2003 Chrysler PT Cruiser Service Repair Manual by 16326108

2003 PT Cruiser Service Manual

INTRODUCTION

INTRODUCTION TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE . . . . . DESCRIPTION - THREADED HOLE REPAIR INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .

...1 ...2

...5 ..5 ...5

page VEHICLE IDENTIFICATION NUMBER DESCRIPTION - VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 E-MARK LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 MANUFACTURER PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10

...6 ...8

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 1) is located in the engine compartment on the plenum behind the right side strut tower (Fig. 2). 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.

BODY CODE PLATE LINE 2 DIGITS 1, 2, AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for Body Color Codes. DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint DIGIT 13 AND 14 Open Space

Fig. 1 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN

DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space

INTRODUCTION

BODY CODE PLATE (Continued) DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • (Refer to VEHICLE DATA/VEHICLE INFORMATION/VEHICLE IDENTIFICATION NUMBER DESCRIPTION) for proper breakdown of VIN code.

Fig. 2 BODY CODE PLATE 2 1 - BODY CODE PLATE 2 - BODY CODE EMBOSS

DIGITS 20, 21, AND 22 Engine Code • EJD = 1.6L Four Cylinder 16 Valves SOHC Gasoline • ECC = 2.0L Four Cylinder 16 Valves DOHC Gasoline • EDJ = 2.2L Four Cylinder Turbo Diesel Engine • EDZ = 2.4L Four Cylinder 16 Valves DOHC Gasoline • EDV = 2.4L Four Cylinder 16 Valves DOHC H.O. Turbo Gasoline DIGIT 23 Open Space

BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGL = 41TE 4-Speed Electronic Automatic Transaxle • DD5 = NV T350 5-Speed Manual Transaxle • DDD = GETRAG 288 5-Speed Manual Transaxle DIGIT 4 Open Space

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 (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 3) and (Fig. 4).

INTRODUCTION

PT FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER IDENTIFICATION

INTRODUCTION

FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER STRENGTH

INTRODUCTION

FASTENER USAGE

DESCRIPTION - THREADED HOLE REPAIR

DESCRIPTION

Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.

DESCRIPTION - FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 5) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

Fig. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 2 3 4 5 6 7 8 9 10 11 12

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter

INTRODUCTION

The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

TO GET

MULTIPLY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

x 3.281

= Feet

Yards

x 0.9144

= Meters

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m).

Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 6).

INTRODUCTION

PT METRIC SYSTEM (Continued)

Fig. 6 METRIC CONVERSION CHART

INTRODUCTION

TORQUE REFERENCES

tions Chart for torque references not listed in the individual torque charts (Fig. 7).

DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-

Fig. 7 TORQUE SPECIFICATIONS

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER DESCRIPTION - VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left A-Pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle (Fig. 8). Refer to VIN Code Decoding 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. 8 VEHICLE IDENTIFICATION NUMBER LOCATION 1 - Vehicle Identification Number (VIN) 2 - Instrument Panel

VIN CODE DECODING POSITION

INTERPRETATION

Country of Origin

Make

Vehicle Type

Other

Line

5 - Export

Line

CODE = DESCRIPTION 1 = Built in United States by DiamlerChrysler 3 = Built in Mexico by DiamlerChrysler De Mexico C = Chrysler 4 = Multi-purpose Passenger Vehicle Less Side Air Bags 8 = Multi-purpose Passenger Vehicle with Side Air Bags F = 1815 - 2267 KG (4000 - 5000 lbs.) Y = Cruiser (LHD) E = Cruiser (LHD) Z = Cruiser (RHD) 4 = High Line

Series

5 = Premium 6 = Sport X = Special

6 - Export

Transmission

Body Style

Engine

B = 4-Speed Automatic N = 5-Speed Manual 8 = Hatchback 9 = 2.0L 4 Cyl. Gasoline DOHC (MPI) B = 2.4 L 4 Cyl. 16 Valve Gasoline DOHC G = 2.4 L 4 Cyl. 16 Valve Gasoline DOHC H.O. F = 1.6L 4 Cyl. 16V Gasoline SOHC

8 - Export

Engine

9 = 2.0L 4 Cyl. Gasoline DOHC (MPI) U = 2.2L 4 Cyl. Turbo Diesel Engine (MPI)

Check Digit

See explanation in this section.

Model Year

3 = 2003

Assembly Plant

12 Though 17

Vehicle Build Sequence

T = Toluca Assembly U = Graz Assembly 6 digit number assigned by assembly plant.

INTRODUCTION

VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label is attached to the rear shutface of the driver’s door (Fig. 9). 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.

Fig. 10 E-MARK LABEL 1 2 3 4

- COUNTRY CODE - REGULATION NUMBER - APPROVAL NUMBER - AMENDMENT NUMBER

the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

MANUFACTURER PLATE DESCRIPTION Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL TYPICAL

E-MARK LABEL DESCRIPTION An E-mark Label (Fig. 10) is located on the rear shut face of the driver’s door. The label contains the following information: • Date of Manufacture • Month-Day-Hour (MDH) • Vehicle Identification Number (VIN) • Country Codes • Regulation Number • Regulation Amendment Number • Approval Number

The Manufacturer Plate (Fig. 11) is located in the engine compartment on the passenger side rear corner of the hood. The plate contains five lines of information: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3. Gross Train Mass (GTM) 4. Gross Front Axle Rating (GFAR) 5. Gross Rear Axle Rating (GRAR)

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches

Fig. 11 MANUFACTURER PLATE

LUBRICATION & MAINTENANCE

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LUBRICATION & MAINTENANCE TABLE OF CONTENTS page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE OIL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE COOLANT . . DESCRIPTION - TRANSMISSION FLUID DESCRIPTION - FUEL REQUIREMENTS FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES . FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . .

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... ... .. ..

. . . .

.1 .3 .3 .3

......5

page LUBRICATION POINTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 HOISTING STANDARD PROCEDURE - HOISTING . . . . . . . 14 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TOWING STANDARD PROCEDURE - TOWING . . . . . . . . 15

......5

INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).

Fig. 1 INTERNATIONAL SYMBOLS

FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE OIL AND LUBRICANTS 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. When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI)

API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified (GF-3). MOPARt provides engine oils, meeting Material Standard MS-6395, that meet or exceed this requirement.

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

SAE VISCOSITY

SYNTHETIC ENGINE OILS

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 2). • SAE 5W-30 engine oil is preferred. SAE 5W-30 engine oils improve low temperature starting and helps vehicle fuel economy.

There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that meet the American Petroleum Institute (API) and SAE viscosity standard. Follow the service schedule that describes your driving type.

MATERIALS ADDED TO ENGINE OIL The manufacturer does not recommend the addition of any additive to the specified engine oil.

GEAR LUBRICANTS SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W90.

LUBRICANTS AND GREASES

Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 4) 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 latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans (Fig. 3). This symbol means that the oil has been certified by the American Petroleum Institute (API). DiamlerChrysler only recommends API Certified (GF-3) engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395.

Fig. 4 NLGI SYMBOL 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

SPECIALIZED LUBRICANTS AND OILS Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the correct application of these lubricants.

Fig. 3 API SYMBOL

LUBRICATION & MAINTENANCE

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FLUID TYPES (Continued)

DESCRIPTION - ENGINE COOLANT 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 OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an

emergency, it should be replaced with the specified coolant as soon as possible.

DESCRIPTION - TRANSMISSION FLUID NOTE: Refer to the maintenance schedules in the Owner’s Manual for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well.

TRANSMISSION FLUID Mopart ATF+4 (Automatic Transmission FluidType 9602) is required in the 41TE automatic. Substitute fluids can induce torque converter clutch shudder. Mopart ATF+4 (Automatic Transmission FluidType 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure. G288 and T350 Manual transaxles require the use of Mopart ATF+4 (Automatic Transmission Fluid) FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommended. The use of premium

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued) gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available.

REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as “reformulated” gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components.

line retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline.

SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section.

GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle.

MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions.

CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components.

FUEL SYSTEM CAUTIONS

MMT IN GASOLINE

• The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. • An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. • When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the tem-

MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasoline free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gaso-

CAUTION: Follow these guidelines to maintain your vehicle’s performance:

LUBRICATION & MAINTENANCE

0-5

FLUID TYPES (Continued) perature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. • The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you.

FLUID FILL/CHECK LOCATIONS DESCRIPTION The fluid check/fill point locations are located in each applicable service manual section.

LUBRICATION POINTS DESCRIPTION Lubrication point locations are located in each applicable Sections.

MAINTENANCE SCHEDULES FLUID CAPACITIES

DESCRIPTION

SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

Fuel Tank

57L (15 gal.)

Engine Oil* - 1.6L

4.3L (4.5 qts.)

Engine Oil* - 2.0L

4.3L (4.5 qts.)

Engine Oil* - 2.2L Diesel

7.0L (7.4 qts.)

Engine Oil* - 2.4L

4.8L (5.0 qts.)

Cooling System** - 1.6L, 2.0L, and 2.4L

6.2L (6.5 qts.)

Cooling System** - 2.2L Diesel

9.0L (9.5 qts.)

Automatic Transaxle Estimated Service Fill

3.8L (4.0 qts.)

Automatic Transaxle Overhaul Fill Capacity with Torque Converter Empty

8.1L (8.6 qts.)

Manual Transaxle - NV T350 Manual Transaxle Getrag 288

2.4 - 2.7L (2.5 - 2.8 qts.) 2.2L Turbo Diesel: 2.0L (2.1 qts.) 2.4L Turbo: 1.8L (1.9 qts.)

*(includes new filter) **(Includes heater and coolant recovery bottle filled to MAX level.)

Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual. There are three maintenance schedules that show required service for your vehicle. First is Schedule “B”—ALL ENGINES. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. • Day or night temperatures are below 0° C (32° F). • Stop and go driving. • Extensive engine idling. • Driving in dusty conditions. • Short trips of less than 16 km (10 miles). • More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F).† • Trailer towing.†L • Taxi, police, or delivery service (commercial service).†L • Off-road or desert operation. • If equipped for and operating with E-85 (ethanol) fuel. NOTE: Most vehicles are operated under the conditions listed for Schedule (B(. Second is Schedule “A”—NON TURBO CHARGED ENGINES. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9—ALL ENGINES. Second is Schedule “A”—TURBO CHARGED ENGINES. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9—ALL ENGINES. Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.

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LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel • Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. • Check the windshield washer solvent and add if required. Once a Month • Check tire pressure and look for unusual wear or damage. • Inspect the battery and clean and tighten the terminals as required. • Check the fluid levels of coolant reservoir, brake master cylinder, power steering and transaxle and add as needed. • Check all lights and all other electrical items for correct operation. • Check rubber seals on each side of the radiator for proper fit. At Each Oil Change • Change the engine oil filter. • Inspect the exhaust system. • Inspect the brake hoses. • Inspect the CV joints and front suspension components. • Check the automatic transaxle fluid level. • Check the manual transaxle fluid level and fill plug condition. Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings.

• Check the coolant level, hoses, and clamps. • Rotate the tires at each oil change interval shown on Schedule “A”—NON TURBO CHARGED ENGINES 10 000 km (6,000 miles), Schedule “A”— TURBO CHARGED ENGINES 8 000 km (5,000 miles), or every other interval shown on Schedule “B”—ALL ENGINES 10 000 km (6,000 miles).

SCHEDULE “B”—ALL ENGINES Follow schedule “B”—All Engines if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 77 000 km (48,000 miles) if the vehicle is usually operated under one or more of the conditions marked with an L. Change the manual transaxle fluid every 77 000 km (48,000 miles) if the vehicle is usually operated under one or more of the conditions marked with an †. • Day or night temperatures are below 0° C (32° F). • Stop and go driving. • Extensive engine idling. • Driving in dusty conditions. • Short trips of less than 16.2 km (10 miles). • More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F).† • Trailer towing.†L • Taxi, police, or delivery service (commercial service).†L • Off-road or desert operation. • If equipped for and operating with E-85 (ethanol) fuel.

3,000

6,000

9,000

12,000

15,000

18,000

(5 000)

(10 000)

(14 000)

(19 000)

(24 000)

(29 000)

Inspect the engine air cleaner filter.Replace as necessary.*

Inspect the PCV make-up air filter. Replace as necessary.

Inspect the generator belt, and replace as necessary.

Inspect and adjust the power steering pump belt tension.

LUBRICATION & MAINTENANCE

0-7

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers) Change engine oil and engine oil filter.

21,000

24,000

27,000

30,000

33,000

36,000

(34 000)

(38 000)

(43 000)

(48 000)

(53 000)

(58 000)

Inspect the brake linings.

Replace the engine air cleaner filter.

Replace the spark plugs.

Inspect the tie rod ends and boot seals.

Inspect the PCV valve and replace as necessary.*

Replace the PCV make-up air filter.

Inspect and adjust the power steering pump belt tension.

Inspect the generator belt, and replace as necessary.

Miles (Kilometers) Change engine oil and engine oil filter.

39,000

42,000

45,000

48,000

51,000

54,000

(62 000)

(67 000)

(72 000)

(77 000)

(82 000)

(86 000)

Inspect the brake linings.

Change the brake fluid. If vehicle is used for trailer towing.

Inspect the engine air cleaner filter. Replace as necessary.*

Change the automatic transaxle fluid and filter.

Change the manual transaxle fluid.

Inspect the PCV make-up air filter. Replace as necessary.

Inspect and adjust the power steering pump belt tension.

Inspect the generator belt, and replace as necessary.

0-8

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers) Change engine oil and engine oil filter.

57,000

60,000

63,000

66,000

69,000

72,000

(91 000)

(96 000)

(101 000)

(106 000)

(110 000)

(115 000)

Inspect the brake linings.

Replace the engine air cleaner filter.

Replace the spark plugs and ignition cables.

Inspect the tie rod ends and boot seals.

Inspect the PCV valve and replace if necessary. Not required if previously changed. * â&#x20AC;Ą

Inspect the PCV make-up air filter. Replace as necessary.

Inspect and adjust the power steering pump belt tension.

Inspect the generator belt, and replace as necessary.

Miles (Kilometers) Change engine oil and engine oil filter.

75,000

78,000

81,000

84,000

87,000

90,000

(120 000)

(125 000)

(130 000)

(134 000)

(139 000)

(144 000)

Inspect the brake linings. Inspect the engine air cleaner filter and replace as necessary.*

X X

Replace the engine air cleaner filter.

Replace the spark plugs.

Inspect the tie rod ends and boot seals.

Inspect the PCV valve and replace if necessary. Not required if previously changed. * â&#x20AC;Ą

Replace the engine timing belt.*

Inspect the PCV make-up air filter. Replace as necessary.

Inspect and adjust the power steering pump belt tension.

Inspect the generator belt, and replace as necessary.

X X X

LUBRICATION & MAINTENANCE

0-9

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers) Change engine oil and engine oil filter.

93,000

96,000

99,000

100,000

102,000

105,000

(149 000)

(154 000)

(158 000)

(160 000)

(163 000)

(168 000)

Inspect the brake linings.

Change the brake fluid. If vehicle is used for trailer towing.

Inspect the engine air cleaner filter and replace as necessary.* Change the automatic transaxle fluid and filter.

Change the manual transaxle fluid.

Flush and replace the engine coolant at 60 months or 100,000 miles.

Inspect the PCV make-up air filter. Replace as necessary.

Inspect and adjust the power steering pump belt tension.

Inspect the generator belt, and replace as necessary.

* This maintenance is recommended by the manufacturer to the owner but is not required to maintain the emissions warranty. â&#x20AC;Ą This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

0 - 10

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE “A”—NON TURBO CHARGED ENGINES Miles

6,000

12,000

18,000

24,000

30,000

36,000

(10 000)

(19 000)

(29 000)

(38 000)

(48 000)

(58 000)

[Months]

[6]

[12]

[18]

[24]

[30]

[36]

Change engine oil and engine oil filter.

(Kilometers)

Inspect the brake linings.

Replace the engine air cleaner filter.

Replace the spark plugs.

Inspect the tie rod ends and boot seals.

Replace the PCV make-up air filter.

Adjust generator drive belt tension

Miles (Kilometers) [Months] Change engine oil and engine oil filter. Inspect the brake linings.

42,000

48,000

54,000

60,000

66,000

(67 000)

(77 000)

(86 000)

(96 000)

(106 000)

[42]

[48]

[54]

[60]

[66]

Replace the engine air cleaner filter.

Replace the spark plugs and ignition cables.

Inspect the tie rod ends and boot seals.

and replace, if

Inspect the PCV valve

necessary.* Flush and replace the engine coolant at 60 months, regardless of mileage.

Replace the PCV make-up air filter.

Adjust generator drive belt tension.

LUBRICATION & MAINTENANCE

0 - 11

MAINTENANCE SCHEDULES (Continued) Miles

72,000

78,000

84,000

90,000

96,000

102,000

(115 000)

(125 000)

(134 000)

(144 000)

(154 000)

(163 000)

[72]

[78]

[84]

[90]

[96]

[102]

Change engine oil and engine oil filter.

Inspect the brake linings.

(Kilometers) [Months]

Replace the engine air cleaner filter.

Replace the spark plugs.

Inspect the tie rod ends and boot seals.

and replace if necessary. Not required if previously changed. * â&#x20AC;Ą

Inspect the PCV valve

Replace the PCV make-up air filter.

Replace power steering belt if necessary.

Adjust or replace, if necessary, generator drive belt.

Flush and replace the engine coolant if not done at 60 months.

Replace engine timing belt.

0 - 12

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE “A”—2.4L TURBO CHARGED ENGINES Miles (Kilometers)

5,000

10,000

15,000

20,000

25,000

30,000

(8 000)

(16 000)

(24 000)

(32 000)

(40 000)

(48 000)

[12]

[18]

[Months]

[6]

Change engine oil and engine oil filter.

Inspect the brake linings.

[24] X

Replace the engine air cleaner filter.

Replace the spark plugs.

Inspect the tie rod ends and boot seals.

Replace the PCV make-up air filter.

Adjust the generator drive belt tension.

Miles (Kilometers)

35,000

40,000

45,000

50,000

55,000

(56 000)

(64 000)

(72 000)

(80 000)

(88 000)

[36]

[42]

[Months]

[30]

Change engine oil and engine oil filter.

Inspect the brake linings. Miles

X 60,000

65,000

70,000

75,000

80,000

85,000

(96 000)

(104 000)

(112 000)

(120 000)

(128 000)

(136 000)

[48]

[54]

[60]

[66]

Change engine oil and engine oil filter.

Inspect the brake linings.

Replace the engine air cleaner filter.

Replace the spark plugs and ignition cables.

Inspect the tie rod ends and boot seals.

(Kilometers) [Months]

Inspect the PCV valve and replace if necessary. Not required if previously changed. * ‡

Flush and replace the engine coolant at 60 months, regardless of mileage.

Replace the PCV make-up air filter.

Adjust generator drive belt tension.

LUBRICATION & MAINTENANCE

0 - 13

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers) [Months] Change engine oil and engine oil filter.

90,000

95,000

100,000

105,000

(144 000)

(156 000)

(160 000)

(168 000)

[72]

[78]

Inspect the brake linings. X

Replace the spark plugs.

Inspect engine accessory drive belts, replace if necessary. Adjust the generator drive belt tension if not replacing belt.

Inspect the tie rod ends and boot seals.

Inspect the PCV valve and replace if necessary. Not required if previously changed. * â&#x20AC;Ą

Flush and replace the engine coolant if not done at 60 months. Replace the engine timing belt. * This maintenance is recommended by the manufacturer to the owner but is not required to maintain the emissions warranty. â&#x20AC;Ą This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

Replace the engine air cleaner filter.

Replace the PCV make-up air filter.

[84]

X X X WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.

0 - 14

LUBRICATION & MAINTENANCE

HOISTING

JUMP STARTING

STANDARD PROCEDURE - HOISTING

STANDARD PROCEDURE - JUMP STARTING

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. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result. Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands (Fig. 5). A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas.

WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN BATTERY/STARTING/CHARGING SECTIONS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. 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 ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. 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.

Fig. 5 Hoisting and Jacking Points 1 2 2 2 2

DRIVE ON LIFT FRAME CONTACT LIFT (SINGLE POST) CHASSIS LIFT (DUAL POST) OUTBOARD LIFT (DUAL LIFT) FLOOR JACK

(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+) or remote terminal. BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, elec-

LUBRICATION & MAINTENANCE

0 - 15

JUMP STARTING (Continued) trical arc will result. Review all warnings in this procedure. (5) On disabled vehicle connect RED jumper cable clamp to positive (+) remote terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 6). (a) Pull the protective sleeve from the remote positive terminal. (b) Connect RED jumper cable clamp to positive (+) remote terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 6). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

Fig. 6 POSITIVE JUMPER CABLE CLAMP CONNECTION 1 - BATTERY POSITIVE REMOTE TERMINAL

TOWING STANDARD PROCEDURE - TOWING WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR REAR BUMPER, OR BUMPER ENERGY ABSORBER UNITS. DO NOT VENTURE UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. USE A SAFETY CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. To avoid damage to bumper fascia and air dams use of a wheel lift or flat bed towing device (Fig. 7) is recommended. When using a wheel lift towing device, be sure the unlifted 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.

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • Disconnect RED cable clamp from battery positive remote terminal.

Fig. 7 Recommended Towing Devices 1 - WHEEL LIFT 2 - FLAT BED

SUSPENSION

2-1

SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION .....................1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 26

page WHEEL ALIGNMENT

. . . . . . . . . . . . . . . . . . . . . 52

FRONT SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION . . . . . . . 2 OPERATION - FRONT SUSPENSION . . . . . . . . . 2 WARNING WARNINGS AND CAUTIONS . . . . . . . . . . . . . . 2 STANDARD PROCEDURE - LUBRICATION ....2 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE . . 4 SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 4 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB ....................6 REMOVAL .............................6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 KNUCKLE DESCRIPTION - STEERING KNUCKLE .......6 OPERATION - STEERING KNUCKLE . . . . . . . . . 6 DIAGNOSIS AND TESTING - STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL - STEERING KNUCKLE . . . . . . . . . . . 6 DISASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB) . . . . . . . . . . . . . 8 ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB) . . . . . . . . . . . . . . . . . . . 10 INSTALLATION - STEERING KNUCKLE . . . . . . 11 LOWER BALL JOINT DIAGNOSIS AND TESTING - BALL JOINT . . . . . 12 LOWER BALL JOINT SEAL BOOT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12

page LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . REMOVAL - LOWER CONTROL ARM . . . . . . . DISASSEMBLY DISASSEMBLY - LOWER CONTROL ARM (BALL JOINT) . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) . . . . . . . . . . . ASSEMBLY ASSEMBLY - LOWER CONTROL ARM (BALL JOINT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) . . . . . . . . . . . INSTALLATION - LOWER CONTROL ARM ... STABILIZER BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . STRUT ASSEMBLY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

. 13 . 13 . 13 . 13

. 15 . 15

. 16 . 17 . 17 . 19 . 19 . 19 . 19 . 19 . 20 . 20 . 20 . 20 . 21 . 24 . 24

2-2

FRONT SUSPENSION

FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION This vehicle has a gas pressurized MacPherson strut type front suspension design (Fig. 1). The front suspension consists of these major components: • Hub (pressed into bearing) • Bearing (pressed into steering knuckle) • Lower control arm (2) • Stabilizer bar • Steering knuckle (2) • Strut assembly (2) Refer to individual components for additional information.

OPERATION - FRONT SUSPENSION The front suspension allows each front wheel on a vehicle to adapt to different road surfaces and conditions without greatly affecting the opposite wheel and the ability to control the vehicle. Each side of the front suspension is allowed to pivot so the vehicle can be steered in the direction preferred. When a vehicle strikes a bump, the force is transferred through the hub, bearing, and knuckle, into the strut assembly to absorb the force and dampen it. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint mounted on the lower control arm) turn as an assembly.

AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE THE COIL SPRING IS COMPRESSED WITH A COMPRESSION TOOL. THE SPRING IS HELD UNDER HIGH PRESSURE. CAUTION: Only frame contact hoisting equipment can be used on this vehicle. It cannot 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. CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener be installed in the shock tower to take the place of an original plastic clip. It may come into contact with the strut or coil spring. CAUTION: Wheel bearing damage will result if after loosening the hub nut, the vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires for a length of time.

STANDARD PROCEDURE - LUBRICATION WARNING WARNINGS AND CAUTIONS WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY

There are no serviceable lubrication points on the front suspension. The front lower ball joints have grease fittings which have had the head snapped off by the manufacturer after they have been filled. This has been done to eliminate the possibility of damaging the non-vented seals. Grease will not leak from the broken grease fittings. The ball joints are sealed for life and require no maintenance. CAUTION: No attempt should be made to replace the ball joint grease fitting with a new fitting, then filling the ball joint with grease. Damage to the grease seal can result.

FRONT SUSPENSION

PT FRONT SUSPENSION (Continued)

Fig. 1 Front Suspension System

2-3

2-4

FRONT SUSPENSION

FRONT SUSPENSION (Continued) 11 - HUB 12 - KNUCKLE 13 - STRUT 14 - LOWER SPRING ISOLATOR 15 - COIL SPRING 16 - JOUNCE BUMPER 17 - DUST SHIELD 18 - SPRING SEAT AND BEARING 19 - STRUT ASSEMBLY 20 - LOWER CONTROL ARM

1 - UPPER MOUNT 2 - VEHICLE STRUT TOWER 3 - OUTER TIE ROD 4 - JAM NUT 5 - STEERING GEAR 6 - CROSSMEMBER 7 - STABILIZER BAR 8 - STABILIZER BAR CUSHION AND RETAINER 9 - BALL JOINT 10 - STABILIZER BAR LINK

SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE N·m

Ft. Lbs.

In. Lbs.

Ball Joint Stud Pinch Bolt

—

Hub Nut

244

180

—

Disc Brake Caliper Adapter Knuckle Bolts

104

—

Lower Control Arm Front Pivot Bolt

170

125

—

Lower Control Arm Rear Pivot Bolt

250

185

—

Stabilizer Bar Cushion Retainer Bolts

250

Stabilizer Bar Link Nuts

250

54 + 90° turn

40 + 90° turn

—

Strut Shaft Nut

—

Strut-to-Tower Nuts

—

Tie Rod Adjuster Jam Nut

—

Tie Rod End-to-Knuckle Nut

—

Wheel Bearing Retainer Plate Bolts

250

Wheel Mounting (Lug) Nuts

135

100

—

DESCRIPTION

Strut Clevis-to-Knuckle Nuts

Installer, Bearing 5052

Remover/Installer 6644 (-2)

Installer 6758

SPECIAL TOOLS FRONT SUSPENSION Installer 6760

Splitter, Bearing 1130

FRONT SUSPENSION

PT FRONT SUSPENSION (Continued)

Remover 6804 Remover C-4150A

Socket/Wrench Strut Nut 6864

Remover/Installer 6908 (â&#x20AC;&#x201C;2)

Press, Ball Joint C-4212F

Installer Adapter C-4698-2

Remover MB-990799 Remover/Installer 8373

Remover MB991113

2-5

2-6

FRONT SUSPENSION

HUB / BEARING DESCRIPTION The wheel bearing and hub are pressed into the steering knuckle. (Refer to 2 - SUSPENSION/ FRONT/KNUCKLE - DESCRIPTION)

OPERATION The wheel bearing and hub are pressed into the steering knuckle. (Refer to 2 - SUSPENSION/ FRONT/KNUCKLE - OPERATION)

DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - DIAGNOSIS AND TESTING) for the procedure on measuring hub runout.

REMOVAL The wheel bearing and hub are pressed into the knuckle. (Refer to 2 - SUSPENSION/FRONT/ KNUCKLE - REMOVAL)

INSTALLATION The wheel bearing and hub are pressed into the knuckle. (Refer to 2 - SUSPENSION/FRONT/ KNUCKLE - INSTALLATION)

KNUCKLE DESCRIPTION - STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end (Fig. 1). The steering knuckle also has two machined, drilled

and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the wheel bearing and hub (Fig. 1). The wheel hub is pressed into a sealed-forlife wheel bearing that is pressed into the steering knuckle. A retainer plate also holds the bearing in place. The hub supports the driveshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a nut retainer and cotter pin. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub has five studs pressed into its flange.

OPERATION - STEERING KNUCKLE The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub, wheel bearing and axle shaft. The hub and wheel bearing work together. The wheel bearing has internal bearings that allow the hub to rotate with the driveshaft and the tire and wheel assembly. The hubâ&#x20AC;&#x2122;s five studs mount the tire and wheel to the vehicle.

DIAGNOSIS AND TESTING - STEERING KNUCKLE The front suspension steering knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle.

REMOVAL - STEERING KNUCKLE NOTE: Before proceeding, review all Warnings and Cautions. (Refer to 2 - SUSPENSION/FRONT WARNING) (1) Apply the brakes and hold in place. (2) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (3) Remove the front tire and wheel assembly. (4) Remove the cotter pin, lock nut and spring washer from the hub nut (Fig. 2). (5) While the brakes are applied, loosen and remove the hub nut on the end of the driveshaft (Fig. 2). (6) Release the brakes.

FRONT SUSPENSION

2-7

KNUCKLE (Continued)

Fig. 2 Hub Nut 1 2 3 4

HUB NUT NUT LOCK COTTER PIN SPRING WASHER

(7) Remove the front disc brake caliper and adapter as an assembly, and the brake rotor from the steering knuckle. Refer to BRAKE ROTOR in the BRAKE section for the procedure. (8) Remove the nut attaching the outer tie rod to the steering knuckle. To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench (Fig. 3).

Fig. 4 Tie Rod Removal 1 - OUTER TIE ROD 2 - STEERING KNUCKLE

(10) Remove the tie rod heat shield. (11) Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle (Fig. 5).

Fig. 5 Ball Joint Bolt And Nut 1 - NUT 2 - BOLT 3 - BALL JOINT

Fig. 3 Tie Rod Nut Removal/Installation 1 - OUTER TIE ROD 2 - STUD 3 - NUT

(9) Remove the tie rod end from the steering knuckle using Remover, Special Tool MB991113 (Fig. 4).

CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckles while removing the nuts, then tap the bolts out using a pin punch. (12) Remove the two bolts attaching the strut to the steering knuckle. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut.

2-8

FRONT SUSPENSION

KNUCKLE (Continued) (13) Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle (Fig. 6).

(1) Remove steering knuckle, hub, and wheel bearing as an assembly from the vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL) (2) Three wheel studs across from one another require removal from the hub flange. Rotate the hub to align each wheel mounting stud with the notch in the bearing retainer plate before removal. Using Remover, Special Tool Câ&#x20AC;&#x201C;4150A (Fig. 7), press the three wheel mounting studs out of the hub flange. Remove the wheel mounting studs from the hub through the open notch (Fig. 8).

Fig. 6 Separate Ball Joint From Knuckle 1 2 3 4

STEERING KNUCKLE PRY BAR LOWER CONTROL ARM BALL JOINT STUD

NOTE: Do not allow the driveshaft to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. (14) Pull the steering knuckle off the driveshaft outer C/V joint splines and remove the steering knuckle.

Fig. 7 Special Tool C-4150A 1 2 3 4

SPECIAL TOOL 4150A WHEEL MOUNTING STUD HUB FLANGE STEERING KNUCKLE

NOTE: The cartridge type front wheel bearing used on this vehicle is not transferable to the replacement steering knuckle. If the replacement steering knuckle does not come with a wheel bearing, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing and hub must be done before installing the steering knuckle on the vehicle. (15) If the wheel bearing and hub need removal, (Refer to 2 - SUSPENSION/FRONT/KNUCKLE DISASSEMBLY). Do not reuse the wheel bearing.

DISASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB) NOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle using the following procedure.

Fig. 8 Stud Removal From Hub 1 - BEARING RETAINER PLATE 2 - NOTCH

(3) Rotate the hub so the stud mounting holes in the hub are facing in the direction shown in the figure (Fig. 9).

FRONT SUSPENSION

2-9

KNUCKLE (Continued) (4) Install the Bearing Splitter, Special Tool 1130, between the hub and the bearing retainer plate as shown (Fig. 9). Absence of the three wheel mounting studs allows the bearing splitter to be installed behind the flange. Hand tighten the nuts to hold bearing splitter in place on steering knuckle.

(8) Remove the three bolts mounting the bearing retainer plate to the steering knuckle (Fig. 11). Remove the bearing retainer plate from the steering knuckle.

Fig. 11 Wheel Bearing Retainer Plate Fig. 9 Bearing Splitter Properly Installed

1 - NOTCH 2 - BOLTS 3 - BEARING RETAINER PLATE

1 - KNUCKLE

(5) Place the steering knuckle face down in an arbor press supported by the bearing splitter as shown (Fig. 10).

(9) Place the steering knuckle back in the arbor press face down as shown (Fig. 12). The press support blocks must not obstruct the bearing while it is being pressed out of the steering knuckle. (10) Place Remover/Installer, Special Tool MB-990799 on the outer race of the wheel bearing (Fig. 12). Press the wheel bearing out of the steering knuckle.

Fig. 10 Steering Knuckle Positioned In Press 1 - PRESS RAM 2 - HUB

(6) Position Remover/Installer, Special Tool 6644-2, on the small end of the hub (Fig. 10). Using the arbor press, remove the hub from the wheel bearing. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. (7) Remove the bearing splitter from the steering knuckle.

Fig. 12 Wheel Bearing Removal 1 - PRESS RAM

(11) Remove the bearing race that is still pressed onto the hub. To do so, install Bearing Splitter, Special Tool 1130, between the hub flange and the bearing race (Fig. 13). Place the hub, bearing race and bearing splitter in an arbor press as shown (Fig. 13).

2 - 10

FRONT SUSPENSION

KNUCKLE (Continued) Place Remover/Installer, Special Tool 6644-2 on end of hub. Press the hub out of the bearing race.

Fig. 14 Wheel Bearing Installation Fig. 13 Bearing Race Removal From Hub 1 2 3 4 5 6

- ARBOR PRESS - HUB - SPECIAL TOOL 1130 - PRESS BLOCKS (2) - BEARING RACE - SPECIAL TOOL 6644–2

NOTE: For steering knuckle reassembly, (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - ASSEMBLY).

ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB)

1 - PRESS RAM 2 - BEARING

(a) Place the studs in the three holes in the hub flange. (b) Place the hub in the arbor press supported by Special Tool C-4698-1, allowing the first stud to extend down into the tool (Fig. 15). (c) Press the wheel mounting stud into the hub flange until it is fully seated against the back side on the hub flange. (d) Remove the hub and tool from the press. (e) Repeat the steps (b), (c) and (d) on the remaining two studs.

(1) Wipe the bore of the steering knuckle clean of any grease or dirt with a clean, dry shop towel. (2) Place the steering knuckle in an arbor press with Installer, Special Tool C-4698-2, supporting the steering knuckle (Fig. 14). (3) Place the NEW wheel bearing into the bore of the steering knuckle. Be sure the wheel bearing is placed squarely into the bore. (4) Place Installer, Special Tool 5052, on the outer race of the wheel bearing (Fig. 14). Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle. (5) Remove the knuckle from the press. NOTE: Use only the original or identical replacement bolts to mount the bearing retainer plate to the steering knuckle. (6) Noting the notch location, install the bearing retainer plate on the steering knuckle as shown (Fig. 11). Install the three bearing retainer mounting bolts. Tighten the bearing retainer plate mounting bolts to a torque of 28 N·m (250 in. lbs.). (7) Install the previously removed wheel mounting studs back into the hub flange. To do so:

Fig. 15 Wheel Mounting Stud Installation 1 - ARBOR PRESS RAM 2 - HUB 3 - SPECIAL TOOL C-4698–1 4 - NO GAP IS ALLOWED BETWEEN STUD FLANGE AND HUB HERE 5 - WHEEL MOUNTING STUD

FRONT SUSPENSION

2 - 11

KNUCKLE (Continued) (8) Place the steering knuckle with the wheel bearing installed back in the arbor press with the smaller end of Remover/Installer, Special Tool MB-990799, supporting the inner race of the wheel bearing as shown (Fig. 16). (9) Place the hub in the wheel bearing making sure it is square with the bearing inner race (Fig. 16). Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing.

Fig. 16 Hub Installation 1 - PRESS RAM 2 - HUB

(10) Remove the steering knuckle and tools from the press. (11) Verify the hub turns smoothly without rubbing or binding. (12) Install the steering knuckle on the vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE INSTALLATION)

once installed. Install the nuts. Holding the bolts in place tighten the nuts to a torque of 53 N·m (40 ft. lbs.) plus an additional 90° turn after the specified torque is met. (5) Place the tie rod heat shield on the steering knuckle arm so that the shield is positioned straight away from the steering gear and tie rod end once installed. Align the hole in the shield with the hole in the steering knuckle arm. (6) Install the outer tie rod ball stud into the hole in the steering knuckle arm. Start the tie rod attaching nut onto the stud. Hold the tie rod end stud with a wrench while tightening the nut with a standard wrench or crowfoot wrench (Fig. 3). To fully tighten the nut to specifications, use a crowfoot wrench on a torque wrench to turn the nut, and a wrench on the stud. Tighten the nut to a torque of 55 N·m (40 ft. lbs.). (7) Install the brake rotor, disc brake caliper and adapter. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - INSTALLATION) (8) Clean all foreign matter from the threads of the driveshaft outer C/V joint. (9) Install the hub nut in the end of the driveshaft and snug it (Fig. 2). (10) Have a helper apply the brakes. With vehicle brakes applied to keep brake rotor and hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) (11) Install the spring washer, lock nut and cotter pin on the hub nut (Fig. 2). Wrap the cotter pin ends tightly around the lock nut (Fig. 17).

INSTALLATION - STEERING KNUCKLE (1) Slide the hub of the steering knuckle onto the splines on the driveshaft C/V joint. (2) Install the steering knuckle onto the ball joint stud aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud. (3) Install a new ball joint stud pinch bolt and nut (Fig. 5). Tighten the nut to a torque of 95 N·m (70 ft. lbs.).

Fig. 17 Correctly Installed Cotter Pin CAUTION: The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. (4) Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes (Fig. 1). Install the two attaching bolts. The bolts should be installed with so that the nuts face towards the front of the vehicle

1 - COTTER PIN 2 - NUT LOCK

(12) Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 135 N·m (100 ft. lbs.). (13) Lower the vehicle. (14) Set the front toe on the vehicle to required specification. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

2 - 12

FRONT SUSPENSION

LOWER BALL JOINT DIAGNOSIS AND TESTING - BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the headless grease fitting as shown (Fig. 18). With no mechanical assistance or added force, attempt to move the grease fitting. If the ball joint is worn, the grease fitting will move. If movement is noted, replace the ball joint.

Fig. 19 Seal Boot Removal 1 - TOOL 2 - SEAL BOOT 3 - LOWER CONTROL ARM

Fig. 18 Checking Ball Joint Wear 1 - BALL JOINT 2 - HEADLESS GREASE FITTING

CAUTION: No attempt should be made to service the headless grease fitting on the ball joint. It has been purposely snapped off by the manufacturer to avoid over-greasing.

LOWER BALL JOINT SEAL BOOT REMOVAL (1) Remove steering knuckle from vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE REMOVAL) (2) Using a screwdriver or other suitable tool, pry seal boot off of ball joint (Fig. 19).

INSTALLATION (1) Wipe off used grease around ball joint stem. CAUTION: When installing the sealing boot on the ball joint, position the upward lip on the seal boot outside perimeter outward, away from the control arm once installed (Fig. 20). It is there to help shield heat from the sealing boot.

Fig. 20 Seal Boot Installation 1 - SEAL BOOT UPWARD LIP 2 - BALL JOINT

(2) Place NEW ball joint seal boot over ball joint stem. Upward lip located on outside perimeter of seal boot must point outward, away from control arm once installed (Fig. 20). (3) By hand, start sealing boot over sides of the ball joint. (4) Position Installer, Special Tool 6758, over sealing boot outer diameter as shown (Fig. 20). By hand, apply pressure to top of Installer until seal boot is pressed squarely down against top surface of lower control arm. (5) Remove tool. (6) Remove headless grease fitting on ball joint and replace it with standard zirc-type grease fitting. Do not discard headless grease fitting.

FRONT SUSPENSION

2 - 13

LOWER BALL JOINT SEAL BOOT (Continued) CAUTION: It is important to lubricate the ball joint before installation of steering knuckle to allow proper venting when the seal is filled. If the ball joint is lubricated after installation to knuckle, damage to the seal can occur. (7) Using a hand operated pump grease gun, fill the ball joint seal boot with Mopart Multi-Mileage Lube or equivalent until grease pushes out past ball joint stem. Wipe off overfill. (8) Remove standard zirc-type grease fitting and reinstall headless grease fitting on ball joint to prevent future lubricating. See above caution. (9) Install steering knuckle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION)

LOWER CONTROL ARM DESCRIPTION There is one lower control arm on each side of the vehicle. Each lower control arm is a stamped steel unit using rubber isolated pivot bushings to isolate it from the front suspension crossmember and frame of the vehicle (Fig. 1) . The rear bushing can be serviced separately. The front of the lower control arm is bolted to the front crossmember using a bolt through the center of the rubber pivot bushing. The rear of the lower control arm is mounted to both the front crossmember and the frame rail of the vehicle using a thru-bolt. The thru-bolt goes through both the crossmember and rear lower control arm bushing, threading directly into a caged nut in the frame rail of the vehicle. The left and right lower control arms are interconnected through a linked rubber isolated stabilizer bar. The outboard end of each lower control arm connects to the steering knuckle using a ball joint. The lower control arm connects to the steering knuckle through a ball joint mounted at the outboard end of the arm (Fig. 1) . The ball joint is pressed into the lower control arm and has a non-tapered stud with a notch for steering knuckle pinch bolt clearance. The ball joint stud is clamped and locked to the steering knuckle lower leg using a pinch bolt. The ball joint is lubricated for life during the manufacturing process. Once lubricated for life, the grease fitting head is snapped off by the manufacturer. This is done to eliminate the possibility of lubrication later in the ball joints life thus damaging the non-vented ball joint seal boot. The ball joint used on this vehicle is replaceable and can be serviced as a separate component of the lower control arm.

OPERATION The lower control arm supports the lower end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel. The lower control arm ball joint connects the arm to the steering knuckle. The ball joint is a pivotal joint on the lower control arm that allows the knuckle to move up and down, and turn with ease.

DIAGNOSIS AND TESTING - LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm stamping is serviced only as a complete component. The serviceable components of the lower control arm are: the ball joint, the ball joint grease seal and the lower control arm rear isolator bushing. Inspect both lower control arm isolator bushings for severe deterioration and replace as required. Inspect the ball joint per the inspection procedure in this section of the service manual and replace as required. (Refer to 2 - SUSPENSION/FRONT/ LOWER BALL JOINT - DIAGNOSIS AND TESTING).

REMOVAL - LOWER CONTROL ARM NOTE: Before proceeding, (Refer to 2 - SUSPENSION/FRONT - WARNING). (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove the front tire and wheel assembly. (3) Remove both stabilizer bar links from the vehicle (Fig. 21). Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt. (4) Rotate the forward ends of the stabilizer bar downward. It may be necessary to loosen the stabilizer bar cushion retainer bolts a little to ease any turning resistance. (5) Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle (Fig. 22). CAUTION: After removing the steering knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the steering knuckle outward at this point can separate the inner C/V joint on the driveshaft. Refer to FRONT DRIVESHAFTS in the DIFFERENTIAL AND DRIVELINE group for further information.

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