Chrysler pacifica 2004 service repair manual by jhjsnefyudd

GROUP TAB LOCATOR Introduction

0 2 3 5 7 8A 8B 8C 8E 8F 8G 8H 8I 8J 8L 8M 8N 8Ns 8O 8P 8Q 8R 8T 8W 9 11 13 14 14s 19 19s 21 21s 22 23 24 25

Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling Audio/Video Chime/Buzzer Clock Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Navigation/Telecommunication Wiring Engine Exhaust System Frame & Bumpers Fuel System Fuel System Steering Steering Transmission/Transaxle Transmission/Transaxle Tires/Wheels Body Heating & Air Conditioning Emissions Control Component and System Index

Service Manual Comment Forms

(Rear of 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 . . . . . . . . . . . . . . . . . . . . . . .

...1 ...2

...5 ..5 ...5

page METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10

BODY CODE PLATE

BODY CODE PLATE – LINE 3

DESCRIPTION

DIGITS 1 THROUGH 12 Vehicle Order Number

The Body Code Plate (Fig. 1) is located in the engine compartment on the right headlamp mounting bracket. 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.

DIGITS 13 THROUGH 17 Open Space DIGITS 18 AND 19 Vehicle Shell Line • CS DIGIT 20 Carline • Chrysler

FWD • M = Pacifica AWD • F = Pacifica DIGIT 21 Price Class • 5 = P (Premium) • 6 = S (Sport)

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 22 AND 23 Body Type • 8 = Sport Utility 4 Door

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

INTRODUCTION

BODY CODE PLATE (Continued) DIGITS 5 THROUGH 7 Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS). DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint

DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED

DIGITS 15 THROUGH 18 Interior Trim Code

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.

DIGIT 19 Open Space

FASTENER IDENTIFICATION

DIGIT 13 AND 14 Open Space

DIGITS 20, 21, AND 22 Engine Code • EGN = 3.5L 6 Cyl. 24 Valve Gasoline (MPI) DIGIT 23 Open Space

BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGB = 4-Speed Automatic Transaxle • DGL = 41AE/TE 4-Speed Electronic Automatic DIGIT 4 Open Space DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States

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. 2) and (Fig. 3).

INTRODUCTION

CS FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER IDENTIFICATION

INTRODUCTION

FASTENER IDENTIFICATION (Continued)

Fig. 3 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. 4) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

Fig. 4 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

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

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. 5).

INTRODUCTION

CS METRIC SYSTEM (Continued)

Fig. 5 METRIC CONVERSION CHART

INTRODUCTION

TORQUE REFERENCES

tions Chart for torque references not listed in the individual torque charts (Fig. 6).

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

Fig. 6 TORQUE SPECIFICATIONS

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left corner of the instrument panel, near the left windshield pillar (Fig. 7). The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. 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. 7 VEHICLE IDENTIFICATION NUMBER (VIN) 1 - INSTRUMENT PANEL 2 - VEHICLE IDENTIFICATION NUMBER (VIN)

VIN CODE BREAKDOWN CHART POSITION

INTERPRETATION

Country of Origin

CODE = DESCRIPTION 1 = Manufactured by DaimlerChrysler Corporation 2 = Manufactured by DaimlerChrysler Canada Inc.

Make

Vehicle Type

C = Chrysler 4 = Multipurpose Passenger Vehicle Less Side Airbags 8 = Multipurpose Passenger Vehicle With Side Airbags

Gross Vehicle Weight Rating

Car Line

F = 1815 - 2267 kg. (4001 - 5000 lbs.) G = 2268 - 2721 kg. (5001 - 6000) F = Pacifica - AWD M = Pacifica - FWD

Series

5 = Premium 6 = Sport

Body Style

Engine

8 = Sport Utility 4 Door 4 = 3.5L V6 cyl. 24 -Valve Gasoline (MPI)

Check Digit

See explanation in this section.

Model Year

4 = 2004

Assembly Plant

12 through 17

Sequence Number

R = Windsor Assembly A six digit number assigned by assembly plant.

INTRODUCTION

VEHICLE CERTIFICATION LABEL DESCRIPTION A vehicle certification label is attached to the rear shutface of the driver’s door (Fig. 8). 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. 8 VEHICLE CERTIFICATION LABEL - TYPICAL

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment. It can-

not 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.

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 - FLEXIBLE FUEL ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - AUTOMATIC TRANSAXLE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - FUEL REQUIREMENTS . DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE OIL - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - AWD REAR DRIVELINE MODULE FLUIDS . . . . . . . . . . . . . . . . . . DESCRIPTION - AWD POWER TRANSFER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

....1

....1 ....3 ....3 ....4 ....4 ....6 ....6 ....6

page FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6 FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LUBRICATION POINTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MAINTENANCE SCHEDULES DESCRIPTION DESCRIPTION ........................7 DESCRIPTION - EXPORT . . . . . . . . . . . . . . . 14 HOISTING STANDARD PROCEDURE - HOISTING . . . . . . . 21 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING . 21 TOWING STANDARD PROCEDURE - TOWING . . . . . . . . 22 VEHICLE STORAGE STANDARD PROCEDURE . . . . . . . . . . . . . . . . 24

....6

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

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.

Fig. 1 INTERNATIONAL SYMBOLS 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.

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued) • 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.

SAE VISCOSITY 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).

Fig. 3 API SYMBOL

SYNTHETIC ENGINE OILS 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.

ENGINE OIL ADDITIVES/SUPPLEMENTS

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.

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 Mopart or an equivalent oil meeting the specification MS-6395.

The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: • Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee emissions performance to 80,000 miles. • Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. • Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures.

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.

LUBRICATION & MAINTENANCE

0-3

FLUID TYPES (Continued)

LUBRICANTS AND GREASES 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 of the 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.

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.

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 - FLEXIBLE FUEL ENGINE OIL The information in this section is for Flexible Fuel Vehicles (FFV) only. These vehicles can be identified by the unique Fuel Filler Door Label that states Ethanol (E-85) or Unleaded Gasoline Only. This section only covers those subjects that are unique to these vehicles. Please refer to the other sections of this manual for information on features that are common between Flexible Fuel and gasoline only powered vehicles.

ETHANOL FUEL (E-85) E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline. WARNING: Ethanol vapors are extremely flammable and could cause serious personal injury. Never have any smoking materials lit in or near the vehicle when removing the fuel filler tube cap (gas cap) or filling the tank. Do not use E-85 as a cleaning agent and never use it near an open flame.

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

FUEL REQUIREMENTS The vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any mixture of these two. For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be avoided. When you do switch fuels, it is recommended that • you do not switch when the fuel gauge indicates less than 1/4 full • you do not add less than 5 gallons when refueling • you operate the vehicle immediately after refueling for a period of at least 5 minutes Observing these precautions will avoid possible hard starting and/or significant deterioration in driveability during warm up.

FFV STARTING The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below 0°F. In the range of 0°F to 32°F, you may experience an increase in the time it takes for your engine to start, and a deterioration in driveability (sags and/or hesitations) until the engine is fully warmed up.

Engine Operating on E-85 Fuel If vehicle operates on E-85 fuel either full or parttime, use only Mopart Flexible Fuel 5W-30 engine oil or an equivalent that meets DaimlerChrysler Standard MS-9214. Equivalent commercial Flexible Fuel engine oils may be labeled as Multi-Fuel, Variable Fuel, Flexible Fuel, etc. These engine oils may be satisfactory if they meet the DaimlerChrysler Standard. SAE 5W-30 engine oil is preferred for use in Flexible Fuel engines. CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result.

CRUISING RANGE Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase in fuel consumption. You can expect your MPG and your driving range to decrease by about 30% compared to gasoline operation.

DESCRIPTION - AUTOMATIC TRANSAXLE FLUID NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for these transaxles.

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 Fluid) is required in the 41TE automatic transaxles. Substitute fluids can induce transmission problems and/or failure. Mopart ATF+4 (Automatic Transmission Fluid) 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. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. 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 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 experi-

LUBRICATION & MAINTENANCE

0-5

FLUID TYPES (Continued) ence 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.

GASOLINE/OXYGENATE BLENDS

fornia 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.

MATERIALS ADDED TO FUEL

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.

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.

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

MMT IN GASOLINE 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 gasoline 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 Cali-

FUEL SYSTEM CAUTIONS

• 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 temperature 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.

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued) NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you.

DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE WARNING: DO NOT USE ALCOHOL OR GASOLINE AS A FUEL BLENDING AGENT. THEY CAN BE UNSTABLE UNDER CERTAIN CONDITIONS AND HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH DIESEL FUEL. Use good quality diesel fuel from a reputable supplier. For most year-round service, number 2 diesel fuel meeting DIN EN 590 (Class 0 - 4) will provide good performance. If the vehicle is exposed to extreme cold (below -18°C/0°F) or is required to operate at colder than normal conditions for prolonged periods, use climatize No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel as long as it meets ASTM D 975: 1D and 2D and the quality of lubrication behavior is in accordance with DIN EN 590. This will provide better protection from fuel gelling or wax plugging of the fuel filters. Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freezing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold starting and warm up performance.

DESCRIPTION - ENGINE OIL - DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL2104C or API Classification CD or higher or CCML D4, D5.

DESCRIPTION - AWD REAR DRIVELINE MODULE FLUIDS The AWD Rear Driveline Module Assembly consists of two subassemblies, the Overrunning Clutch Housing (front) and the Differential Carrier (rear). The recommended lubricant for the Overrunning Clutch Housing is Mopart ATF+4. The recommended lubricant for the Differential Carrier is Mopart 75W-90 Gear and Axle Lubricant.

DESCRIPTION - AWD POWER TRANSFER UNIT The recommended lubricant for the AWD Power Transfer Unit is Mopart 75W-90 Gear and Axle Lubricant.

FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

Fuel Tank (Gas)

87 L (23 gal.)

Engine Oil* - 3.5 L

5.2 L (5.5 qts.)

Cooling System** - 3.5 L

9.9 L (10.5 qts.)

Automatic 4-Speed Service Fill

3.8 L (4.0 qts.)

Automatic Transmission 41TE/41AE Overhaul Fill

9.2 L (9.7 qts.)

AWD Power Transfer Unit

1.0 L (2.1 pts.)

Power Steering

1.2 L (2.5 pts.)

AWD Bi-directional Overrunning Clutch

0.575 L (1.22 pts.)

AWD Rear Carrier

0.7 L (1.48 pts.)

* (includes oil filter) ** (includes heater and recovery/reserve bottle filled to MAX level)

SAE VISCOSITY GRADE

FLUID FILL/CHECK LOCATIONS

CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation.

DESCRIPTION

To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils that meet Chrysler material standard MS-6395, be used in accordance to ACEA B3, B4 specification. European Grade 10W-40 oils are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15°C.

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 DESCRIPTION DESCRIPTION There are two maintenance schedules that show the required service for your vehicle. First is Schedule “B”. 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 32° F (0° C). • Stop and go driving. • Extensive engine idling. • Driving in dusty conditions. • Short trips of less than 10 miles (16 km). • More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C). • Trailer towing.L • Taxi, police, or delivery service (commercial service).L • Off-road or desert operation. NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule (B(. Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9. Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first. NOTE: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.

LUBRICATION & MAINTENANCE

0-7

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 bottle, brake master cylinder and transmission, add as needed. • Check all lights and all other electrical items for correct operation. 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 transmission fluid level. • Check the coolant level, hoses, and clamps. • Rotate the tires at each oil change interval shown on Schedule “A” 6,000 miles (10 000 km) or every other interval shown on Schedule “B” 6,000 miles (10 000 km).

0-8

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 60,000 miles (96 000 km) if the vehicle is usually operated under one or more of the conditions marked with an L. • Day or night temperatures are below 32° F (0° C). • Stop and go driving. • Extensive engine idling. • Driving in dusty conditions. • Short trips of less than 10 miles (16 km). • More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C). Miles (Kilometers) Change engine oil and engine oil filter.

• Trailer towing.L • Taxi, police, or delivery service (commercial service).L • Off-road or desert operation. NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Maintenance Schedules9 section of this manual.

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 brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter. *

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Replace the air conditioning filter.

Miles

21, 000

24, 000

27, 000

30, 000

33, 000

36, 000

(Kilometers)

(34 000)

(38 000)

(43 000)

(48 000)

(53 000)

(58 000)

Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valve and replace as necessary.*

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of this chart) Replace the air conditioning filter.

LUBRICATION & MAINTENANCE

0-9

MAINTENANCE SCHEDULES (Continued) Miles

39, 000

42, 000

45, 000

48, 000

51, 000

54, 000

(Kilometers)

(62 000)

(67 000)

(72 000)

(77 000)

(82 000)

(86 000)

Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter. *

Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart)

X X

Replace the air conditioning filter.

Miles

57, 000

60, 000

63, 000

66, 000

69, 000

72, 000

(Kilometers)

(91 000)

(96 000)

(101 000)

(106 000)

(110 000)

(115 000)

Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valve and replace if necessary.*

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Change the automatic transmission fluid and filter.

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart) Replace the air conditioning filter.

X X

0 - 10

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) 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, replace if necessary. *

Replace the engine air cleaner filter

Replace the spark plugs on 3.5 liter engines.

X X

Inspect the tie rod ends and boot seals. (Front & Rear)

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

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart)

Replace the air conditioning filter.

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. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter *

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart)

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Flush and replace the engine coolant at 60 months or 100,000 miles. Replace the air conditioning filter.

X X

LUBRICATION & MAINTENANCE

0 - 11

MAINTENANCE SCHEDULES (Continued) Miles

108, 000

111, 000

114, 000

117, 000

120, 000

(Kilometers)

(173 000)

(178 000)

(182 000)

(187 000)

(192 000)

Change engine oil and engine oil filter.

Inspect the brake linings.

Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valve and replace as necessary.*

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Change the automatic transmission fluid and filter.

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Replace the air conditioning filter.

* This maintenance is recommended by the manufacture 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.

X The AWD power transfer unit fluid and the AWD overrunning clutch/ rear carrier fluid must be changed at the more frequent intervals shown in schedule B if the vehicle is operated under any of the conditions noted by a diamond (L) at the beginning of the schedule.

0 - 12

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE A 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. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Replace the air conditioning filter.

Miles

42, 000

48, 000

54, 000

60, 000

66, 000

72, 000

(Kilometers)

(67 000)

(77 000)

(86 000)

(96 000)

(106 000)

(115 000)

[42]

[48]

[54]

[60]

[66]

[72]

[Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Check the PCV valve and replace, if necessary.*

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

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

Replace the air conditioning filter.

LUBRICATION & MAINTENANCE

0 - 13

MAINTENANCE SCHEDULES (Continued) Miles (Kilometers)

78, 000

84, 000

90, 000

96, 000

100, 000

(125 000)

(134 000)

(144 000)

(154 000)

(160 000)

[78]

[84]

[90]

[96]

[Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Check and replace the PCV valve, if necessary.*

Inspect the serpentine drive belt, replace if necessary. ‡

Replace the spark plugs 3.5 liter engines.

Flush and replace the engine coolant at 100,000 miles, if not done at 60 months.

Replace the air conditioning filter.

Miles

102, 000

108, 000

114, 000

120, 000

(Kilometers)

(163 000)

(173 000)

(182 000)

(192 000)

[102]

[108]

[114]

[120]

[Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Check the PCV valve and replace, if necessary.*

Inspect the serpentine drive belt, replace if necessary. ‡

Flush and replace the engine coolant at 120 months, if not done at 100,000 miles (160 000 km). Replace the air conditioning filter. * This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty. ‡ 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.

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

MAINTENANCE SCHEDULES (Continued)

DESCRIPTION - EXPORT There are two maintenance schedules that show the required service for your vehicle. First is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9. Second is Schedule “B”. 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).L • Trailer towing.L • Taxi, police, or delivery service (commercial service).L • Off-road or desert operation. NOTE: If ANY of these apply to you then change your engine oil every 5 000 km (3,000 miles) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule (B(. Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first. 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 bottle, brake master cylinder and transmission, add as needed. • Check all lights and all other electrical items for correct operation. 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 transmission fluid level. • Check the coolant level, hoses, and clamps. • Rotate the tires at each oil change interval shown on Schedule “A” 12 000 km (7,500 miles) or every other interval shown on Schedule “B” 10 000 km (6,000 miles).

LUBRICATION & MAINTENANCE

0 - 15

MAINTENANCE SCHEDULES (Continued)

SCHEDULE A - EXPORT ONLY Kilometers

12 000

24 000

36 000

48 000

60 000

72 000

(Miles)

(7,500)

(15,000)

(22,500

(30,000)

(37,500)

(45,000)

[Months]

[6]

[12]

[18]

[24]

[30]

[36]

Change engine oil and engine oil filter.

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Replace the air conditioning filter. Kilometers (Miles) [Months] Change engine oil and engine oil filter.

84 000

96 000

108 000

120 000

132 000

144 000

(52,500)

(60,000)

(67,500)

(75,000)

(82,500)

(90,000)

[42]

[48]

[54]

[60]

[66]

[72]

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Check the PCV valve and replace, if necessary.*

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Flush and replace the engine coolant at 60 months, regardless of mileage. Replace the air conditioning filter.

0 - 16

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) Kilometers

156 000

160 000

168 000

180 000

192 000

(Miles)

(97,500)

(100,000)

(105,000)

(112,500)

(120,000)

[78]

[84]

[90]

[96]

[Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Check and replace the PCV valve, if necessary.*

Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

Replace the spark plugs 3.5 liter engines.

Flush and replace the engine coolant at 100,000 miles, if not done at 60 months.

Replace the air conditioning filter.

* This maintenance is recommended by the manufacture 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.

LUBRICATION & MAINTENANCE

0 - 17

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B - EXPORT ONLY Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 96 000 km (60,000 miles) if the vehicle is usually operated under one or more of the conditions marked with an L. • 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).L Kilometers (Miles) Change engine oil and engine oil filter.

• Trailer towing.L • Taxi, police, or delivery service (commercial service).L • Off-road or desert operation. NOTE: If ANY of these apply to you then change your engine oil every 5 000 km (3,000 miles) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Maintenance Schedules9 section of this manual.

5 000

10 000

14 000

19 000

24 000

29 000

(3,000 )

(6,000 )

(9,000)

(12,000)

(15,000)

(18,000)

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter. *

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Replace the air conditioning filter.

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

34 000

38 000

43 000

48 000

53 000

58 000

(21,000)

(24,000)

(27,000)

(30,000)

(33,000)

(36,000)

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valveand replace as necessary.*

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See the note at the end of this chart) Replace the air conditioning filter.

0 - 18

LUBRICATION & MAINTENANCE

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

62 000

67 000

72 000

77 000

82 000

86 000

(39,000)

(42,000)

(45,000)

(48,000)

(51,000)

(54,000)

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter. *

Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart)

(Miles) Change engine oil and engine oil filter.

91 000

96 000

101 000

106 000

110 000

115 000

(57,000)

(60,000)

(63,000)

(66,000)

(69,000)

(72,000)

X X

Replace the engine air cleaner filter.

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valve and replace if necessary.*

Change the automatic transmission fluid and filter.

Inspect the serpentine drive belt, replace if necessary.

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart) Replace the air conditioning filter.

Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

Replace the air conditioning filter. Kilometers

X X

LUBRICATION & MAINTENANCE

0 - 19

MAINTENANCE SCHEDULES (Continued) Kilometers

120 000

125 000

130 000

134 000

139 000

144 000

(Miles)

(75,000)

(78,000)

(81,000)

(84,000)

(87,000)

(90,000)

Change engine oil and engine oil filter. Inspect the brake linings.

Inspect the engine air cleaner filter, replace if necessary. *

Replace the engine air cleaner filter

Replace the spark plugs on 3.5 liter engines.

X X

Inspect the tie rod ends and boot seals. (Front & Rear) Inspect the serpentine drive belt, replace if necessary. â&#x20AC;Ą

X X

Check the PCV valve and replace if necessary. Not required if previously changed.* Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.)

Change the All Wheel Drive (AWD) overrunning clutch and rear carrier fluid. (See note at the end of this chart) Replace the air conditioning filter.

Kilometers

149 000

154 000

158 000

160 000

163 000

168 000

(Miles)

(93,000)

(96,000)

(99,000)

(100,000)

(102,000)

(105,000)

Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter *

Inspect serpentine drive belt, replace if necessary. â&#x20AC;Ą

Change the All Wheel Drive (AWD) power transfer unit, overrunning clutch and rear carrier fluid. (See note at the end of this chart)

Flush and replace the engine coolant at 60 months or 100,000 miles. Replace the air conditioning filter.

X X

0 - 20

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued) Kilometers (Miles)

173 000

178 000

182 000

187 000

192 000

(108,000)

(111,000)

(114,000)

(117,000)

(120,000)

Change engine oil and engine oil filter.

Inspect the brake linings.

Inspect the engine air cleaner filter, replace if necessary. *

X X

Replace the engine air cleaner filter.

Inspect serpentine drive belt, replace if necessary. â&#x20AC;Ą

Inspect the tie rod ends and boot seals. (Front & Rear)

Inspect the PCV valve and replace as necessary.*

Change the automatic transmission fluid and filter.

Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

Replace the air conditioning filter.

changed at the more frequent intervals shown in schedule B if the vehicle is operated under any of the conditions noted by a diamond at the beginning of the schedule. 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.

LUBRICATION & MAINTENANCE

0 - 21

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 any suspension component, including the front or rear suspension crossmembers. Do not hoist on the front and rear bumpers, the lower liftgate crossmember, the lower radiator crossmember, or the front engine mount. FOR PROPER HOIST PLACEMENT REFER TO (Fig. 5). The front hoisting points for frame contact hoists are on the down standing sill flanges, approximately 200 mm behind the front front wheel opening and 150 mm forward of the rear wheel opening. Under no circumstances are the front lower radiator support to be used as lift points. Wheel lifts are acceptable.

WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE). • DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. • 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: DO NOT ATTEMPT TO PUSH OR TOW THE VEHICLE TO START IT. THE VEHICLE CANNOT BE STARTED THIS WAY. PUSHING WITH ANOTHER VEHICLE MAY DAMAGE THE TRANSAXLE OR THE REAR OF THE VEHICLE. (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Clear or bright color test indicator, if equipped. • 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 (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure.

0 - 22

LUBRICATION & MAINTENANCE

JUMP STARTING (Continued) (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. 6). (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE). (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 Jumper Cable Clamp Connections 1 2 3 4 5 6

BATTERY NEGATIVE TERMINAL POSITIVE JUMPER CABLE TEST INDICATOR (IF EQUIPPED) BATTERY POSITIVE TERMINAL BATTERY NEGATIVE JUMPER CABLE

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter may overheat and could fail. (7) If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (2 minutes), before cranking again.

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.

TOWING STANDARD PROCEDURE - TOWING WARNINGS AND CAUTIONS 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. DO NOT GO 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 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.

RECOMMENDED TOWING EQUIPMENT • FWD vehicles, use of a flat bed towing device or a wheel lift is recommended (Fig. 7). • AWD vehicles, a flat bed towing device is recommended (Fig. 7) or (Fig. 8). When using a wheel lift towing device, be sure the 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.

LUBRICATION & MAINTENANCE

0 - 23

TOWING (Continued) CAUTION: • Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia and air dams will result. • The only approved method of towing is with a flat bed truck. • Do not tow the vehicle from the rear. Damage to the rear sheet metal, liftgate and fascia will occur. • Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transmission may result.

LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler.

FLAT BED TOWING TIE DOWNS CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result. The vehicle can be tied to a flat bed device using the pair of front transportation slots on the bottom surface of the rails, behind the front wheels. The rear transportation slots are on the bottom of the left bumper extension and in the bracket extending inboard of the right bumper extension.

TOWING – FRONT WHEEL DRIVE

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

Your vehicle may be towed under the following conditions: The gear selector must be in NEUTRAL, the distance to be traveled must not exceed 100 miles (160 km), and the towing speed must not exceed 44 mph (72 km/h). Exceeding these towing limits may cause a transmission gear train failure. If the transmission is not operative, or if the vehicle is to be towed more than 100 miles (160 km), the vehicle must be towed with the front wheels off the ground.

TOWING – ALL WHEEL DRIVE Your vehicle may be towed under the following conditions: The gear selector must be in NEUTRAL, the distance to be traveled must not exceed 100 miles (160 km), the towing speed must not exceed 44 mph (72 km/h), and both front and rear wheels must be on the ground. If your vehicle must be towed farther or at a higher rate of speed, it must be transported on a flat bed truck.

ALL TRANSMISSIONS Fig. 8 FLAT BED CARRIER

GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels from the front end of the vehicle and lower the front end closer to the ground, to increase the ground clearance at the rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake rotors.

• Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia will result. • The only approved method of towing is with a flat bed truck. • Do not tow the vehicle from the rear. Damage to the rear sheet metal, liftgate and fascia will occur. • Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transmission may result. If it is necessary to use the accessories while being towed (wipers, defrosters, etc.), the key must be in the ON position, not the ACCESSORY position. Make certain the transmission remains in NEUTRAL.

0 - 24

LUBRICATION & MAINTENANCE

TOWING (Continued)

WITHOUT THE IGNITION KEY Special care must be taken when the vehicle is towed with the ignition in the LOCK position. The only approved method of towing with out the ignition key is with a flat bed truck. Proper towing equipment is necessary to prevent damage to the vehicle.

TOWING THIS VEHICLE BEHIND ANOTHER VEHICLE (Flat towing with all four wheels on the ground) Flat towing of vehicles equipped with an automatic transmission, is only permitted within the limitations described in this section.

FLAT TOWING WITH TOW BAR • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. • AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOWING EQUIPMENT in this section.

TOWING THIS VEHICLE BEHIND ANOTHER VEHICLE WITH A TOW DOLLEY The manufacture does not recommend that you tow an All-Wheel Drive (AWD) or front wheel drive vehicle on a tow dolley. Vehicle damage may occur.

VEHICLE STORAGE STANDARD PROCEDURE If you are leaving your vehicle dormant for more than 21 days you may want to take steps to protect your battery. You may: • Rotate the holder and 30 Amp fuse in the Integrated Power Module labeled Ignition-Off Draw (IOD) 180 degrees. • Or, disconnect the negative cable from the battery. • Anytime you store your vehicle, or keep it out of service (i.e. vacation) for two weeks or more, run the air conditioning system at idle for about five minutes in the fresh air and high blower setting. This will insure adequate system lubrication to minimize the possibility of compressor damage when the system is started again.

SUSPENSION

2-1

SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION

.....................1

page REAR SUSPENSION

. . . . . . . . . . . . . . . . . . . . . . 19

FRONT SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . HUB / BEARING DIAGNOSIS AND TESTING - HUB AND BEARING ......................... REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL .......................... INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . LOWER BALL JOINT DIAGNOSIS AND TESTING - LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BALL JOINT SEAL BOOT REMOVAL ..........................

..2 ...2

...2 ...3 ...4 . . . .

. . . .

.5 .5 .7 .7

...8 ...8

page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LOWER CONTROL ARM REMOVAL .............................9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 STABILIZER BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 STRUT ASSEMBLY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIAGNOSIS AND TESTING - STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 15 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-2

FRONT SUSPENSION

SPECIAL TOOLS

FRONT SUSPENSION

SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE N·m

Ft. Lbs.

In. Lbs.

81 + 90° turn

60 + 90° turn

—

Brake Caliper Adapter Mounting Bolts

169

125

—

Engine Cradle Mounting Bolts

163

120

—

Hub And Bearing Mounting Bolts

—

Hub And Bearing Axle Hub Nut

244

180

—

Lower Control Arm Frame Bolts

163

120

—

Stabilizer Bar Cushion Retainer Bolts

—

Stabilizer Bar Link Nuts

—

Strut Body/Tower Mounting Nuts

250

Strut Clevis-to-Knuckle Nuts

88 + 90° turn

65 + 90° turn

—

Strut Shaft Nut

100

—

Tie Rod Adjuster Jam Nut

—

HUB / BEARING

Tie Rod Steering Arm Nut

47 + 180° turn

35 + 180° turn

—

DIAGNOSIS AND TESTING - HUB AND BEARING

135

100

—

DESCRIPTION Ball Joint Nut

Wheel Mounting (Lug) Nuts

Puller, Tie Rod C-3894-A

Installer, Ball Joint 6758

Wrench, Strut Rod Nut 6864

The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure detailed below. The bearing contained in the Unit III front hub/ bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph).

FRONT SUSPENSION

2-3

HUB / BEARING (Continued)

REMOVAL NOTE: Replacement of front hub and bearing assembly can normally be done without having to remove steering knuckle from vehicle. In event that hub/bearing is frozen in steering knuckle and cannot be removed by hand, it will have to be pressed out of steering knuckle. Steering knuckle will then require removal before hub and bearing can be pressed out. (Refer to 2 - SUSPENSION/FRONT/ KNUCKLE - REMOVAL) (1) Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove tire and wheel assembly. (3) Remove cotter pin, nut lock and spring washer from halfshaft stub shaft (Fig. 1).

Fig. 2 Brake Hose And Wheel Speed Sensor Connections 1 2 3 4 5 6 7

WIRING HARNESS CONNECTOR WHEEL SPEED SENSOR CONNECTOR ROUTING CLIP PORT ON BRAKE CALIPER COPPER SEALING WASHER BRAKE HOSE BANJO FITTING BANJO BOLT

Fig. 1 Cotter Pin, Nut Lock, And Spring Washer 1 2 3 4

HUB NUT NUT LOCK COTTER PIN SPRING WASHER

(4) With aid of a helper applying brakes to keep front hub from turning, remove hub nut (Fig. 1). (5) Access and remove front brake rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL) (6) Disconnect vehicle wiring harness from wheel speed sensor connector (Fig. 2). (7) Unclip wheel speed sensor connector and routing clip from frame rail outer reinforcement (Fig. 2). (8) Remove screw fastening wheel speed sensor routing bracket to strut assembly (Fig. 3). (9) Open routing clip at knuckle and remove wheel speed sensor cable (Fig. 4). (10) Push in on end of halfshaft stub shaft, pushing its splines out of hub splines.

Fig. 3 Wheel Speed Sensor Mounting To Strut 1 - STRUT ASSEMBLY 2 - SCREW 3 - WHEEL SPEED SENSOR ROUTING BRACKET

2-4

FRONT SUSPENSION

HUB / BEARING (Continued)

Fig. 6 Hub And Bearing Assembly (Typical)

Fig. 4 Sensor Mounting To Front Hub And Bearing 1 2 3 4

MOUNTING SCREW HUB AND BEARING ROUTING CLIP FRONT WHEEL SPEED SENSOR

(11) Remove four hub and bearing mounting bolts from rear of steering knuckle (Fig. 5).

Fig. 5 Hub And Bearing Mounting Bolts 1 - KNUCKLE 2 - HUB AND BEARING MOUNTING BOLTS 3 - HALFSHAFT

(12) Remove hub and bearing with wheel speed sensor from steering knuckle.

INSTALLATION CAUTION: Hub and bearing mounting surfaces on steering knuckle and stub shaft (Fig. 6) must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly.

1 - HALFSHAFT OUTER C/V JOINT 2 - STUB SHAFT 3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS BEFORE INSTALLING BEARING ASSEMBLY 4 - STEERING KNUCKLE

(1) Install hub and bearing onto halfshaft stub shaft and into steering knuckle until squarely seated on face of steering knuckle. (2) Install four hub and bearing mounting bolts from rear of knuckle. Progressively and equally tighten all four mounting bolts using a criss-cross pattern. Tighten mounting bolts to 65 N·m (45 ft. lbs.) torque. (3) Place wheel speed sensor cable grommet in clip at knuckle (Fig. 4). Close clip. (4) Attach wheel speed sensor routing bracket to strut assembly (Fig. 3). Tighten screw to 13 N·m (115 in. lbs.) torque. (5) Clip wheel speed sensor connector and routing clip to frame rail outer reinforcement (Fig. 2). (6) Connect vehicle wiring harness to wheel speed sensor connector (Fig. 2). (7) Install brake rotor, then install disc brake caliper and adapter assembly. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTOR INSTALLATION) (8) Verify that wheel speed sensor is not routed improperly allowing cable to come in contact with brake rotor or other moving parts. (9) Install washer and hub nut on end of halfshaft stub shaft (Fig. 1). With aid of a helper applying brakes to keep front hub from turning, tighten hub nut to 244 N·m (180 ft. lbs.) torque. (10) Install spring washer and hub nut lock over hub nut and stub shaft. Install a NEW cotter pin securing nut lock in place and tightly wrap cotter pin prongs around nut lock.

FRONT SUSPENSION

2-5

HUB / BEARING (Continued) (11) Install tire and wheel assembly (Refer to 22 TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts to a torque of 135 N·m (100 ft. lbs.). (12) Lower vehicle. (13) Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle. (14) Check and adjust brake fluid level as necessary. (15) Perform wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

KNUCKLE DESCRIPTION The steering knuckle is a single aluminum casting with legs machined for attachment of the strut assembly, steering linkage, disc brake caliper adapter, lower control arm ball joint and steering linkage. The hub and bearing assembly is mounted in the center of the steering knuckle using 4 bolts. The driveshaft’s constant velocity (C/V) stub shaft is splined through the center of the hub and bearing and is held in place using a nut, nut lock and cotter pin. Service replacement of the front hub and bearing assembly can be done with the steering knuckle remaining on the vehicle.

Fig. 7 Tie Rod Attachment 1 2 3 4 5

STEERING KNUCKLE JAM NUT (TIE ROD ADJUSTMENT) INNER TIE ROD SERRATIONS OUTER TIE ROD NUT

(12) Remove tie rod from steering knuckle using Remover, Special Tool C-3894-A (Fig. 8).

REMOVAL (1) Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove wheel and tire assembly. (3) Remove cotter pin, nut lock and spring washer from end of halfshaft stub shaft and hub nut (Fig. 1). (4) With aid of a helper applying brakes to keep front hub from turning, remove hub nut (Fig. 1). (5) Access and remove front brake rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL) (6) Disconnect vehicle wiring harness from wheel speed sensor connector (Fig. 2). (7) Unclip wheel speed sensor connector and routing clip from frame rail outer reinforcement (Fig. 2). (8) Remove screw fastening wheel speed sensor routing bracket to strut assembly (Fig. 3). (9) Open routing clip at knuckle and remove wheel speed sensor cable (Fig. 4). (10) Push in on end of halfshaft stub shaft, pushing its splines out of hub splines. (11) Remove nut attaching outer tie rod to steering knuckle (Fig. 7) by holding outer tie rod stud stationary while loosening and removing nut with a wrench.

Fig. 8 Using C-3894-A To Release Tie Rod 1 2 3 4

PULLER C-3894-A OUTER TIE ROD STEERING KNUCKLE TIE ROD STUD

(13) Remove two bolts attaching strut clevis to steering knuckle (Fig. 9) (Fig. 10). (14) Tip knuckle outward at top and remove halfshaft stub shaft from hub and bearing. Suspend driveshaft straight outward using a bungee cord or

2-6

FRONT SUSPENSION

KNUCKLE (Continued) stud from distorting while stud is released from knuckle in following step. CAUTION: Do not remove ball joint stud from steering knuckle using a hammer. Damage to Aluminum knuckle, ball joint or control arm will result. NOTE: Lubricate Remover, Special Tool C-4150A, screw-drive threads before use to ease use and promote tool longevity. (17) Place Remover, Special Tool C-4150A, over ball joint stud and nut as shown (Fig. 11). Release ball joint stud from steering knuckle by tightening tool screw-drive. To ease Remover installation and use, it may help to rotate knuckle around so inside of knuckle faces outward.

Fig. 9 Left Side Correctly Oriented Mounting Bolts 1 - STRUT 2 - BOLT 3 - NUT

Fig. 10 Right Side Correctly Oriented Mounting Bolts 1 - STRUT 2 - BOLT 3 - NUT

wire. Do not allow driveshaft to hang by inner joint. (15) Remove ball joint nut using a power impact wrench. Because tapered stud is held sufficiently in knuckle at this time, it is not necessary to hold stud stationary to remove nut. (16) Reinstall ball joint nut until top of nut is even with top of ball joint stud. This action will keep

Fig. 11 Using C-4150A To Release Ball Joint 1 2 3 4

- ALUMINUM KNUCKLE - SPECIAL TOOL C-4150A - LOWER CONTROL ARM - NUT INSTALLED ON BALL JOINT STEM

(18) Remove tool and nut from top of ball joint stud. (19) Remove steering knuckle from vehicle. (20) If hub and bearing needs to be transferred, remove four bolts attaching hub and bearing to knuckle, then remove hub and bearing.

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