2004 chrysler sebring and stratus senda service repair manual by servicemanual89d98

GROUP TAB LOCATOR Introduction

0 2 3 5 6 7 8A 8B 8E 8F 8G 8H 8I 8J 8L 8M 8N 8O 8P 8Q 8R 8W 9 11 13 14 19 21 22 23 24 25

Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering 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 . . . . . . . . . . . . . . . . . . . . . . . METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .

...1 ...2

...5 ..5 ...5 ...5

page TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 E-MARK LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 MANUFACTURER PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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 10 THROUGH 12 Secondary Paint

DIGIT 19 Open Space

DIGIT 13 AND 14 Open Space

DIGITS 20, 21, AND 22 Engine Code â&#x20AC;¢ ECC = 2.0L Four Cylinder 16 Valves DOHC Gasoline

DIGITS 15 THROUGH 18 Interior Trim Code

INTRODUCTION

BODY CODE PLATE (Continued) • EDV = 2.4L Four Cylinder 16 Valves DOHC Gasoline TURBO • EDZ = 2.4L Four Cylinder 16 Valves DOHC Gasoline • EEE = 2.7L Six Cylinder 24 Valves FFV • EER = 2.7L Six Cylinder 24 Valves DOHC 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 • DDR = NV T850 5-Speed Manual Transaxle DIGIT 4 Open Space 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 Identification Number (VIN) paragraph for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate (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. 2) and (Fig. 3).

INTRODUCTION

JR FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER IDENTIFICATION

INTRODUCTION

FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH

INTRODUCTION

FASTENER USAGE

INTERNATIONAL SYMBOLS DESCRIPTION

DESCRIPTION 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.

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.

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.

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

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 (Continued) 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

JR 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) is located on 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 table for decoding information.

Fig. 7 Vehicle Identification Number (VIN Plate) 1 2 3 4

V.I.N. PLATE DASH PANEL 17 DIGITS WINDSHIELD OPENING

VIN CODE BREAKDOWN POSITION

INTERPRETATION

Country of Origin

Make

CODE = DESCRIPTION 1 = Manufacture By DaimlerChrysler Corporation. B = Dodge C = Chrysler

Vehicle Type

Passenger Safety

3 = Passenger Car A = Active Front and Side Airbag D = Without Airbags E = Active Driver and Passenger Airbag

Car Line

Series

J = Stratus/Cirrus L = Sebring 3 = M (Medium) 4 = H (High line) 5 = P (Premium) 6 = S (Sport) 7 = X (Special)

Transmission Table For Bux w/ABB, ABJ 7

Body Style

B = 4 Speed Automatic N = 5-Speed Manual 5 = Convertible / Open Body 6 = 4 Door Sedan

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER (Continued) POSITION

INTERPRETATION

Engines

CODE = DESCRIPTION J = 2.4L 4 Cyl. 16V Pzev R = 2.7L 6 Cyl. 24V DOHC Gasoline S = 2.4L 4 Cyl. 16V DOHC Turbo Gasoline T = 2.7L 6 Cyl. 24V DOHC FFV X = 2.4L 4 Cyl. 16V DOHC Gasoline

Check Digit

0 through 9 or X

Model Year

4 = 2004

Plant

12 through 17

Sequence Number

N = Sterling Heights Assembly Plant 6 digit number assigned by assembly plant.

VIN CHECK DIGIT DESCRIPTION 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.

VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety 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 SAFETY CERTIFICATION LABEL TYPICAL • Regulation Amendment Number • Approval Number

E-MARK LABEL DESCRIPTION An E-mark Label (Fig. 9) 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

Fig. 9 E-MARK LABEL 1 2 3 4

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

INTRODUCTION

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicleâ&#x20AC;&#x2122;s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

1. 2. 3. 4. 5.

Vehicle Identification Number (VIN) Gross Vehicle Mass (GVM) Gross Train Mass (GTM) Gross Front Axle Rating (GFAR) Gross Rear Axle Rating (GRAR)

MANUFACTURER PLATE DESCRIPTION The Manufacturer Plate (Fig. 10) is located in the engine compartment on the passenger side rear corner of the hood. The plate contains five lines of information:

Fig. 10 MANUFACTURER PLATE

LUBRICATION & MAINTENANCE

0-1

LUBRICATION & MAINTENANCE TABLE OF CONTENTS page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE OIL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE COOLANT . . . . . DESCRIPTION - FLEXIBLE FUEL VEHICLES (2.7L ENGINES ONLY) . . . . . . . . . . . . . . . . DESCRIPTION - AUTOMATIC/MANUAL TRANSAXLE FLUID . . . . . . . . . . . . . . . . . . DESCRIPTION - FUEL REQUIREMENTS . . FLUID CAPACITIES SPECIFICATIONS FLUID CAPACITIES . . . . . . . . . . . . . . . . . .

...1

...1 ...3 ...3 ...4 ...5

page FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LUBRICATION POINTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MAINTENANCE SCHEDULES DESCRIPTION DESCRIPTION ........................7 DESCRIPTION - EXPORT . . . . . . . . . . . . . . . 13 HOISTING STANDARD PROCEDURE - HOISTING . . . . . . . 17 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING . 17 TOWING STANDARD PROCEDURE - TOWING . . . . . . . . 18

...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. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI)

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

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. 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.

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.

Fig. 3 API SYMBOL

ENGINE OIL ADDITIVES/SUPPLEMENTS 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.

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

LUBRICATION & MAINTENANCE

0-3

FLUID TYPES (Continued) 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.

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 VEHICLES (2.7L ENGINES ONLY) 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. CAUTION: Only vehicles with the E-85 fuel filler door label can operate on E-85.

Ethanol Fuel (E-85) 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.

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.

0-4

LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

Fuel Requirements

Cruising Range

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.

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.

NOTE: When the ambient temperature is above 90°F, you may experience hard starting and rough idle following start up even if the above recommendations are followed.

Maintenance If you operate the vehicle using E-85 fuel, follow Schedule B in the maintenance schedule section of this manual.

Engine Oil Selection for Operating on E-85

DESCRIPTION - AUTOMATIC/MANUAL TRANSAXLE FLUID

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.

Engine Oil Selection for Operating on Gasoline If you operate the vehicle on regular unleaded gasoline ONLY, use Mopart oil or an equivalent that meets certified API (American Petroleum Institute) Quality.

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.

Replacement Parts Many components in your Flexible Fuel Vehicle (FFV) are designed to be compatible with ethanol. Always be sure that your vehicle is serviced with correct ethanol compatible parts. CAUTION: Replacing fuel system components with non-ethanol compatible components can damage your vehicle and may void the warranty.

NOTE: Refer to the maintenance schedules in the vehicle 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 Fluid) is required in the 41TE automatic and T350/T850 manual transaxles. Substitute fluids can induce torque converter clutch shudder, or premature geartrain 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. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure.

LUBRICATION & MAINTENANCE

0-5

FLUID TYPES (Continued) 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 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.

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

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 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.

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LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

MATERIALS ADDED TO FUEL

FLUID CAPACITIES

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.

SPECIFICATIONS

FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle’s performance: • 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. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you.

FLUID CAPACITIES DESCRIPTION

SPECIFICATION

Fuel Tank

60.5L (16.0 gal.) Engine Oil

2.0L Engines*

4.25L (4.5 qts.)

2.4L Engines*

4.75L (5.0 qts.)

2.7L Engines*

4.75L (5.0 qts.)

COOLING SYSTEM** 2.0L Engine

7.5L (8.0 qts.)

2.4L Engine

7.5L (8.0 qts.)

2.7L Engine

9.0L (9.5 qts.)

AUTOMATIC TRANSAXLE Automatic Transaxle Estimated Service Fill

3.8L (4.0 qts.)

Automatic Transaxle Overhaul Capacity with Torque Converter Empty

8.7L (9.2 qts.)

MANUAL TRANSAXLE Capacity-T350

2.4-2.7L (2.5-2.8 qts.)

Capacity-T850

2.4-2.7L (2.5-2.8 qts.)

*(includes new filter) **(includes heater and recovery bottle)

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 DESCRIPTION DESCRIPTION There are two maintenance schedules for North America 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).L • 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: 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 “B” . NOTE: Under no circumstances should oil change intervals exceed 6 months or 6,000 miles, whichever comes first. CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

LUBRICATION & MAINTENANCE

0-7

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. • 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 linings, hoses and calipers. • Inspect the CV joints and front and rear suspension components. • Check the automatic transmission fluid level. • Check the manual 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). NOTE: In 2.7L Engines equipped with Flex Fuel Engine (FFV), change engine oil every 5 months or 5,000 miles, whichever comes first. This applies to both Maintenance Schedule A and B.

0-8

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B - NORTH AMERICA 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 (16.2 km). • More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).L Miles

• Trailer towing.L • Taxi, police or delivery service (commercial services).L • Off-road or desert operation. • If equipped for and operating with E-85 (ethanol) fuel. 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.

3,000

6,000

9,000

12,000

15,000

18,000

(5 000)

(10 000)

(14 000)

(19 000)

(24 000)

(29 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Inspect the front and rear brake linings and rotors. Miles

21,000

24,000

27,000

30,000

33,000

36,000

(34 000)

(38 000)

(43 000)

(48 000)

(53 000)

(58 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

(Kilometers)

Replace the air cleaner filter.

Inspect the front and rear brake linings and rotors.

Check and replace, if necessary, the PCV valve.*

Replace the spark plugs on 2.4 liter engines.

Miles

39,000

42,000

45,000

48,000

51,000

54,000

(62 000)

(67 000)

(72 000)

(77 000)

(82 000)

(86 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Inspect the front and rear brake linings and rotors.

LUBRICATION & MAINTENANCE

0-9

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B - NORTH AMERICA Miles

57,000

60,000

63,000

66,000

69,000

72,000

(91 000)

(96 000)

(101 000)

(106 000)

(110 000)

(115 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Replace the air cleaner filter.

Inspect the front and rear brake linings and rotors.

Replace the ignition cables on 2.4 liter engine.

Replace alternator with accessory drive belts on the 2.7 liter engine.

Replace the spark plugs on the 2.4 liter engine.

Check and replace, if necessary, the PCV valve. *â&#x20AC;Ą

Change the automatic transmission fluid and filter.L

Miles

75,000

78,000

81,000

84,000

87,000

90,000

(120 000)

(125 000)

(130 000)

(134 000)

(139 000)

(144 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Replace the air cleaner filter.*

Replace the engine timing belt on 2.4 liter engine.

Inspect the front and rear brake linings and rotors.

Replace the spark plugs on 2.4 liter engine.

Inspect and replace PCV Valve if required.

0 - 10

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B - NORTH AMERICA Miles

93,000

96,000

99,000

100,000

102,000

105,000

(149 000)

(154 000)

(158 000)

(160 000)

(163 000)

(168 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Replace the air cleaner filter. Inspect the front and rear brake linings and rotors.

X X

Flush and replace the engine coolant.

Replace the spark plugs on the 2.7 liter engine.

Check and retension accessory drive belts on 2.7 liter engine. Replace the accessory drive belts on 2.4 liter engine.

* 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 - 11

MAINTENANCE SCHEDULES (Continued)

SCHEDULE A - NORTH AMERICA 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.

Inspect the air cleaner filter and replace if necessary.*

(Kilometers)

Replace the air cleaner filter.*

Replace the spark plugs on 2.4 liter engine.

X X

Inspect the front brake pads and rear brake linings, rotors and drums. Inspect and replace PCV valve if required. Miles

42,000

48,000

54,000

60,000

66,000

72,000

(67 000)

(77 000)

(86 000)

(96 000)

(106 000)

(115 000)

[42]

[48]

[54]

[60]

[66]

[72]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

(Kilometers) [Months]

Replace the air cleaner filter.* Inspect the front brake pads and rear brake linings, rotors, drums.

X X

Replace the spark plugs on 2.4 liter engine.

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

Check and replace, if necessary, the PCV valve. *â&#x20AC;Ą

Replace the ignition cables on 2.4 liter engine.

Replace alternator with accessory drive belts in 2.7 liter engine.

0 - 12

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE A - NORTH AMERICA Miles

78,000

84,000

90,000

96,000

102,000

(125 000)

(134 000)

(144 000)

(154 000)

(163 000)

[78]

[84]

[90]

[96]

[102]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

(Kilometers) [Months]

Replace the air cleaner filter.*

Inspect the front brake pads and rear brake linings, rotors.

Replace the spark plugs on 2.4 liter engine.

Replace the spark plugs on 2.7 liter engine. Check and replace, if necessary, the PCV valve.*â&#x20AC;Ą

X X

Replace the engine timing belt on 2.4 liter engine.*

Check and retension alternator drive belts on 2.7 liter engine.

Replace the accessory drive belts on 2.4L engine. Flush and replace the engine coolant at 60 months or 100,000 miles. * 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 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.

LUBRICATION & MAINTENANCE

0 - 13

MAINTENANCE SCHEDULES (Continued)

DESCRIPTION - EXPORT

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

There are two maintenance schedules Export Only 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 “B”. 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 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).L • 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: 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.

At Each Oil Change • Change the engine oil filter. • Inspect the exhaust system. • Inspect the brake linings, hoses and calipers. • Inspect the CV joints and front and rear suspension components. • Check the automatic transmission fluid level. • Check the manual 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).

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. NOTE: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.

SCHEDULE A - EXPORT ONLY Kilometers

12 000

24 000

36 000

48 000

60 000

(Miles)

(7,500)

(15,000)

(22,500

(30,000)

(37,500)

[Months]

[6]

[12]

[18]

[24]

[30]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

Replace the air cleaner filter. *

Replace the spark plugs on 2.0 liter engine.

Inspect the front brake pads and rear brake linings, rotors and drums.

0 - 14

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE A - EXPORT ONLY Kilometers

72 000

84 000

96 000

108 000

120 000

(45,000)

(52,500)

(60,000)

(67,500)

(75,000)

[36]

[42]

[48]

[54]

[60]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

(Miles) [Months]

Replace the air cleaner filter.* Inspect the front brake pads and rear brake linings, rotors, drums.

X X

Replace the spark plugs on 2.0 liter engine.

Flush and replace engine coolant at 60 months or 160,000 km.

Check and replace, if necessary, the PCV valve. *

Replace the ignition cables on 2.0 liter engine.

Replace alternator drive belts in 2.7 liter engine.

Kilometers

132 000

144 000

156 000

168 000

(Miles)

(82,000)

(90,000)

(97,500)

(105,000)

[66]

[72]

[78]

[84]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

[Months]

Replace the air cleaner filter.*

Inspect the front brake pads and rear brake linings, rotors.

Replace the spark plugs on 2.0 liter engine.

Check and replace, if necessary, the PCV valve.*â&#x20AC;Ą

Replace the engine timing belt on 2.0 liter engine.*

Check and retension alternator drive belts on 2.7 liter engine.

Replace the drive belts.

Flush and replace the engine coolant at 160,000 km if not done at 60 months.

* 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 - 15

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 48,000 miles (77 000 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 (16.2 km). Kilometers

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).L • Trailer towing.L • Taxi, police or delivery service (commercial services).L • Off-road or desert operation. • If equipped for and operating with E-85 (ethanol) fuel. If ANY of these apply to you, change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first, and follow the maintenance recommendations in “Maintenance Schedule B.”

5 000

10 000

14 000

19 000

24 000

29 000

(3,000 )

(6,000 )

(9,000)

(12,000)

(15,000)

(18,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Miles)

Inspect the front and rear brake linings and rotors. Kilometers

34 000

38 000

43 000

48 000

53 000

58 000

(21,000)

(24,000)

(27,000)

(30,000)

(33,000)

(36,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

(Miles)

Replace the air cleaner filter.

Inspect the front and rear brake linings and rotors.

Check and replace, if necessary, the PCV valve.*

Replace the spark plugs on 2.0 liter engines.

Kilometers

62 000

67 000

72 000

77 000

82 000

86 000

(39,000)

(42,000)

(45,000)

(48,000)

(51,000)

(54,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

(Miles)

Inspect the front and rear brake linings and rotors.

Change the automatic transmision fluid and filter.

0 - 16

LUBRICATION & MAINTENANCE

MAINTENANCE SCHEDULES (Continued)

SCHEDULE B — EXPORT ONLY Kilometers

91 000

96 000

101000

106000

110000

115000

(57,000)

(60,000)

(63,000)

(66,000)

(69,000)

(72,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if

(Miles)

necessary.* X

Replace the air cleaner filter. Inspect the front and rear brake linings and rotors.

Replace the ignition cables on 2.0 liter engine.

Replace the accessory drive belts on 2.0 and 2.7 liter engines.

Replace the spark plugs on the 2.0 and 2.7 liter

engines. Kilometers

120000

125000

130000

134000

139000

144000

(Miles)

(75,000)

(78,000)

(81,000)

(84,000)

(87,000)

(90,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

X X

Replace the air cleaner filter.* Inspect the front and rear brake linings and rotors.

Check and replace, if necessary, the PCV valve.*‡

Replace the spark plugs on 2.0 liter engine.

Replace engine timing belt on 2.0 liter engines.

Kilometers

149000

154000

158000

(Miles)

(93,000)

(96,000)

(99,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if necessary.*

Inspect the front and rear brake linings and rotors.

Change the automatic transmission fluid and filter.

160000

(100,000) (102,000)

Flush and replace the engine coolant at 60 months or 160,000 km.

Replace the spark plugs on the 2.7 liter engine.

Check and retension accessory drive belts on 2.7 liter engine * 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.

163000

168000 (105,000)

LUBRICATION & MAINTENANCE

0 - 17

HOISTING STANDARD PROCEDURE - HOISTING Refer to Ownerâ&#x20AC;&#x2122;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. Refer to (Fig. 5), OR (Fig. 6) for proper locations.

Fig. 6 HOISTING AND JACKING POINTS - JR-27 1 2 3 4 5

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

JUMP STARTING STANDARD PROCEDURE - JUMP STARTING

Fig. 5 HOISTING AND JACKING POINTS - JR-41 1 2 3 4 5

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

WARNING: 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.

0 - 18

LUBRICATION & MAINTENANCE

JUMP STARTING (Continued) CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. • Low battery fluid level. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, 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. (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. 7). (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. 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.

Fig. 7 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

BATTERY POSITIVE CABLE POSITIVE JUMPER CABLE TEST INDICATOR BATTERY NEGATIVE CABLE BATTERY NEGATIVE JUMPER CABLE ENGINE GROUND

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 PRECAUTIONS 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.

LUBRICATION & MAINTENANCE

0 - 19

TOWING (Continued) 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.

RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift (Fig. 8) 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.

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 TOWING WITH TOW BAR • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Five speed manual transaxle vehicles can be flat towed at any legal highway speed for extended distances. The gear selector must be in the neutral position.

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. JR vehicles can be tied to a flat bed device using the reinforced loops located under the front and rear bumpers on the drivers side of the vehicle. There are also four reinforced elongated holes for T or R hooks located on the bottom of the front frame rail torque boxes behind the front wheels and forward of the rear wheels inboard of the rocker panel weld seam.

TOWING – FRONT WHEEL LIFT

Fig. 8 Recommended Towing Equipment 1 - WHEEL LIFT 2 - FLAT BED

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 lifted end of the vehicle and lower the vehicle 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 drums or rotors.

DaimlerChrysler Corporation recommends that a vehicle be towed with the front end lifted, whenever possible. A 90 cm (36 in.) length of 4x4 wood beam can be placed between the wheel lift device and the bottom of the fascia to prevent damage to vehicle during the lifting operation. The beam can removed after lifting the front of the vehicle.

TOWING – REAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lifted, the rear wheels can be lifted provided the following guide lines are observed. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. • Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. • Place front wheels on a towing dolly.

SUSPENSION

2-1

SUSPENSION TABLE OF CONTENTS page

page

SUSPENSION STANDARD PROCEDURE - LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

FRONT SUSPENSION .....................2 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 32 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 52

SUSPENSION STANDARD PROCEDURE - LUBRICATION POINTS There are no serviceable lubrication points on the suspension of this vehicle. All joints are sealed-forlife type and require no maintenance.

2-2

FRONT SUSPENSION

FRONT SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION . . . . . . . 3 OPERATION - FRONT SUSPENSION . . . . . . . . . 4 WARNING .............................4 CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE . . 4 SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 5 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DIAGNOSIS AND TESTING - HUB AND BEARING ............................6 REMOVAL .............................6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING - STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOWER BALL JOINT SEAL BOOT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DIAGNOSIS AND TESTING - LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DISASSEMBLY DISASSEMBLY - FRONT ISOLATOR BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

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FRONT SUSPENSION

FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION This vehicle’s front suspension is a short long arm (SLA) design used in conjunction with a gas pressurized shock absorber and coil spring assembly (Fig. 1). SLA offers three advantages over the customary MacPherson strut system for front-wheel-drive vehicles. • Better handling through geometry that keeps the tires more perpendicular to the road • Better noise isolation • Better ride through reduced friction The upper control arm of the vehicle is mounted using rubber isolation bushings to an aluminum casting which is attached to the shock tower using 4 mounting bolts. This aluminum casting is also used as the upper mount for the front shock/coil spring assembly. The shock absorber is isolated from the aluminum bracket using a microcellular urethane

isolator. The lower control arm is mounted to the vehicle’s front suspension crossmember using 2 through bolts per control arm. The lower control arm is also isolated from the vehicle using 2 rubber bushings of unique design for the front and rear mounting location. The bottom of the shock absorber is mounted to the lower control arm by a clevis bracket which is part of the shock absorber assembly. The clevis bracket is mounted to and isolated from the lower control arm using a rubber isolation bushing and a through-bolt. The front steering knuckle is mounted to the vehicle by a ball joint located in the upper and lower control arms. A sealed for life front hub and bearing assembly is attached to the front steering knuckle. The outer C/V joint assembly is splined to the front hub and bearing assembly and is retained by a nut, nut retainer and cotter pin.

Fig. 1 Front Suspension Components (Typical) 1 2 3 4

UPPER CONTROL ARM FRONT SUSPENSION CROSSMEMBER STABILIZER BAR HUB AND BEARING

2-3

5 - STEERING KNUCKLE 6 - LOWER CONTROL ARM 7 - SHOCK ASSEMBLY

2-4

FRONT SUSPENSION

FRONT SUSPENSION (Continued)

OPERATION - FRONT SUSPENSION The front suspension allows each front wheel on vehicle to adapt to different road surfaces and conditions without affecting the control of the vehicle. Each side of the front suspension is allowed to move independently from the other. Both sides of the front suspension are allowed to pivot so the vehicle can be steered in the direction preferred. Steering of the vehicle is provided by a rack and pinion steering gear which is connected directly to each steering knuckle by an outer tie rod.

original plastic clip. Also, NO holes can be drilled into the front shock tower in the area shown in (Fig. 2), for the installation of any metal fasteners into the shock tower. Because of the minimum clearance in this area installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. NOTE: If a suspension component becomes bent, damaged or fails, no attempt should be made to straighten or repair it. Always replace it with a new component.

WARNING WARNING: DO NOT REMOVE A SHOCK ROD NUT WHILE THE SHOCK ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE THE SHOCK ASSEMBLY SPRING IS COMPRESSED.

SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION

CAUTION CAUTION: Only frame contact hoisting equipment should be used on this vehicle. All vehicles have a fully independent rear suspension. Vehicles must not be hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used, damage to rear suspension components will occur. 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

TORQUE

Shock Assembly Clevis Pinch Bolt

88 N·m (65 ft. lbs.)

Shock Tower Bolts

101 N·m (75 ft. lbs.)

Clevis To Control Arm Bolt

88 N·m (65 ft. lbs.)

Rod To Upper Mount Nut

54 N·m (40 ft. lbs.)

Steering Knuckle Disc Brake Caliper Adapter Bolts

108 N·m (80 ft. lbs.)

Tie Rod Nut

61 N·m (45 ft. lbs.)

Tie Rod Adjustment Jam Nuts

61 N·m (45 ft. lbs.)

Hub And Bearing Axle Hub Nut

203 N·m (150 ft. lbs.)

Wheel Stud Lug Nut

135 N.m (100 ft. lbs.)

Upper Control Arm Ball Joint Stud Nut

27 N·m (20 ft. lbs.)

Shock Bracket Bolt

90 N·m (66 ft. lbs.)

Lower Control Arm

Fig. 2 Shock Tower To Spring Minimum Clearance Area 1 - SHOCK TOWER 2 - COIL SPRING 3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL FASTENERS ARE TO BE INSTALLED IN SHOCK TOWER AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER IN THIS SAME AREA.

Ball Joint Stud Castle Nut

74 N·m (55 ft. lbs.)

Crossmember Front Pivot Bolt

183 N·m (135 ft. lbs.)

Crossmember Rear Bolt

95 N·m (70 ft. lbs.)

Ball Joint Heat Shield Attaching Bolts

13 N·m (10 ft. lbs.)

Stabilizer Bar Bushing Clamp Bolts

61 N·m (45 ft. lbs.)

Link Nuts

101 N·m (75 ft. lbs.)

FRONT SUSPENSION

2-5

FRONT SUSPENSION (Continued)

SPECIAL TOOLS FRONT SUSPENSION

Remover/Installer Control Arm Bushing 6602â&#x20AC;&#x201C;5 (In Tool Kit 6602) Puller C-3894-A

Installer/Receiver, Control Arm Bushing 6876 Installer, Ball Joint 6758

Remover / Installer C-4366-2 (In Tool Kit C-4366)

Press, Ball Joint Remover/Installer C-4212F

Receiver, Ball Joint 6756

Remover, Ball Joint MB-990799

Installer, Bushing 6760

2-6

FRONT SUSPENSION

FRONT SUSPENSION (Continued) mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly.

OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel.

Remover/Installer Control Arm Clevis Bushing 6877

Installer, Ball Joint Seal Boot Retainer 6875

Remover, Tie Rod

DIAGNOSIS AND TESTING - HUB AND BEARING The hub and 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. The bearing is not serviceable. 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 2 - BRAKES/HYDRAULIC-MECHANICAL/ROTOR - DIAGNOSIS AND TESTING).

REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/JUMP STARTING - STANDARD PROCEDURE). (2) Remove front tire and wheel assembly. CAUTION: Wheel bearing damage will result if hub nut is loose, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.

Remover, Lower Ball Joint C-4150A

HUB / BEARING DESCRIPTION The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The hub and bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub and bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective. The wheel

(3) Loosen hub nut with brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. (4) Remove disc brake caliper, adapter, shoes and rotor from steering knuckle. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTOR - REMOVAL) (5) If equipped with antilock brakes, remove bolt securing wheel speed sensor cable routing bracket to steering knuckle (Fig. 3). (6) Remove nut from upper ball joint stud. (7) Remove upper ball joint stud from steering knuckle using Puller, Special Tool, C-3894-A (Fig. 4).

FRONT SUSPENSION

2-7

HUB / BEARING (Continued) (9) Remove 3 bolts attaching the hub and bearing assembly to steering knuckle (Fig. 5).

Fig. 3 Speed Sensor Cable Routing Bracket 1 2 3 4 5

- WHEEL SPEED SENSOR CABLE - SPEED SENSOR CABLE ROUTING BRACKET - STEERING KNUCKLE - ATTACHING BOLT - BRAKE CALIPER FLEX HOSE

Fig. 5 Hub And Bearing Attaching Bolts 1 - STEERING KNUCKLE 2 - HUB AND BEARING ASSEMBLY 3 - ATTACHING BOLTS

(10) Remove hub and bearing assembly from front of steering knuckle. NOTE: If bearing will not come out of steering knuckle, it can be tapped out using a soft faced hammer.

INSTALLATION

Fig. 4 Ball Joint Stud Removal From Steering Knuckle 1 2 3 4 5

BALL JOINT BALL JOINT STUD SPECIAL TOOL C-3894-A SHOCK ABSORBER ASSEMBLY UPPER CONTROL ARM

NOTE: Care must be taken not to separate driveshaft inner C/V joint during the following steps. Do not allow driveshaft to hang by inner C/V joint; driveshaft must be supported. (8) Separate steering knuckle (hub and bearing) from outer C/V joint by tipping top of steering knuckle outward while sliding outer C/V joint out rear of hub and bearing. Once separated, support outer end of driveshaft with wire hanger or cord to avoid damaging inner C/V joint.

(1) Thoroughly clean all hub and bearing assembly mounting surfaces on steering knuckle. (2) Install hub and bearing assembly in steering knuckle aligning bolt boles in bearing flange with holes in steering knuckle. (3) Install 3 mounting bolts (Fig. 5) and tighten evenly to ensure bearing is square to face of steering knuckle. Tighten mounting bolts to 110 N·m (80 ft. lbs.) torque. (4) Slide driveshaft outer C/V into front hub and bearing assembly. (5) Install steering knuckle onto upper ball joint stud and install nut. (6) Using a crow foot and torque wrench, tighten upper ball joint nut to 27 N·m (20 ft. lbs.) torque. (7) If equipped with antilock brakes, install wheel speed sensor cable routing bracket on steering knuckle (Fig. 3). Install and tighten mounting bolt to 12 N·m (105 in. lbs.) torque. (8) Install brake rotor, and caliper, shoes and adapter assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - INSTALLATION) (9) Clean all foreign matter from threads of outer C/V joint stub axle.

2-8

FRONT SUSPENSION

HUB / BEARING (Continued) (10) Install hub nut on C/V joint stub axle threads. With vehicle brakes applied to keep stub axle from turning, tighten hub nut to 203 N·m (150 ft. lbs.) torque. (11) Install wheel and tire assembly. Install wheel mounting nuts and progressively tighten in crisscross sequence. Tighten nuts to a torque of 135 N·m (100 ft. lbs.). (12) Lower vehicle. (13) Set front toe on vehicle to required specification. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

(3) Loosen hub nut with brakes applied.The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. (4) Remove disc brake caliper, adapter, shoes and rotor from steering knuckle. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTORS - REMOVAL) (5) Remove nut attaching outer tie rod to steering knuckle (Fig. 6). Remove nut from tie rod by holding tie rod stud with a socket while loosening and removing nut with wrench (Fig. 6).

KNUCKLE DESCRIPTION The steering knuckle is a single casting with legs machined for attachment to the vehicle’s upper and lower control arm ball joints. the steering knuckle has the hub and bearing mounted in its center. The axle shaft constant velocity joint stub shaft is splined through the hub and bearing assembly in the center of the knuckle. The steering knuckle also supports and aligns the front brake caliper adapter and caliper assembly.

OPERATION The steering knuckle pivots between the upper and lower ball joints. 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 and bearing and axle shaft.

DIAGNOSIS AND TESTING - STEERING KNUCKLE

Fig. 6 Outer Tie Rod Attaching Nut 1 2 3 4 5

TIE ROD HEAT SHIELD STEERING KNUCKLE TIE ROD STUD NUT

(6) Remove the tie rod end from the steering knuckle using Remover, Special Tool C-3894-A. (7) Remove ABS wheel speed sensor cable routing bracket from steering knuckle (Fig. 7).

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 (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - SERVICE PROCEDURE). (2) Remove front tire and wheel assembly from hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.

Fig. 7 Speed Sensor Cable Routing Bracket 1 2 3 4 5

- WHEEL SPEED SENSOR CABLE - SPEED SENSOR CABLE ROUTING BRACKET - STEERING KNUCKLE - ATTACHING BOLT - BRAKE CALIPER FLEX HOSE

FRONT SUSPENSION

2-9

KNUCKLE (Continued) (8) Remove cotter pin and castle nut from lower ball joint stud (Fig. 8).

Fig. 9 Separating Ball Joint Stud From Steering Fig. 8 Lower Ball Joint Attachment To Steering Knuckle 1 2 3 4 5 6

DRIVESHAFT COTTER PIN CASTLE NUT HEAT SHIELD LOWER CONTROL ARM SHOCK ABSORBER CLEVIS

CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 9 below.

1 2 3 4 5

HAMMER BALL JOINT STUD STEERING KNUCKLE BOSS HEAT SHIELD LOWER CONTROL ARM

(10) Lift up on steering knuckle separating it from lower ball joint stud. Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut. (11) Separate steering knuckle from outer C/V joint. Separate steering knuckle from outer C/V joint holding driveshaft in place while pulling steering knuckle away from outer C/V joint (Fig. 10).

CAUTION: When striking the steering knuckle, do not hit the heat shield covering the ball joint grease seal. Bending the heat shield against the ball joint grease seal will cause the grease seal to fail. (9) Turn steering knuckle so front of it is facing as far outboard in wheel well as possible. Using a hammer, strike boss on steering knuckle (Fig. 9) until steering knuckle separates from lower ball joint stud. CAUTION: Care must be taken not to separate the inner C/V joint during the following steps. Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint, thus damaging it. Do not allow driveshaft to hang by inner C/V joint; driveshaft must be supported upon removal from knuckle.

Fig. 10 Separating Steering knuckle from driveshaft 1 2 3 4

HUB/BEARING BEARING SHIELD OUTER C/V JOINT STEERING KNUCKLE

2 - 10

FRONT SUSPENSION

KNUCKLE (Continued) (12) Remove nut from upper ball joint stud. (13) Remove upper ball joint stud from steering knuckle using Puller, Special Tool, C-3894-A (Fig. 11).

(7) Install wheel speed sensor cable routing bracket on steering knuckle (Fig. 7) and securely tighten attaching bolt. CAUTION: When installing tie rod on steering knuckle, the heat shield (Fig. 12) must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. (8) Install outer tie rod stud into steering knuckle. Start outer tie rod attaching nut onto tie rod stud. While holding stud of tie rod stationary, tighten nut using a crowfoot and socket to 61 N·m (45 ft. lbs.) torque (Fig. 12).

Fig. 11 Ball Joint Stud Removal From Steering Knuckle 1 2 3 4 5

BALL JOINT BALL JOINT STUD SPECIAL TOOL C-3894-A SHOCK ABSORBER ASSEMBLY UPPER CONTROL ARM

(14) Remove steering knuckle from vehicle. (15) If necessary, remove lower ball joint grease seal heat shield on steering knuckle. (16) If steering knuckle is being replaced and hub and bearing is found to be in usable condition, it can be transferred to replacement steering knuckle. To remove the hub and bearing, (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING - REMOVAL).

INSTALLATION (1) If required, install hub/bearing assembly into steering knuckle before installing steering knuckle on vehicle. (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING - INSTALLATION) (2) If removed, install lower ball joint grease seal heat shield on steering knuckle. (3) Slide driveshaft into front hub/bearing assembly as steering knuckle is installed onto lower ball joint stud. (4) Install lower ball joint castle nut. Do not tighten at this time. (5) Install upper ball joint in steering knuckle. Install upper ball joint nut. Tighten upper ball joint nut to 27 N·m (20 ft. lbs.) torque. (6) Using a crowfoot and torque wrench, tighten the lower ball joint nut 75 N·m (55 ft. lbs.) torque (Fig. 8). Install cotter pin.

Fig. 12 Torquing Tie Rod Attaching Nut 1 2 3 4 5 6

HEAT SHIELD OUTER TIE ROD STEERING KNUCKLE TORQUE WRENCH 11/32 SOCKET CROWFOOT

(9) Install brake rotor, and caliper, shoes and adapter assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION) (10) Clean all foreign matter from threads of outer C/V joint stub axle. Install hub nut onto driveshaft stub axle. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 N·m (150 ft. lbs.) torque. (11) Install front wheel and tire assembly. Install front wheel lug nuts and progressively tighten in crisscross sequence to 135 N·m (100 ft. lbs.) torque. (12) Lower vehicle. (13) Set front toe on vehicle to required specification. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

FRONT SUSPENSION

LOWER BALL JOINT DESCRIPTION The ball joint used in the lower control arm of this vehicle is a sealed for life ball joint. The ball joint can not be replaced as a separate component of the lower control arm assembly. If the ball joint is determined to be defective it will require replacement of the complete lower control arm assembly. The lower ball joint connection to the steering knuckle is achieved by an interference fit created by the tapered stud of the ball joint and a tapered hole in the steering knuckle. The ball joint stud is retained in the steering knuckle using a castle nut and a cotter pin. The cotter pin is used for positive retention of the castle nut. The lower ball joint is lubricated for life at the time it is assembled in the lower control arm. NOTE: The ball joint does not require any type of additional lubrication for the life of the vehicle. No attempt should be made to ever add any lubrication to the lower ball joint.

DIAGNOSIS AND TESTING - LOWER BALL JOINT (1) Raise the vehicle on jack stands or centered on a frame contact type hoist. (Refer to LUBRICATION & MAINTENANCE/HOISTING - SERVICE PROCEDURE). (2) Install a dial indicator on the vehicle so it is contacting the top surface of the steering knuckle near the lower ball joint stud castle nut. (3) Grab wheel and tire assembly and push it up and down firmly. (4) Record the amount of up and down movement of the steering knuckle recorded on the dial indicator. (5) Replace lower control arm if the movement in the lower control arm exceeds 1.5 mm (.059 in.).

LOWER BALL JOINT SEAL BOOT REMOVAL CAUTION: seal boot seal boot procedure

The replacement of the lower ball joint can only be done in the event that the is damaged while performing a service on the vehicle.

2 - 11

CAUTION: Under no circumstances can a lower ball joint seal boot be replaced if it is determined that the vehicle had been driven with the seal boot damaged. If the vehicle has been driven with a damaged seal boot contamination of the ball joint has occurred. When contamination of the ball joint has occurred the lower control arm must be replaced. This is to ensure excessive wear of the ball joint does not occur from the contamination present in the ball joint. CAUTION: Excessive wear in the ball joint can lead to a separation of the ball joint from the lower control arm. CAUTION: The procedure below must be carefully followed when replacing the ball joint seal in the event it is damaged while servicing a vehicle. CAUTION: The ball joint used in the lower control arm of this vehicle is a lubricated for life ball joint. This ball joint does not required any additional lubrication for the life of the vehicle. Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint. If it is determined that the ball joint is lacking proper lubrication, the lower control arm will need to be replaced. (1) Remove lower control arm assembly from vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL). (2) Wrap a shop towel around the ball joint and seal boot. This is to prevent dirt and cleaning solvent to enter ball joint when cleaning area around ball joint. (3) Using ONLY a solvent such as Mopar Foamy Engine Degreaser or an equivalent, thoroughly clean lower control arm in area around ball joint and seal. Then using a shop towel saturated with the engine degreaser, carefully wipe off the ball joint seal boot.

2 - 12

FRONT SUSPENSION

LOWER BALL JOINT SEAL BOOT (Continued) (4) Using 2 screwdrivers (Fig. 13) remove the ball joint seal retaining ring from the bottom of the ball joint seal.

CAUTION: The procedure below must be carefully followed when replacing the ball joint seal in the event it is damaged while servicing a vehicle. CAUTION: The ball joint used in the lower control arm of this vehicle is a lubricated for life ball joint. This ball joint does not required any additional lubrication for the life of the vehicle. Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint. If it is determined that the ball joint is lacking proper lubrication, the lower control arm will need to be replaced. CAUTION: When replacing ball joint seal, do not use any other type of grease to lubricate ball joint other than the lubricant provided in the Mopar Ball Joint Seal service kit.

Fig. 13 Removing Ball Joint Seal Retaining Ring 1 2 3 4 5 6

UPPER SEALING RING LOWER CONTROL ARM BALL JOINT SCREWDRIVERS BALL JOINT SEAL RETAINING RING BALL JOINT SEAL

(1) Apply grease from the ball joint seal kit, to the specified areas of the ball joint stud and seal (Fig. 14). Be sure no grease is present on the seal boot installation section of the seal boot or lower control arm (Fig. 14).

(5) Remove ball joint seal from ball joint.

INSTALLATION CAUTION: seal boot seal boot procedure

The replacement of the lower ball joint can only be done in the event that the is damaged while performing a service on the vehicle.

Fig. 14 Grease Correctly Applied To Ball Joint Stud And Seal Boot 1 - UPPER SEALING RING 2 - LIP 3 - GREASE 4 - BALL JOINT STUD TAPERED SECTION 5 - GREASE 6 - BOOT INSTALLATION SECTION Wipe off the grease. 7 - BOOT INSTALLATION SECTION Wipe off the grease. 8 - BALL JOINT SEAL BOOT

(2) Slide ball joint seal boot with upper seal ring installed, (Fig. 14) down tapered section of ball joint stud (Fig. 14). Seal boot is to be installed on stud of ball joint until seal boot is sitting on seal groove in lower control arm.

FRONT SUSPENSION

2 - 13

LOWER BALL JOINT SEAL BOOT (Continued) (3) Carefully position ball joint seal boot in seal retaining groove on lower control arm. After installing seal boot in retaining groove, carefully bleed air out of sealing boot without getting grease pushed into seal boot retaining groove in lower control arm. (4) Place Retaining Ring Installer, Special Tool, 6875-1 over ball joint seal boot (Fig. 15). Using adjusting knob, adjust tool so bottom edge of tool is even with top of retaining ring groove in seal boot (Fig. 15).

(5) Place seal boot retaining ring on Installer, Special Tool, 6875- 1 (Fig. 16). Then place expandable collar from Installer, Special Tool, 6875 over tapered cone of the special tool (Fig. 16).

Fig. 16 Retaining Ring And Expandable Collar Installed On Tool 1 - SPECIAL TOOL 6875 2 - LOWER CONTROL ARM 3 - SEAL BOOT RETAINING RING

(6) Using the expandable collar of Installer, Special Tool, 6875 (Fig. 17) push the seal boot retaining ring down the cone of Installer, Special Tool, 6875.

Fig. 15 Correctly Installed Ball Joint Seal Retaining Ring Tool 1 - SPECIAL TOOL 6875-1 2 - ADJUSTING KNOB 3 - LOWER CONTROL ARM 4 - SEAL BOOT RETAINING RING GROOVE 5 - BOTTOM EDGE OF TOOL MUST BE EVEN WITH TOP OF RETAINING RING GROOVE IN SEAL BOOT AS SHOWN

Fig. 17 Installing Seal Boot Retaining Ring 1 - LOWER CONTROL ARM 2 - RETAINING RING 3 - SPECIAL TOOL 6875

2 - 14

FRONT SUSPENSION

LOWER BALL JOINT SEAL BOOT (Continued) (7) Continue pushing retaining ring down Installer, Special Tool, 6875, until it is installed in the retaining ring groove of the seal boot (Fig. 18)

(10) Install lower control arm assembly back on vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - INSTALLATION).

LOWER CONTROL ARM DESCRIPTION The lower control arm is a ductile iron casting using 2 rubber bushings to isolate it from the front suspension crossmember and body of the vehicle. The isolator bushings consist of 2 metal encased rubber isolated pivot bushings. 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 the front suspension crossmember using a through-bolt. The lower control arms are inter-connected through a linked rubber isolated sway bar.

Fig. 18 Retaining Ring Installed In Ball Joint Seal Boot 1 - LOWER CONTROL ARM 2 - SEAL BOOT RETAINING RING 3 - SPECIAL TOOL 6875

(8) Remove Installer, Special Tool, 6875 from the ball joint seal boot. When removing tool from seal boot be careful not to damage the seal boot with the tool. (9) Check retaining ring installation on seal boot to ensure it is fully seated in seal boot groove and the ends are not twisted (Fig. 19). Also, make sure upper sealing ring is on seal boot and correctly installed (Fig. 19). Check seal boot for damage before installing back on car.

Fig. 19 Properly Installed Ball Joint Seal Boot 1 2 3 4 5

LOWER CONTROL ARM UPPER SEALING RING SEAL BOOT RETAINING RING SEAL BOOT BALL JOINT STUD

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. It also provides a lower mounting point for the shock assembly.

DIAGNOSIS AND TESTING - LOWER CONTROL ARM If damaged, the lower control arm casting is serviced only as a complete component. Inspect lower control arm for signs of damage from contact with the ground or road debris. If lower control arm shows any sign of damage, inspect lower control arm for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. The replaceable components of the lower control arm are: the ball joint grease seal and the control arm bushings. Inspect both control arm bushings for severe deterioration, and replace if required. Inspect the lower ball joint for wear. Use the wear inspection procedure in the diagnosis and testing section in this group of service manual to determine if the wear is excessive and ball joint (lower control arm) replacement is required. Service procedures to replace these components are detailed in the specific component removal and installation sections in this group of the service manual.

REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - SERVICE PROCEDURE). (2) Remove tire and wheel assembly.

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