vehicle on a level surface. (2) Start engine and allow to idle in PARK for at least 60 seconds. The warmer the transaxle fluid, the more accurate the reading. (3) While sitting in driver seat, apply brakes and place gear selector in each position. Return gear selector to park. (4) Raise hood and remove transaxle fluid level indicator (dipstick) and wipe clean with a suitable cloth. (5) Install dipstick and verify it is seated in fill tube (Fig. 1). CAUTION: Do not overfill automatic transaxle, fluid leak or damage can result. (6) Remove dipstick, with handle above tip, take fluid level reading (Fig. 2). If the vehicle has been driven for at least 15 minutes before inspecting fluid

SELECTING AUTOMATIC TRANSAXLE FLUID Chrysler Corporation recommends Mopar ATF Plus (automatic transmission fluid type 7176) be used to add to or replace automatic transaxle fluid. If ATF

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LUBRICATION AND MAINTENANCE

Plus is not available use Dexront II or Dexron IIe Automatic Transmission Fluid or equivalent.

Fig. 3 Differential Fill Plug Fig. 1 Transaxle Fill tube

Fig. 2 Transaxle Dipstickâ&#x20AC;&#x201D;Typical

DIFFERENTIAL The differential should be inspected for oil leaks and proper oil level when other under vehicle service is performed. To inspect the differential oil level, position the vehicle on a level surface and remove fill plug (Fig. 3). The oil level should be at the bottom edge of oil fill opening. The differential does not require periodic maintenance when subjected to normal driving conditions. The oil should be changed when water contamination is suspected. If oil has foamy or milky appearance it probably is contaminated. For proper diagnostic and service procedures, refer to Group 21, Transaxle.

SELECTING LUBRICANT Chrysler Corporation recommends Mopar Gear Lube, SAE 80W-90, or equivalent, be used to fill the differential.

DRIVE SHAFT BOOTS The front drive shaft constant velocity and tripod joint boots (Fig. 4) should be inspected when other under vehicle service is performed. Inspect boots for cracking, tears, leaks or other defects. If service repair is required, refer to Group 2, Suspension.

Fig. 4 Drive Shaft Boots

WHEEL BEARINGS The wheel bearings are permanently sealed, requiring no lubrication. For proper diagnostic and service procedures refer to Group 2, Suspension.

TIRES The tires should be inspected at every engine oil change for proper inflation and condition. The tires should be rotated at the distance intervals described in the Lubrication and Maintenance Schedules of the General Information section in this group. For tire inflation specifications refer to the Ownerâ&#x20AC;&#x2122;s Manual. A Tire Inflation sticker is located in the driver door opening. For proper diagnostic procedures, see Group 22, Wheels and Tires.

TIRE ROTATION The Forward Cross rotation method is recommended for use on Chrysler Corporation vehicles (Fig. 5). Other rotation methods can be used, but may not have the benefits of the recommended method. Only the four tire

LUBRICATION AND MAINTENANCE

0 - 15

rotation method can be used if the vehicle is equipped with a space saver spare tire.

Fig. 5 Tire Rotation

CHASSIS AND BODY INDEX page Body Lubrication Brakes . . . . . . . Headlamps . . . Power Steering

... .... .... ....

. . . .

17 16 16 15

STEERING LINKAGE INSPECTION The steering linkage and steering gear should be inspected for wear, leaks or damage when other under vehicle service is performed. The rack and pinion steering gear end boots should not have excess oil or grease residue on the outside surfaces or surrounding areas. If boot is leaking, it should be repaired. For proper service procedures refer to Group 19, Steering. The tie rod end ball joints are permanently sealed, requiring no lubrication. For proper diagnostic and service procedures refer to Group 2, Suspension.

page Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 15 Supplemental Airbag System . . . . . . . . . . . . . . . . 17 Suspension Ball Joints . . . . . . . . . . . . . . . . . . . . . 15

POWER STEERING The power steering fluid level should be inspected when other under hood service is performed. If the fluid level is low and system is not leaking, use Mopar Power Steering Fluid or equivalent. The power steering system should be inspected for leaks when other under vehicle service is performed. For proper service procedures refer to Group 19, Steering. The power steering pump drive belt should be inspected at the time and distance interval described in the Lubrication and Maintenance Schedules. Refer to the General Information section of this group.

POWER STEERING FLUID INSPECTION

SUSPENSION BALL JOINTS The ball joints are permanently sealed, requiring no lubrication. For proper diagnostic and service procedures refer to Group 2, Suspension.

WARNING: ENGINE MUST NOT BE RUNNING WHEN INSPECTING POWER STEERING FLUID LEVEL, PERSONAL INJURY CAN RESULT.

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LUBRICATION AND MAINTENANCE

CAUTION: Do not over fill power steering reservoir when adding fluid, seal damage and leakage can result. TO INSPECT FLUID LEVEL (1) Position vehicle on a level surface with engine at normal running temperature. (2) Turn OFF engine and remove ignition key. (3) Using a wiping cloth, clean oil and dirt residue from around power steering reservoir cap. (4) Remove reservoir cap or dipstick and wipe off fluid. (5) Install cap or dipstick. (6) Remove cap or dipstick. Holding handle or cap above tip of dipstick, read fluid level (Fig. 1). Add fluid if reading is below cold level mark on dipstick.

and Maintenance Schedules. Refer to General Information section of this group. A hose must be replaced if it has signs of cracking, chafing, fatigue or bulging. For proper service procedures, refer to Group 5, Brakes.

BRAKE LINE INSPECTION The metal brake lines should be inspected when other under vehicle service is preformed. If a line is pinched, kinked, or corroded, it should be repaired. For proper service procedures, refer to Group 5, Brakes. BRAKE RESERVOIR LEVEL INSPECTION WARNING: DO NOT ALLOW PETROLEUM OR WATER BASE LIQUIDS TO CONTAMINATE BRAKE FLUID, SEAL DAMAGE AND BRAKE FAILURE CAN RESULT. The brake reservoir level should be inspected when other under hood service is performed. It is normal for the reservoir level to drop as disc brake pads wear. When fluid must be added, use Mopar Brake Fluid or equivalent. Use only brake fluid conforming to DOT 3, Federal, Department of Transportation specification. To avoid brake fluid contamination, use fluid from a properly sealed container. If fluid level should become low after several thousand kilometers (miles), fill the reservoir to level marks on the side of the reservoir (Fig. 2).

Fig. 1 Power Steering Reservoir Dipstick

BRAKES BRAKE PAD AND LINING INSPECTION The brake pads and linings should be inspected at distance intervals described in the Lubrication and Maintenance Schedules. Refer to the General Information section of this group. If brake pads or linings appear excessively worn, the brakes would require service. For proper service procedures, refer to Group 5, Brakes. BRAKE HOSE INSPECTION WARNING: IF FRONT WHEEL, REAR AXLE, OR ANTI-LOCK UNIT BRAKE HOSE OUTER COVER IS CRACKED, CHAFED, OR BULGED, REPLACE HOSE IMMEDIATELY. BRAKE FAILURE CAN RESULT. The front wheel, rear axle and anti-lock unit (if equipped) brake hoses should be inspected at time and distance intervals described in the Lubrication

Fig. 2 Brake Reservoirâ&#x20AC;&#x201D;Typical

HEADLAMPS The headlamps should be inspected for intensity and aim whenever a problem is suspected. When luggage compartment is heavily loaded, the headlamp aim should be adjusted to compensate for vehicle height change. For proper service procedures, refer to Group 8L, Lamps.

LUBRICATION AND MAINTENANCE SUPPLEMENTAL AIRBAG SYSTEM WARNING: FAILURE TO HAVE THE AIRBAG SYSTEM PROMPTLY SERVICED BY AN AUTHORIZED DEALER SHOULD ONE OF THE FOLLOWING CONDITIONS EXIST CAN LEAD TO POSSIBLE INJURY IN THE EVENT OF AN ACCIDENT. If the AIRBAG indicator lamp does not light at all, stays lit or lights momentarily or continuously while driving, a malfunction may have occurred. Prompt service is required. Refer to Group 8M, Restraint Systems for proper diagnostic procedures.

0 - 17

During winter season, external lock cylinders should be lubricated with Mopar Lock Lubricant or equivalent to assure proper operation when exposed to water and ice. To assure proper hood latching component operation, use engine oil to lubricate the latch, safety catch and hood hinges when other under hood service is performed. Mopar Multi-purpose Grease or equivalent should be applied sparingly to all pivot and slide contact areas.

BODY LUBRICATION

USE ENGINE OIL ON • Door hinges—Pivot points. • Hood hinges—Pivot points. • Trunk lid hinges—Pivot points.

Body mechanisms and linkages should be inspected, cleaned and lubricated as required to maintain ease of operation and to prevent corrosion and wear. Before a component is lubricated, oil, grease and dirt should be wiped off. If necessary, use solvent to clean component to be lubricated. After lubrication is complete, wipe off excess grease or oil.

USE MOPAR LUBRIPLATE OR EQUIVALENT ON • Ash receiver slides. • Door check straps. • Park brake mechanism. • Front seat tracks. • Trunk latch.

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SUSPENSION AND DRIVESHAFTS CONTENTS page

page

DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . 40 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 4 FRONT SUSPENSION SERVICE PROCEDURES . 6

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 53 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 72

GENERAL INFORMATION Throughout this group, references may be made to a particular L.H. platform vehicle by letter or number designation. A chart showing the breakdown of these designations is included in the Introduction section at the front of this Service Manual. The L.H. platform vehicles have a MacPherson gas pressurized strut front suspension design (Fig. 1). The MacPherson strut shock absorber assembly includes the following components. A rubber isolated top mount, seat and bearing assembly and a coil spring insulator. The MacPherson strut assembly is attached to the vehicle at the shock tower using 3 studs which are part of the isolated top mount. The lower end of the MacPherson strut assembly is attached to the upper leg of the steering knuckle. Attachment of the MacPherson strut assembly to the steering knuckle is by 2 serrated bolts. A forged lower

control arm assembly (Fig. 1) is attached to the front cradle and steering knuckle. A tension strut (Fig. 1) connects the lower control arm assembly to the front cradle. A sealed for life front hub and bearing assembly is attached to the front steering knuckle. The outer C/V joint assembly is splined to the front hub and bearing assembly and is retained by a prevailing torque nut. CAUTION: ONLY FRAME CONTACT HOISTING EQUIPMENT CAN BE USED ON L.H. PLATFORM VEHICLES. The L.H. platform vehicles have a fully independent rear suspension. The L.H. platform vehicles can not be hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used damage to rear suspension components will occur.

Fig. 1 L.H. Platform Front Suspension

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SUSPENSION AND DRIVESHAFTS SUSPENSION/STEERING/DIAGNOSIS FRONT WHEEL DRIVE

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SUSPENSION AND DRIVESHAFTS FRONT SUSPENSION

FRONT SUSPENSION MAJOR COMPONENTS (FIG. 2) STRUT ASSEMBLY The front strut and suspension of the vehicle is supported by coil springs positioned around the struts. The springs are contained between an upper seat, located just below the top strut mount assembly (Fig. 2) and a lower spring seat on the strut lower housing. The top of each strut assembly is bolted to the upper fender reinforcement (shock tower) through a rubber isolated mount. The bottom of the strut assembly attaches to the top of the steering knuckle with two serrated through bolts and prevailing torque nuts. Caster is a fixed setting (net build) on all vehicles and is not adjustable. STEERING KNUCKLE The steering knuckle (Fig. 2) is a single casting with legs machined for attachment to the front strut assembly and lower control arm ball joint. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub and bearing assembly using a prevailing torque nut. LOWER CONTROL ARM The lower control arm (Fig. 2) is a steel forging with 2 rubber bushings isolating the lower control arm from the front cradle assembly. The isolator bushings consist of a metal encased pivot bushing and a solid rubber tension strut bushing. The lower control arm is bolted to the cradle assembly using a pivot bolt through the center of the rubber pivot bushing and at the tension strut isolator bushing (Fig. 2). The ball joint is an integral part of the control arm and has a non-tapered stud with a notch for clamp

bolt clearance. The stud is clamped and locked into the steering knuckle leg with a clamp bolt. The ball joint used on the L.H. Platform vehicle is nonserviceable and if defective must be serviced as part of the lower control arm.

DRIVESHAFTS A left and right driveshaft is attached inboard to the transaxle differential output (or stub) shaft, and outboard to the driven wheel hub and bearing assembly. To deliver driving force from the transaxle to the front wheels during turning maneuvers and suspension movement. Both shafts are constructed with constant velocity universal joints at both ends. Both shafts have a Tripod (sliding) joint at the transaxle end and C/V joints (with splined stub shafts) on the hub ends. Due to the transaxle location the connecting shafts between the C/V joints are of different length and construction. The left shaft is longer than the right. Both the left and right drive shafts are of the solid bar type. No tubular drive shafts are used on any available L.H. platform vehicle and powertrain combinations. TENSION STRUTS The L.H. platform vehicle uses a tension strut (Fig. 2) on each side of the vehicles front suspension. The tension strut controls longitudinal (for-and-aft) movement of the front wheels of the vehicles. Controlling the longitudinal movement of the wheels reduces harshness when wheels hit sudden irregularities in the road surface. STABILIZER BAR (SWAY BAR) The stabilizer bar (Fig. 2) interconnects the front strut assemblies of the vehicle. The purpose of a stabilizer bar is to control the body roll of the vehicle. STABILIZER BAR LINK ASSEMBLY The stabilizer bar link assembly (Fig. 2) is used to attach the stabilizer bar to the front strut assemblies. This reduces the fore-and-aft rate of the sway bar from the rest of the suspension.

Fig. 2 L.H. Platform Front Suspension

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SUSPENSION AND DRIVESHAFTS FRONT SUSPENSION SERVICE PROCEDURES INDEX page

page

Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Front Suspension Serviceable Components . . . . . . 6 Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . 6 Hub and Bearing Assembly . . . . . . . . . . . . . . . . . 34 Lower Control Arm Bushing Service . . . . . . . . . . . 18 Lower Control Arm Service . . . . . . . . . . . . . . . . . . 12 Servicing Stabilizer Bar and Bushings . . . . . . . . . . 21

Servicing Wheel Studs . . . . . . . . . . . . . . . . . . . . . 37 Steering Knuckle Service . . . . . . . . . . . . . . . . . . . 29 Strut Damper Assembly . . . . . . . . . . . . . . . . . . . . . 7 Suspension Coil Springs . . . . . . . . . . . . . . . . . . . 12 Tension Strut Service . . . . . . . . . . . . . . . . . . . . . . 15 Wheel Alignment Service Procedure . . . . . . . . . . . . 7

FRONT SUSPENSION SERVICEABLE COMPONENTS

The method of checking front alignment will vary depending on the type of equipment being used. The instructions furnished by the manufacturer of the equipment should always be followed. With the exception that the alignment specifications recommended by Chrysler Corporation be used. There are six basic factors which are the foundation to front wheel alignment. These are vehicle height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors only TOE IN is mechanically adjustable on the L.H. platform vehicle (Fig. 1).

The following components may be replaced either individually or as an assembly. • Gas pressurized front strut must be replaced as an assembly. The strut is not serviceable. It is not necessary to replace strut assemblies in pairs. • Strut assembly upper mounts are replaceable. • Bearing and seat assemblies may be replaced individually. • Coil springs may be replaced individually from the strut assemblies. • Coil spring lower isolator may be replaced individually. • Front wheel hub and bearing assemblies are individually replaceable. • Front lower control arm assemblies are replaceable. The ball joint is integral to the control arm and will require replacement of the control arm if defective. The ball joint seal is individually replaceable. Lower control arm bushings are serviced as individual components of lower control arm assembly, and do not require replacement of lower control arm if defective. • Tension struts are replaceable as are the tension strut to cradle assembly isolator bushings. Tension strut washers at the lower control arm and cradle are replaceable, with proper approved replacement parts ONLY. • Front stabilizer bar is replaceable. Front stabilizer bar isolator bushings, clamps and stabilizer bar link assemblies are also replaceable. • Driveshaft seal and boot replacement, is the only service to be performed on the driveshaft assemblies. Any failure of an internal driveshaft component will require the replacement of the driveshaft assembly.

FRONT WHEEL ALIGNMENT Front wheel alignment is the proper settings of all the interrelated suspension angles affecting the running and steering of the front wheels of the vehicle. On the L.H. platform vehicle the only adjustable suspension setting is wheel TOE.

CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. Wheel alignment adjustments can only be made for the Toe In setting on the L.H. platform vehicles. Toe is measured in degrees or inches and is the distance the front edges of the tires are closer (or farther apart) than the rear edges. See Front Wheel Drive Specifications for Toe settings.

PRE-ALIGNMENT Before any attempt is made to change or correct front wheel alignment. The following inspection and necessary corrections must be made on those parts which influence the steering of the vehicle. (1) Check and inflate tires to recommended pressure. All tires should be the same size and in good condition and have approximately the same wear. Note type of tread wear which will aid in diagnosing, see Wheels and Tires, Group 22. (2) Check front wheel and tire assembly for radial runout. (3) Inspect lower ball joints and all steering linkage for looseness. (4) Check for broken or front and rear springs. Alignment must only be checked after the vehicle has had the following checked or adjusted. Tires set

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to recommended pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or alignment rack. Just prior to each alignment reading. The vehicle should be bounced (rear first, then front) by grasping bumper at center and jouncing each end an equal number of times. Always release bumpers at bottom of down cycle.

Fig. 2 Front Wheel Toe Adjustment Location

Fig. 3 Tie Rod Adjustment Sleeve Thread Engagement (4) Tighten tie rod adjustment sleeve locknuts to 75 Nzm (55 ft. lbs.) torque. (5) Remove steering wheel clamp.

STRUT DAMPER ASSEMBLY Fig. 1 L.H. Platform Toe Adjustment

WHEEL ALIGNMENT SERVICE PROCEDURE FRONT WHEEL TOE ADJUSTMENT (1) Prepare vehicle as described in the PreAlignment procedure. (2) Center steering wheel and hold with steering wheel clamp. (3) Loosen tie rod adjustment sleeve jamnuts. Rotate adjustment sleeve to align toe to specifications (Fig. 2). CAUTION: When setting Toe on vehicle, the maximum dimension of exposed threads allowed on inner and outer tie rod can not exceed the distance shown in (Fig. 3). If the maximum distance is exceeded, inadequate retention of either inner or outer tie rod may result. Ensure that adjustment sleeve jam nuts are torqued to required specification when Toe setting procedure is completed.

REMOVAL (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove front wheel and tire assembly from the vehicle. (3) Remove the stabilizer bar attaching link at the strut assembly (Fig. 1). (4) Loosen but do not remove the outer tie rod end to strut assembly steering arm attaching nut (Fig. 2). Then remove outer tie rod end from steering arm using Puller, Special Tool MB-990635 or equivalent (Fig. 2). (5) If vehicle is equipped with Anti-Lock brakes. Remove speed sensor cable routing bracket from front strut assembly (Fig. 3). (6) Remove brake caliper assembly from steering knuckle and braking disc. Refer to the Brake Section

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SUSPENSION AND DRIVESHAFTS some other method, do not let caliper assembly hang by brake hose (Fig. 4). Remove front braking disc from hub.

Fig. 1 Stabilizer Bar Link Removed From Strut

Fig. 4 Removal And Storage Of Front Caliper CAUTION: The strut assembly to steering knuckle bolts are serrated where they go through strut assembly and steering knuckle. When removing bolts, turn nuts off bolts DO NOT TURN BOLTS IN STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result.

Fig. 2 Removing Outer Tie Rod From Steering Arm

(7) Remove the strut assembly to steering knuckle attaching bolts (Fig. 5).

Fig. 3 Speed Sensor Cable Routing Bracket in this service manual for the required caliper removal and storage procedure. Support caliper assembly by hanging it from frame of vehicle with wire or

Fig. 5 Strut Assembly To Steering Knuckle Attaching Bolts

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(8) Remove the 3 strut assembly upper mount to shock tower mounting nut and washer assemblies (Fig. 6).

bly to steering knuckle attaching bolts (Fig. 7). Torque the caliper assembly attaching bolts to 19 Nzm (192 in. lbs.).

Fig. 6 Strut Assembly Mounting To Shock Tower

Fig. 7 Front Disc Brake Caliper Mounting Bolts

(9) Remove the strut assembly from the vehicle for inspection and or disassembly.

(5) If the vehicle is equipped with Anti-Lock brakes. Install the front speed sensor cable routing bracket onto the front strut assembly (Fig. 3). (6) Install outer tie rod on steering arm of strut assembly (Fig. 8). Install tie rod to steering arm attaching nut on tie rod. Torque the tie rod to steering arm attaching nut to 37 Nzm (27 ft. lbs.). (7) Install stabilizer bar link assembly onto strut assembly (Fig. 8). Torque the stabilizer link assembly to strut assembly attaching nut to 95 Nzm (70 ft. lbs.).

INSPECTION Inspect for evidence of fluid running from the upper end of the reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. INSTALLATION (1) Install front strut assembly into shock tower. Install the 3 strut assembly upper mount to shock tower attaching nuts (Fig. 6). Torque the 3 strut mount to shock tower attaching nuts (Fig. 6) to 33 Nzm (25 ft. lbs.) torque. (2) Position steering knuckle neck into strut assembly. CAUTION: The strut assembly to steering knuckle bolts are serrated were they go through strut assembly and steering knuckle. When installing bolts, turn nuts onto bolts DO NOT TURN BOLTS IN STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result.

Fig. 8 Tie Rod And Stabilizer Bar Link Installation (3) Install the strut assembly to steering knuckle attaching bolts (Fig. 5). Install nuts on attaching bolts (Fig. 5). Torque the strut assembly to steering knuckle attaching bolt nuts to 169 Nzm (125 ft. lbs.). TURN NUTS ON BOLTS DO NOT TURN BOLTS. (4) Install braking disc back on front hub and bearing assembly. Install front brake caliper assembly on steering knuckle. Install the 2 caliper assem-

(8) Install the wheel and tire assembly. (9) Tighten the wheel mounting stud nuts in proper sequence (Fig. 9) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.). (10) Lower vehicle.

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SUSPENSION AND DRIVESHAFTS

Fig. 9 Tightening Wheel Nuts DISASSEMBLY (STRUT DAMPER) The front strut is not serviced and must be replaced as an assembly if found to be defective. The strut is available with 2 calibrations, be sure strut is replaced with an assembly of the same calibration. The components of the strut assembly listed below are replaceable if found to be defective. • Coil spring (Coil springs come in a standard and high rate be sure spring is replaced with a spring of the correct rate.) • Dust shield • Mount assembly • Seat And Bearing • Jounce Bumper • Lower Spring Isolator • Shaft Nut (1) Remove strut assembly requiring service from the vehicle. Refer to Strut Assembly Removal in Servicing Rear Struts, in this section of the service manual. (2) Position strut assembly in a vise, by clamping strut assembly by the steering arm (Fig. 1). Using paint or equivalent, mark the strut unit, lower spring isolator, spring and upper strut mount for indexing of the parts at assembly. (3) Position Spring Compressors, Special Tool C-4838 on the strut assembly spring (Fig. 1). Compress coil spring until all load is removed from upper strut mount assembly. (4) Install Strut Rod Socket, Special Tool, L-4558 or L-4558A on strut shaft nut (Fig. 2). Using a 10 mm socket on end of strut shaft to keep strut shaft from turning (Fig. 2), remove strut shaft nut. (5) Remove upper strut mount assembly from strut shaft (Fig. 3).

Fig. 1 Compressing Strut Assembly Coil Spring

Fig. 2 Remove Strut Shaft Nut

Fig. 3 Upper Strut Mount Removal

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(6) Remove the jounce bumper and the seat/bearing and dust shield as an assembly, from the strut assembly (Fig. 4).

Fig. 6 Lower Spring Isolator

Fig. 4 Jounce Bumper and Seat/Bearing And Dust Shield

(2) Install compressed coil spring onto strut assembly aligning paint mark on spring with paint mark on strut assembly (Fig. 7).

(7) Remove the coil spring and the spring compressor as an assembly from the strut unit (Fig. 5).

Fig. 7 Spring Installation On Strut Assembly (3) Install the strut bearing into the bearing seat (Fig. 8). Bearing must be installed into seat with notches on bearing facing down (Fig. 8).

Fig. 5 Removing Coil Spring And Compressor From Strut (8) Remove lower spring isolator from strut assembly lower spring seat (Fig. 6). Inspect all disassembled components for signs of abnormal wear or failure replacing any components as required. Inspect strut unit for signs of abnormal oil leakage and for loss of gas charge. To check for loss of gas charge in strut unit. Push strut shaft into body of strut and release, strut shaft should return to its fully extended position. If strut shaft does not return to its fully extended position replace strut unit.

STRUT REASSEMBLY (1) Install original or new, lower spring isolator on strut unit (Fig. 6).

Fig. 8 Bearing Installation Into Seat

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(4) Lower seat/bearing and dust shield onto strut assembly and spring. Align paint mark on seat/bearing and dust shield, with paint mark on the strut spring (Fig. 9).

(7) Install Strut Rod Socket, Special Tool, L-4558 or L-4558A on strut shaft nut (Fig. 2). Using a 10 mm socket on end of strut shaft to keep strut shaft from turning (Fig. 2), torque strut shaft nut to 94 Nzm (70 ft. lbs.). (8) Equally loosen the Spring Compressors, Special Tool C-4838 until spring is seated on upper strut mount and all tension is relieved from the spring compressors. (9) Install the strut assembly back into the vehicle. Refer to Strut Assembly Removal in Servicing Front Struts in this section of the service manual.

SUSPENSION COIL SPRINGS Springs are rated separately for each side of vehicle depending on optional equipment and type of service. During service procedures where both springs are removed, mark springs (Chalk, Tape, etc.) (Fig. 11) to ensure installation in original position. If the coils springs require replacement. Be sure that the springs needing replacement, are replaced with springs meeting the correct load and spring rate for the vehicle. During service procedures requiring the removal or installation of a coil spring with Spring Compressor, Special Tool C-4838. It is required that five coils be captured within the jaws of the tool (Fig. 11).

Fig. 9 Seat/Bearing And Dust Shield Installation (5) Install original or replacement jounce bumper onto shaft of strut assembly (Fig. 10).

Fig. 11 Identifying Coil Springs

LOWER CONTROL ARM SERVICE

Fig. 10 Jounce Bumper Installation (6) Install the upper strut mount assembly onto the strut shaft, aligning paint marks (Fig. 3). Install the upper strut mount to strut shaft retaining nut on strut shaft.

The lower control arm if damaged, is serviced only as a complete component. Do not attempt to repair or straighten a broken or bent lower control arm. The only serviceable components of the lower control arm are, the pivot bushing, ball joint seal and tension strut bushing. The service procedure to replace these components is detailed in the specific component sections of this group.

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REMOVAL (ASSEMBLY) (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove the wheel and tire assembly from the vehicle. (3) Remove the ball joint stud to steering knuckle clamp nut and bolt (Fig. 1).

Fig. 2 Separating Ball Joint From Steering Knuckle

Fig. 1 Control Arm To Steering Knuckle Attachment CAUTION: When lower control arm is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle. (4) Carefully insert a pry bar between lower control arm and steering knuckle (Fig. 2). Push down on pry bar to separate ball joint stud from steering knuckle (Fig. 2). Note: Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut.

Fig. 3 Tension Strut To Cradle Mounting

CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. See Driveshafts. (5) Remove tension strut to cradle attaching nut and washer from end of tension strut (Fig. 3). When removing tension strut nut, keep strut from turning by holding tension strut at flat using open end wrench (Fig. 3). Discard tension strut to cradle retaining nut. A NEW tension strut to cradle nut must be used when installing tension strut. (6) Loosen and remove lower control arm pivot bushing to cradle assembly pivot bolt (Fig. 4).

Fig. 4 Lower Control Arm Pivot Bolt

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(7) Separate lower control arm and tension strut from the cradle as an assembly. Lower control arm is removed from cradle, by first removing pivot bushing from cradle and then sliding tension strut out of isolator bushing (Fig. 5).

CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. See Driveshafts. CAUTION: When ball joint stud is installed into steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle. (4) Install lower ball joint stud into steering knuckle. Install steering knuckle to lower ball joint stud, clamp bolt and nut into steering knuckle (Fig. 7). Torque clamp bolt to 55 Nzm (40 ft. lbs.).

Fig. 5 Lower Control Arm Removal From Cradle Inspect lower control arm and tension strut (Fig. 6) for distortion. Check all bushings for signs of sever deterioration. Replace any bushings that show signs of sever deterioration.

Fig. 7 Control Arm To Steering Knuckle Attachment (5) Install the wheel and tire assembly. (6) Tighten the wheel mounting stud nuts in proper sequence (Fig. 8) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.).

Fig. 6 Lower Control Arm And Tension Strut INSTALLATION (ASSEMBLY) (1) Install the lower control arm on the cradle using the following sequence. Install tension strut and isolator bushing into cradle first, then install lower control arm pivot bushing into bracket on cradle (Fig. 5). (2) Install the lower control arm to cradle bracket attaching bolt and nut (Fig. 4). Do not tighten the lower control arm to cradle bracket attaching bolt at this time. (3) Install washer on end of tension strut (Fig. 3). Install a NEW tension strut to cradle bracket nut, on tension strut (Fig.3). Torque tension strut to cradle bracket retaining nut to 150 Nzm (110 ft. lbs.). When torquing tension strut nut, keep tension strut from turning by holding tension strut at flat using an open end wrench (Fig. 3).

Fig. 8 Tightening Wheel Nuts

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(7) Lower vehicle so the suspension is supporting vehicles weight (control arm at design height). Torque the lower control arm pivot bushing to cradle bracket attaching bolt (Fig. 9) to 123 Nzm (90 ft. lbs.).

Fig. 10 Tension Strut Installed In Lower Control Arm. Fig. 9 Lower Control Arm Pivot Bolt

TENSION STRUT SERVICE

When torquing tension strut nut, keep tension strut from turning by holding tension strut at flat using an open end wrench (Fig. 11).

To remove tension strut from vehicle for replacement, the tension strut and lower control arm first MUST be removed as an assembly from the vehicle.

TENSION STRUT REMOVAL AND REPLACEMENT (1) Remove lower control arm and tension strut as an assembly from the vehicle. See Lower Control Arm Removal in this section of the service manual for the required removal procedure. (2) Separate the tension strut from the lower control arm assembly. (3) Inspect tension strut bushing in lower control arm for excessive wear or deterioration. If tension strut bushing is found to be defective replace lower control tension strut bushing at this time. Refer to Lower Control Arm Bushing Service in this section of the service for tension strut removal and installation procedure. (4) Install replacement tension strut into tension strut bushing on lower control arm assembly. Position tension strut in lower control as shown in (Fig. 10), with word FRONT stamped in tension strut positioned away from control arm (Fig. 10). With an open end wrench on flat of tension strut to keep tension strut from turning. Torque NEW tension strut to lower control retaining nut to 150 Nzm (110 ft. lbs.). (5) Install lower control arm and tension strut as an assembly back on the vehicle. See Lower Control Arm Installation in this section of the service manual for the required installation procedure. (6) Install washer on end of tension strut (Fig. 11). Install a NEW tension strut to cradle bracket nut, on tension strut (Fig. 11). Torque the tension strut to cradle bracket retaining nut to 150 Nzm (110 ft. lbs.).

Fig. 11 Tension Strut To Cradle Mounting (7) Install the wheel and tire assembly. (8) Tighten the wheel mounting stud nuts in proper sequence (Fig. 12) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.). (9) Lower vehicle so the suspension is supporting vehicles weight (control arm at design height). Torque the lower control arm pivot bushing to cradle bracket attaching bolt (Fig. 13) to 123 Nzm (90 ft. lbs.).

TENSION STRUT TO CRADLE BUSHING REMOVE To remove tension strut to cradle bushings from vehicle for replacement, the tension strut and lower control arm first MUST be removed as an assembly from the vehicle. (1) Remove lower control arm and tension strut as

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Fig. 12 Tightening Wheel Nuts

Fig. 14 Tension Strut Bushing Installed On Tension Strut

Fig. 13 Lower Control Arm Pivot Bolt an assembly from the vehicle. See Lower Control Arm Removal in this section of the service manual for the required removal procedure. (2) Remove failed tension strut to cradle, isolator bushing from tension strut. Install replacement isolator bushing on tension strut until it is seated against retaining washer (Fig. 14). (3) Remove the failed tension strut to cradle isolator bushing from the cradle assembly. Install replacement tension strut to cradle isolator bushing into cradle, until squarely seated against cradle assembly (Fig. 15). INSTALL (1) Install lower control arm and tension strut as an assembly back on the vehicle. See Lower Control Arm Installation in this section of the service manual for the required installation procedure. (2) Install washer on end of tension strut (Fig. 16). Install a NEW tension strut to cradle bracket nut, on tension strut (Fig. 16). Torque the tension strut to cradle bracket retaining nut to 150 Nzm (110 ft. lbs.).

Fig. 15 Tension Strut Bushing Installed In Cradle When torquing tension strut nut, keep tension strut from turning by holding tension strut at flat using an open end wrench (Fig. 16).

Fig. 16 Tension Strut To Cradle Mounting (3) Install the wheel and tire assembly.

SUSPENSION AND DRIVESHAFTS (4) Tighten the wheel mounting stud nuts in proper sequence (Fig. 17) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.).

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(2) Separate the tension strut from the lower control arm assembly (Fig. 19).

Fig. 19 Tension Strut And Lower Control Arm Bushing Fig. 17 Tightening Wheel Nuts (5) Lower vehicle so the suspension is supporting vehicles weight (control arm at design height). Torque the lower control arm pivot bushing to cradle bracket attaching bolt (Fig. 18) to 123 Nzm (90 ft. lbs.).

(3) Replace tension strut to lower control arm isolator bushing. Refer to Lower Control Arm Bushing Service in this section of the service manual for tension strut isolator bushing removal and installation procedure. (4) Install tension strut into tension strut bushing on lower control arm assembly. Position tension strut in lower control arm as shown in (Fig. 20), with word FRONT stamped in tension strut positioned away from control arm (Fig. 20). With an open end wrench on flat of tension strut, to keep tension strut from turning. Torque NEW tension strut to lower control arm retaining nut to 150 Nzm (110 ft. lbs.)

Fig. 18 Lower Control Arm Pivot Bolt TENSION STRUT TO LOWER CONTROL ARM BUSHING To remove tension strut to lower control arm bushing for replacement, the tension strut and lower control arm MUST first be removed as an assembly from the vehicle. REMOVE (1) Remove lower control arm and tension strut as an assembly from the vehicle. See Lower Control Arm Removal in this section of the service manual for the required removal procedure.

Fig. 20 Tension Strut Installed In Lower Control Arm. INSTALL (1) Install lower control arm and tension strut as an assembly back on the vehicle. See Lower Control Arm Installation in this section of the service manual for the required installation procedure.

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(2) Install washer on end of tension strut (Fig. 21). Install a NEW tension strut to cradle bracket nut, on tension strut (Fig. 21). Torque the tension strut to cradle bracket retaining nut to 150 Nzm (110 ft. lbs.). When torquing tension strut nut, keep tension strut from turning by holding tension strut at flat using an open end wrench (Fig. 21).

Fig. 23 Lower Control Arm Pivot Bolt

LOWER CONTROL ARM BUSHING SERVICE PIVOT BUSHING

Fig. 21 Tension Strut To Cradle Mounting (3) Install the wheel and tire assembly. (4) Tighten the wheel mounting stud nuts in proper sequence (Fig. 22) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.).

Fig. 22 Tightening Wheel Nuts (5) Lower vehicle so the suspension is supporting vehicles weight (control arm at design height). Torque the lower control arm pivot bushing to cradle bracket attaching bolt (Fig. 23) to 123 Nzm (90 ft. lbs.).

REMOVE To perform removal and replacement of the lower control arm pivot bushing. The control arm and tension strut assembly must be removed from the vehicle. The removal and replacement of the lower control arm pivot bushing must be performed using an arbor press. (1) Remove lower control arm and tension strut as an assembly from the vehicle. See Lower Control Arm Removal in this section of the service manual for the required removal procedure. (2) Separate the tension strut from the lower control arm assembly. (3) Position lower control arm in arbor press with large end of pivot bushing inside Receiver, Special Tool MB-990799, and special tool supporting lower control arm (Fig. 1). Position Remover, Special Tool, 6642-2 on top of pivot bushing (Fig. 1). Using arbor press, press on lower control arm pivot bushing until it falls free of lower control arm. (4) Remove the pressed out lower control arm pivot bushing from the Receiver, Special Tool MB-990799 and discard. INSTALL (1) Turn the lower control arm over in the arbor press. So it is positioned on Receiver, Special Tool, MB-990799 as shown in (Fig. 2). (2) Position new pivot bushing in lower control arm so it is square with the bushing hole. Position Installer, Special Tool 6644-1 on top of pivot bushing, with pivot bushing setting in recessed area of Installer (Fig. 2). Bring down ram of arbor press until it is close to Installer, Special Tool. Then square face

SUSPENSION AND DRIVESHAFTS

Fig. 1 Lower Control Arm Pivot Bushing Removal

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Fig. 3 Pivot Bushing Installed In Lower Control Arm

of Installer, Special Tool 6644-1 with end of ram on arbor press and start to press bushing into lower control arm.

Fig. 4 Tension Strut Installed In Lower Control Arm. Arm Installation in this section of the service manual for the required installation procedure.

Fig. 2 Installing Lower Control Arm Pivot Bushing (3) Press lower control arm pivot bushing into lower control arm until Installer, Special Tool 6644-1 squarely bottoms against surface of lower control arm (Fig. 3). When Installer, Special Tool, 6644-1 squarely touches surface of control arm stop installing bushing. When Installer, Special Tool 6644-1 squarely bottoms on control arm, bushing is installed to the correct position in control arm. (4) Install tension strut into tension strut bushing on the lower control arm assembly. Position tension strut in lower control as shown in (Fig. 4), with word FRONT stamped in tension strut positioned away from control arm. With an open end wrench on flat of tension strut to stop tension strut from turning. Torque NEW tension strut to lower control retaining nut to 150 Nzm (110 ft. lbs.) (5) Install lower control arm and tension strut as an assembly back on the vehicle. See Lower Control

TENSION STRUT BUSHING REMOVE To perform removal and replacement of the lower control arm tension strut bushing. The control arm and tension strut assembly must be removed from the vehicle. The removal and replacement of the lower control arm tension strut bushing must be performed using an arbor press. (1) Remove lower control arm and tension strut as an assembly from the vehicle. See Lower Control Arm Removal in this section of the service manual for the required removal procedure. (2) Separate the tension strut from the lower control arm assembly. (3) Position lower control arm in arbor press with tension strut bushing inside Receiver, Special Tool MB-990799 and special tool supporting lower control arm (Fig. 5). Position Remover, Special Tool, 6644-4 on top of tension strut bushing (Fig. 5). Using the ar-

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SUSPENSION AND DRIVESHAFTS

bor press, press Remover, Special Tool, 6644-4 down through the tension strut bushing until the arbor press can push it no farther. As Remover, Special Tool, 6644-4 is pressed down through tension strut bushing it will cut the bushing into two pieces.

Fig. 6 Installing Tension Strut Bushing Into Lower Control Arm

Fig. 5 Removing Lower Control Arm Tension Strut Bushing (4) Remove lower control arm assembly from arbor press. Remove pieces of tension strut and Remover, Special Tool 6644-4, from lower control arm. INSTALL (1) Thoroughly lubricate the replacement tension strut bushing, lower control arm and Installer, Special Tool 6644-3 using Mopart Silicone Spray Lube or an equivalent. (2) By hand, install tension strut bushing into large end of Installer, Special Tool 6644-3. Press bushing into installer as far as it will go by hand. (3) Position lower control arm in arbor press, so tension strut hole in lower control arm is centered on Receiver, Special Tool MB-990799. (Fig. 6). Position Installer, Special Tool 6644-3 with previously installed bushing, inside of tension strut bushing hole in lower control arm (Fig. 6). Position Installer, Special Tool 6644-2 on top of tension strut bushing (Fig. 6). Using the arbor press, press the tension strut bushing into the lower control arm. As the bushing is being pressed into the control arm a pop will be heard. When the pop is heard Installer, Special Tool 6644-3 will slightly move up off the control arm. At this time remove the control arm assembly from the arbor press and pull Special Tool 6644-3 off the tension strut bushing in the control arm. Tension strut bushing is now installed.

joint is found to be defective, the entire lower control arm will need to be replaced. Do not attempt any type of repair on the ball joint assembly.

INSPECTION BALL JOINT WEAR Raise front of vehicle using jack stands or a frame contact type hoist, until front suspension is in full rebound and tires are not in contact with the ground. Grasp tire at top and bottom, and apply an in and out on the wheel and tire. While applying force to the tire, look for any movement between the lower ball joint and lower control arm. If any movement is evident the lower ball joint is worn and the lower control arm requires replacement. BALL JOINT SEAL INSTALLATION (1) By hand, initially install the ball joint seal on the lower control arm. (2) Lower control arm is to be supported using a 1 1/4 inch socket (Fig. 7). Position the 1 1/4 inch socket, lower control arm and Seal Installer, Special Tool MB-990800 in an arbor press (Fig. 7).

BALL JOINTS The lower front suspension ball joints operate with no free play. See Inspection Ball Joint Wear to determine if the ball joint is worn and requires replacement. The ball joints are not replaceable as a separate component of the lower control arm assembly. If a ball

Fig. 7 Installing Ball Joint Seal

SUSPENSION AND DRIVESHAFTS (3) Using Installer, Special Tool MB-990800, press seal onto ball joint housing until it is squarely seated against top surface of control arm (Fig. 7).

SERVICING STABILIZER BAR AND BUSHINGS The stabilizer bar interconnects the front MacPherson strut assemblies of the vehicle and attaches to the front cradle of the vehicle (Fig. 1). Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to stabilize body roll.

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Attachment of stabilizer bar to cradle assembly, is through rubber-isolated bushings (Fig. 1). Stabilizer bar to strut assembly attachment is done utilizing a stabilizer bar link (Fig. 1). All parts are serviceable, and the stabilizer bar to cradle isolator bushings are split for easy removal and installation. The split in the stabilizer bar to crossmember bushing should be positioned toward the front of the vehicle.

Fig. 1 Front Stabilizer Bar And Stabilizer Bar Mounting

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SUSPENSION AND DRIVESHAFTS STABILIZER BAR ISOLATOR BUSHING SERVICE If only the stabilizer bar isolator bushings require service without any service to the stabilizer bar. The stabilizer bar isolator bushings can be removed from the stabilizer bar without requiring the stabilizer bar to be removed from the vehicle. ISOLATOR BUSHING REMOVAL (1) Remove the 2 bolts each, attaching the stabilizer bushing retainer and bushing to cradle assembly (Fig. 2).

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stabilizer bar, so lower part of stabilizer bar is centered in the middle of the cradle assembly. Failure to do this may cause stabilizer bar to come in contact with other suspension components. (2) Align the stabilizer bar bushing retainers with the mounting holes in the cradle assembly (Fig. 2). Install but do not tighten the 4 bushing retainer to cradle assembly mounting bolts. The 4 retaining bolts will be torqued when vehicle is lowered to the ground. (3) Lower vehicle to the ground. (4) With the full weight of the vehicle supported by the suspension. Use a long extension, and torque the 4 stabilizer bar bushing retainer to cradle assembly attaching bolts to 55 Nzm (40 ft. lbs.).

STABILIZER BAR REMOVAL When removing the front stabilizer bar from the L.H. platform vehicle, it is necessary to remove the entire front cradle module (Fig. 4) from vehicle.

Fig. 2 Stabilizer Bar Isolator Bushing Attachment To Cradle (2) Remove the stabilizer bar isolator bushing retainers from the isolator bushings. (3) Inspect for broken or distorted retainers and bushings. If bushing replacement is required, bushing can be removed by opening slit in bushing and removing bushing from around stabilizer bar. The stabilizer bar to cradle assembly bushings, should be positioned on stabilizer bar, so slit in bushing is positioned toward front of vehicle (Fig. 3).

Fig. 4 L.H. Platform Front Cradle SUPPORTING ENGINE To allow for removal of the cradle module assembly from the vehicle. It will be necessary to support the engine and transaxle assembly using Fixture, Engine Support, Special Tool 7137 or equivalent. Refer to (Fig. 5 to 9) for engine supporting locations depending on engine application. CAUTION: No attempt should be made to support or lift either engine application using the intake manifold, or any other location on engine not specified below.

Fig. 3 Isolator Bushings Installed On Stabilizer Bar ISOLATOR BUSHING INSTALLATION (1) Install the isolator bushing retainers back on the stabilizer bar isolator bushings. CAUTION: When stabilizer bar is installed. Position

3.3 LTR ENGINE (1) Mount Fixture, Engine Support Special Tool 7137 or equivalent across engine compartment (Fig. 5). Using nylon webbing material such as seat belt

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SUSPENSION AND DRIVESHAFTS

material or equivalent, mount it to the following locations on the 3.3 ltr. engine. (2) Remove bolt attaching A/C compressor bracket to front of engine. Install webbing material hook on A/C compressor bolt, install bolt and tighten (Fig. 5 and 6). (3) Loosen but do not remove generator to engine mounting bolt, remove spacer between generator and engine. Install webbing material hook between generator and engine, re-install and tighten original bolt (Fig. 5 and 6). (4) Remove electronic ignition coil, mounting bracket bolt from rear of engine. Install webbing material hook on bracket bolt and re-install and tighten bolt. Note: Route webbing material between fuel injector rail and valve cover, not between fuel injector rail and intake manifold. (5) Mount remaining piece of webbing material to left cylinder head using threaded hole on back of cylinder head. Using a bolt of the correct thread size and length, install webbing hook on bolt. Then install bolt into threaded hole on back of cylinder head and tighten bolt. (6) Securely attach pieces of webbing material to hook on engine holding fixture (Fig. 5). Tighten hook on engine holding fixture until all slack is removed from all 4 pieces of webbing material.

Fig. 6 Front Engine Support Attaching Locations 3.3 Ltr. of the correct thread size and length, install webbing hook on bolt. Then install bolt into threaded hole on back of cylinder heads and tighten bolt. (5) Securely attach pieces of webbing material to hook on engine holding fixture (Fig. 7). Tighten hook on engine holding fixture until all slack is remove from all 4 pieces of webbing material.

Fig. 5 Engine Supporting Fixture Installed 3.3 Ltr. 3.5 LTR ENGINE (1) Mount Fixture, Engine Support Special Tool 7137 or equivalent across engine compartment (Fig. 7). Using nylon webbing material such as seat belt material or equivalent, mount it to the following locations on the 3.5 ltr. engine. (2) Remove bolt attaching timing belt housing to front of engine assembly (Fig. 7 and 8). Install webbing material hook on timing belt housing attaching bolt, install bolt and tighten (Fig. 7 and 8). (3) Remove generator to generator mounting bracket attaching nut and bolt (Fig. 9). Install webbing material hook on generator mounting bolt, reinstall and tighten original nut and bolt (Fig. 9). (4) Mount remaining pieces of webbing material to back of right and left cylinder head using the threaded hole on back of cylinder heads. Using a bolt

Fig. 7 Engine Supporting Fixture Installed 3.5 Ltr. CRADLE ASSEMBLY REMOVAL ALL ENGINES (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove both front wheel and tire assemblies from the vehicle.

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CAUTION: When lower control is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle. (4) Carefully insert a pry bar between lower control arm and steering knuckle (Fig. 11), to separate ball joint stud from steering knuckle (Fig. 11). Note: Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut.

Fig. 8 Front Engine Support Attachment To Timing Belt Housing

CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner tripod joint. See Driveshafts.

Fig. 11 Separating Ball Joint From Steering Knuckle Fig. 9 Front Engine Support Attachment To Generator Bracket (3) Remove left and right ball joint stud to steering knuckle clamp nut and bolt (Fig. 10).

(5) Remove ground strap from cradle assembly. Ground strap is located on right side of cradle below half shaft (Fig. 12).

Fig. 12 Ground Strap Fig. 10 Control Arm To Steering Knuckle Attachment

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(6) Remove the 4 nuts attaching motor mounts to cradle assembly (Fig. 13).

Fig. 15 Stabilizer Bar Isolator Bushing Attachment To Cradle MOVE CRADLE WITHOUT USING JACK STANDS TO SUPPORT COMPONENTS. (9) Position a jack stand under front of cradle and at center of transaxle to cradle assembly mount (Fig. 16). Raise jack stand at transaxle mount until transaxle mount just lifts off cradle assembly.

Fig. 13 Motor Mount To Cradle Assembly Attachment (7) Remove the 4 bolts attaching transaxle mount to rear of cradle assembly (Fig. 14).

Fig. 16 Jack Stands Supporting Cradle And Transaxle

Fig. 14 Transmission Mount To Cradle Assembly Mounting Bolts (8) Remove the 2 bolts each, attaching the stabilizer bushing retainer and bushing to cradle assembly (Fig. 15). WARNING: THE JACK STANDS ARE REQUIRED TO SUPPORT CRADLE ASSEMBLY AND TRANSAXLE ASSEMBLY DURING CRADLE ASSEMBLY REMOVAL FROM VEHICLE. DO NOT ATTEMPT TO RE-

(10) Cradle assembly is now ready to be removed from vehicle using the following procedure. A helper will be required when removing cradle assembly from vehicle. • Loosen but do not fully remove the 2 rear cradle assembly to body attaching bolts (Fig. 17). • Loosen and remove the 2 front cradle assembly to body attaching bolts (Fig. 17). • With a helper supporting rear of cradle assembly and the jack stand supporting transaxle. Remove the 2 rear cradle assembly to body attaching bolts (Fig. 17).

SUSPENSION AND DRIVESHAFTS â&#x20AC;˘ Slowly lower front jack stand until weight of engine is supported by engine support fixture and motor mount bolts are clear of cradle assembly. With a helper at rear of cradle assembly, lift front of cradle assembly off jack stand and remove from vehicle.

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bushing from around stabilizer bar. The stabilizer bar to cradle assembly bushings, should be positioned on stabilizer bar, so slit in bushing is positioned toward front of vehicle (Fig. 19).

Fig. 19 Isolator Bushings Installed On Stabilizer Bar CRADLE ASSEMBLY INSTALLATION ALL ENGINES (1) Install stabilizer bar, isolator bushings and retainers back in vehicle as an assembly (Fig. 18). Be sure stabilizer bar in installed through openings in splash shields (Fig. 18). Install the stabilizer bar link to stabilizer bar attaching nuts. Torque stabilizer bar link to stabilizer bar attaching nut to 95 Nzm (70 ft. lbs.). (2) Tie stabilizer bar up against the 2 transaxle to engine block brackets (Fig. 20). This will keep stabilizer bar out of the way when installing cradle assembly.

Fig. 17 Cradle Assembly To Body Attaching Locations (11) After cradle assembly is removed from vehicle. Remove the 2 stabilizer bar, to stabilizer bar link attaching nuts (Fig. 18). Remove stabilizer bar assembly from vehicle.

Fig. 20 Stabilizer Bar Stored For Cradle Installation

Fig. 18 Stabilizer Bar Removal And Installation STABILIZER BAR AND BUSHING INSPECTION Inspect for broken or distorted retainers and bushings. If bushing replacement is required, bushing can be removed by opening slit in bushing and removing

(3) With the aid of a helper raise cradle assembly (Fig. 1) back up into vehicle, resting front of cradle assembly on a jack stand. Then use following procedure to install cradle assembly back into vehicle. â&#x20AC;˘ With the aid of a helper, raise rear of cradle assembly up far enough by hand to start the 2 rear cradle assembly to body attaching bolts (Fig. 21). Install bolts far enough to securely hold cradle assembly in place but DO NOT TIGHTEN.

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• Using jack stand raise front of cradle assembly up against bottom of motor mounts. Be sure all 4 motor mount studs come through holes in cradle assembly. • Continue to raise cradle assembly and engine using jack stand until the 2 front cradle assembly to body attaching bolts (Fig. 21) can be started. • Lower transaxle and align transaxle mount with the 4 transaxle mount attaching holes in the cradle assembly. Install BUT DO NOT TIGHTEN the 4 transaxle mount to cradle assembly attaching bolts (Fig. 14). The 2 long bolts go in the front cradle assembly to transaxle mount holes. CAUTION: Before tightening cradle assembly to body attaching bolts. Check that all 4 cradle assembly to body mounting bolts are installed straight into mounting plates in frame rails and mounting plates are not cocked inside the frame rails. • Using a crisscross pattern, tighten all 4 cradle assembly to body attaching bolts (Fig. 21) until cradle is seated up against body. Then repeating the crisscross pattern, torque all 4 cradle assembly to body mounting bolts to 155 Nzm (115 ft. lbs.).

Fig. 22 Transmission Mount To Cradle Assembly Mounting Bolts CAUTION: When stabilizer bar is installed. Position stabilizer bar, so lower part of stabilizer bar is centered in the middle of the cradle assembly. Failure to do this may cause stabilizer bar to come in contact with other suspension components. (5) Untie the stabilizer bar from brackets and position it on cradle assembly. Align the stabilizer bar bushing retainers with the mounting holes in the cradle assembly (Fig. 15). Install but do not tighten the 4 bushing retainer to cradle assembly mounting bolts. The 4 retaining bolts will be torqued when vehicle is lowered to the ground. (6) Install the 4 motor mount to cradle assembly attaching nuts (Fig. 13). Torque the 4 nuts to 61 Nzm (45 ft. lbs). (7) Install ground strap on cradle assembly (Fig. 12). Be sure ground strap to cradle screw is securely tightened. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. See Driveshafts. CAUTION: When ball joint stud is installed into steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle.

Fig. 21 Cradle Assembly To Body Attaching Bolts (4) Tighten the 4 transaxle mount to cradle assembly mounting bolts (Fig. 22).

(8) Install lower ball joint studs into steering knuckles. Install steering knuckle to lower ball joint stud, clamp bolts and nuts into steering knuckles (Fig. 23). Torque clamp bolt to 55 Nzm (40 ft. lbs.). (9) Install the wheel and tire assembly. (10) Tighten the wheel mounting stud nuts in proper sequence (Fig. 24) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.). (11) Lower vehicle to the ground.

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The front suspension knuckle is not a serviceable component. Do not attempt to straighten or repair the front suspension knuckle in any way. Service repair or replacement of the front (drive) hub and bearing, can be done with the front suspension knuckle remaining on the vehicle.

Fig. 23 Control Arm To Steering Knuckle Attachment

Fig. 24 Tightening Wheel Nuts

Fig. 1 Front Knuckle Assembly

(12) With the full weight of the vehicle supported by the suspension. Use a long extension, and torque the 4 stabilizer bar bushing retainer to cradle assembly attaching bolts to 55 Nzm (40 ft. lbs.). (13) Remove the webbing material from the engine and the engine support fixture from the vehicle. (14) Position vehicle on an alignment rack and check that the vehicles Toe is within specifications. Adjust the vehicle Toe setting if not within specifications.

REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove the front wheel and tire assembly from the vehicle. (3) Remove the front caliper assembly from the front steering knuckle assembly (Fig. 2). Refer to Front Disc Brake Service in the Brake Section of this service manual for caliper removal procedure. (4) Remove front braking disk (rotor) from hub, by pulling it straight off wheel mounting studs (Fig. 3). (5) Remove screw attaching ABS speed sensor head to steering knuckle. Speed sensor head should be removed from steering knuckle, to avoid damage to speed sensor by outer C/V joint when hub and bearing is removed. (6) Carefully, remove sensor head from steering knuckle. If the sensor has seized, due to corrosion,

STEERING KNUCKLE SERVICE The front suspension knuckle (Fig. 1) provides for steering control of the vehicle. Supports the brake caliper and absorbs the loads exerted during vehicle braking. It also supports the front (driving) hub and bearing and stub axle assembly. The front suspension knuckle also provides the ability to align the front wheels of the vehicle. This is done by allowing for front wheel Toe adjustment.

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SUSPENSION AND DRIVESHAFTS

Fig. 2 Disc Brake Caliper Mounting

Fig. 4 Speed Sensor Head Removal (Typical)

Fig. 5 Hub And Bearing To Stub Axle Retaining Nut

Fig. 3 Removing Braking Disc DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and punch (Fig. 4) to tap edge of sensor ear, rocking sensor side to side until free. (7) Remove the hub and bearing to stub axle retaining nut (Fig. 5). (8) Remove the 3 steering knuckle to hub and bearing assembly attaching bolts (Fig. 6). CAUTION: If metal seal (Fig. 7) on hub and bearing assembly is seized to steering knuckle and becomes dislodged on hub and bearing assembly during bearing removal. The hub and bearing assembly MUST not be re-used and MUST be replaced with a new hub and bearing assembly. Also if flinger disc (Fig. 7) becomes damaged (bent or dented) during removal, hub and bearing assembly must be replaced with a new hub and bearing assembly.

Fig. 6 Hub And Bearing Assembly Retaining Bolts (9) Remove hub and bearing assembly from steering knuckle. It is removed by sliding it straight out of steering knuckle and off end of stub axle (Fig. 8). If hub and bearing assembly will not slide out of knuckle, insert a pry bar between hub and bearing

SUSPENSION AND DRIVESHAFTS

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Fig. 9 Prying Hub And Bearing Assembly From Steering Knuckle

Fig. 7 Hub And Bearing Assembly Seal assembly and steering knuckle (Fig. 9) and gently pry hub and bearing from knuckle. If stub shaft is frozen to hub and bearing assembly tap end of stub shaft with soft face hammer to free it from hub and bearing spline.

Fig. 10 Control Arm To Steering Knuckle Attachment (11) Carefully insert a pry bar between lower control arm and steering knuckle (Fig. 11). Push down on pry bar to separate ball joint stud from steering knuckle (Fig. 11). Note: Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut.

Fig. 8 Hub And Bearing Assembly Removal And Installation (10) Remove the ball joint stud to steering knuckle clamp nut and bolt (Fig. 10). CAUTION: When lower control arm is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle.

CAUTION: The strut assembly to steering knuckle bolts are serrated were they go through strut assembly and steering knuckle. When removing bolts, turn nuts off bolts DO NOT TURN BOLTS IN STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result. (12) Remove the strut assembly to steering knuckle attaching bolts (Fig. 12). (13) Remove the steering knuckle from the vehicle.

INSTALL (1) Install steering knuckle on ball joint stud. Install steering knuckle to lower ball joint stud, clamp

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SUSPENSION AND DRIVESHAFTS (2) Position steering knuckle neck into strut assembly. CAUTION: The strut assembly to steering knuckle bolts are serrated where they go through strut assembly and steering knuckle. When installing bolts, turn nuts onto bolts DO NOT TURN BOLTS IN STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result. (3) Install the strut assembly to steering knuckle attaching bolts (Fig. 12). Install nuts on attaching bolts (Fig. 12). Torque the strut assembly to steering knuckle attaching bolt nuts to 169 Nzm (125 ft. lbs.). TURN NUTS ON BOLTS DO NOT TURN BOLTS.

Fig. 11 Separating Ball Joint From Steering Knuckle

CAUTION: Hub and bearing assembly mounting surfaces on steering knuckle and halfshaft (Fig. 14) must be smooth and completely free of foreign material or nicks.

Fig. 12 Strut Assembly To Steering Knuckle Attaching Bolts bolt and nut into steering knuckle (Fig. 13). Torque clamp bolt to 55 Nzm (40 ft. lbs.).

Fig. 14 Hub And Bearing Assembly Mounting Surfaces CAUTION: When installing hub and bearing assembly into steering knuckle, be careful not to damage the flinger disc (Fig. 7) on hub and bearing assembly. If flinger disc becomes damaged, hub and bearing assembly MUST not be used and MUST be replaced with a new hub and bearing assembly.

Fig. 13 Control Arm To Steering Knuckle Attachment

(4) Install hub and bearing assembly onto stub shaft and into steering knuckle until squarely seated on face of steering knuckle. (Fig. 8). (5) Install the 3 steering knuckle to hub and bearing assembly attaching bolts (Fig. 15). Equally tighten all 3 mounting bolts until hub and bearing assembly is squarely seated against front of steering knuckle. Then torque all 3 hub and bearing assembly mounting bolts to 110 Nzm (80 ft.lbs.)

SUSPENSION AND DRIVESHAFTS

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Fig. 15 Hub And Bearing Assembly Retaining Bolts CAUTION: The hub and bearing assembly to stub shaft retaining nut (Fig. 16) is a prevailing torque nut and can not be re-used. A NEW retaining nut MUST be used when assembled. (6) Install a NEW hub and bearing assembly to stub shaft retaining nut (Fig. 16). Tighten, but do not torque the hub nut at this time.

Fig. 17 Installing Braking Disc

Fig. 16 Hub And Bearing To Stub Axle Retaining Nut (7) Coat speed sensor head with High Temperature Multi-purpose E.P. Grease before installing into the steering knuckle. Install speed sensor head into steering knuckle. Install screw tighten to 7 Nzm (60 in. lbs.). (8) Install the braking disk back on the hub and bearing assembly (Fig. 17). (9) Install front brake caliper back over braking disc and align with caliper mounting holes on steering knuckle (Fig. 18). Refer to Front Disc Brake Service in the Brake Section of this service manual for caliper installation procedure. Install the caliper to steering knuckle attaching bolts and torque to 19 Nzm (168 in. lbs.).

Fig. 18 Disc Brake Caliper Mounting (10) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence (Fig. 19) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nzm (95 ft. lbs.). (11) Lower vehicle to the ground.

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SUSPENSION AND DRIVESHAFTS 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 02-13-94 September 23, 1994

(2) Remove the front wheel and tire assembly from the vehicle. (3) Remove the front caliper assembly from the front steering knuckle assembly (Fig. 1). Refer to Front Disc Brake Service in the Brake Section of this service manual for caliper removal procedure.

Fig. 19 Tightening Wheel Nuts CAUTION: When torquing hub and bearing assembly to stub shaft retaining nut, do not exceed the maximum torque of 176 Nzm (130 ft. lbs.). If the maximum torque is exceeded this may result in a failure of the drive shaft.

Fig. 1 Disc Brake Caliper Mounting (12) With the vehicle brakes applied to keep vehicle from moving. Tighten the NEW stub shaft to hub and bearing assembly retaining nut to 163 Nzm Âą 14 (120 ft. lbs. Âą 10) (Fig. 20).

(4) Remove front braking disk (rotor) from hub, by pulling it straight off wheel mounting studs (Fig. 2).

Fig. 20 Tighten Hub And Bearing Retaining Nut

HUB AND BEARING ASSEMBLY This unit is serviced only as a complete assembly. It is mounted to the steering knuckle by 3 mounting bolts that are removed from the rear of the steering knuckle.

Fig. 2 Removing Braking Disc (5) Remove the hub and bearing to stub axle retaining nut (Fig. 3). (6) Remove the 3 steering knuckle to hub and bearing assembly attaching bolts (Fig. 4).

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Fig. 3 Hub And Bearing To Stub Axle Retaining Nut

Fig. 5 Hub And Bearing Assembly Seal and bearing assembly tap end of stub shaft with soft face hammer to free it from hub and bearing spline.

Fig. 4 Hub And Bearing Assembly Retaining Bolts CAUTION: If metal seal (Fig. 5) on hub and bearing assembly is seized to steering knuckle and becomes dislodged on hub and bearing assembly during bearing removal. The hub and bearing assembly MUST not be reused and MUST be replaced with a new hub and bearing assembly. CAUTION: When removing hub and bearing assembly from steering knuckle, be careful not to damage the flinger disc (Fig. 5) on hub and bearing assembly. If flinger disc becomes damaged, hub and bearing assembly MUST not be used and MUST be replaced with a new hub and bearing assembly. (7) Remove hub and bearing assembly from steering knuckle, by sliding it straight out of steering knuckle and off end of stub axle (Fig. 6). If hub and bearing assembly will not slide out of knuckle. Insert a pry bar between hub and bearing assembly and steering knuckle (Fig. 7) and gently pry hub and bearing from knuckle. If stub shaft is frozen to hub

Fig. 6 Hub And Bearing Assembly Removal And Installation INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on steering knuckle and halfshaft (Fig. 8) must be smooth and completely free of foreign material or nicks. CAUTION: When installing hub and bearing assembly into steering knuckle, be careful not to damage the flinger disc (Fig. 5) on hub and bearing assembly. If flinger disc becomes damaged, hub and bearing assembly MUST not be used and MUST be replaced with a new hub and bearing assembly.

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Fig. 7 Prying Hub And Bearing Assembly From Steering Knuckle

Fig. 9 Hub And Bearing Assembly Retaining Bolts

Fig. 10 Hub And Bearing To Stub Axle Retaining Nut Fig. 8 Hub And Bearing Assembly Mounting Surfaces (1) Install hub and bearing assembly onto stub shaft and into steering knuckle until squarely seated on face of steering knuckle. (Fig. 6). (2) Install the 3 hub and bearing assembly to steering knuckle attaching bolts (Fig. 9). Equally tighten all 3 mounting bolts until hub and bearing assembly is squarely seated against front of steering knuckle. Then torque all 3 hub and bearing assembly mounting bolts to 110 Nzm (80 ft.lbs.) CAUTION: The hub and bearing assembly to stub shaft retaining nut (Fig. 10) is a prevailing torque nut and can not be re-used. A NEW retaining nut MUST be used when assembled. (3) Install a NEW hub and bearing assembly to stub shaft retaining nut (Fig. 10). Tighten, but do not torque the hub nut at this time. (4) Install the braking disk back on the hub and bearing assembly (Fig. 11).

Fig. 11 Installing Braking Disc

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