CHRYSLER CORPORATION 1992 Dodge Dynasty Service Manual To order the special service tools used and illustrated, please refer to the instructions on inside back cover.
NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1991 Chrysler Corporation 30M0891
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GROUP TAB LOCATOR Introduction
0
Lubrication and Maintenance
2
Suspension/Driveshafts
5
Brakes
6
Manual Transaxle Clutch
7
Cooling System
9
Engine
11
Exhaust System and Intake Manifold
13
Frame and Bumpers
19
Steering
21
Transaxle
22
Wheels/Tires
23
Body
24
Heating/Air Conditioning Index Component and System
GROUP TAB LOCATOR Introduction
8A
Battery/Starting/Charging Systems Diagnostics
8B
Battery/Starter/Alternator Service
8C
Overhead Console
8D
Ignition Systems
8E
Instrument Panel and Guages
8F
Audio System
8G
Horns
8H
Speed Control System
8J
Turn Signal/Hazard Warning Flasher
8K
Windshield Wiper/Washer Systems
8L
Lamps
8M
Restraint Systems
8N
Rear Window Defogger
8P
Power Locks
8Q
Vehicle Theft Security System
8R
Power Seats
8S
Power Windows
8T
Power Mirrors
8U
Chime Warning/Reminder Systems
14
Fuel Systems
25
Emision Control Systems Index Component and System
GROUP TAB LOCATOR GENERAL INFORMATION FUSE CHARTS AND RELAY BANKS WIRING AND COMPONENT IDENTIFICATION SPLICE LOCATIONS AA-C, D, P WIRING DIAGRAMS AC-C, D/AY-C WIRING DIAGRAMS AG-D, AJ-C WIRING DIAGRAMS AP-P, D WIRING DIAGRAMS
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INTRODUCTION
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INTRODUCTION CONTENTS page
BODY CODE PLATE LOCATION AND DECODING INFORMATION . . . . . . . . . . . . . . . INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . METRIC THREAD AND GRADE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . .
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TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . VEHICLE FAMILY IDENTIFICATION . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL . . . . .
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VEHICLE FAMILY IDENTIFICATON
VEHICLE IDENTIFICATION NUMBER
Throughout this service manual references are made to Vehicle Family, Body Codes, The letters AA, AC, AG, AJ, AP, or AY are body codes that are assigned to an individual vehicle family (Fig. 1). Also digit boxes 34, 35 and 36 on the Body Code Plate indicate the Vehicle family .
The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left windshield pillar. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle (Fig. 2) .
Fig. 2 Vehicle Identification Number (VIN Plate)
VEHICLE SAFETY CERTIFICATION LABEL
Fig. 1 Vehicle Family Identification
A vehicle safety certification label (Fig. 3) is attached to the rear facing of the driver’s door. This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included. All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification Number.
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INTRODUCTION
Fig. 3 Vehicle Safety Certification Label
VEHICLE IDENTIFICATION NUMBER DECODING CHART
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INTRODUCTION BODY CODE PLATE—AA, AC, AP AND AY VEHICLES
BODY CODE PLATE—AG AND AJ VEHICLES
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INTRODUCTION
BODY CODE PLATE LOCATION AND DECODING INFORMATION The Body Code Plate is attached to the top of the radiator closure panel in the engine compartment. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.
BODY CODE PLATE LINE 3 DIGIT BOXES 1,2 AND 3—Paint Procedure DIGIT BOXES 4 THROUGH 7—Primary Paint See Group 23, Body for color codes DIGIT BOXES 8 THROUGH 11—Secondary Paint DIGIT BOXES 12 THROUGH 15—Interior Trim Code DIGIT BOXES 16, 17 AND 18—Engine Code • EDF = 2.2 L, 4 cylinder EFI Gas—Automatic or Manual Transaxle • EDM = 2.5 L, 4 cylinder EFI Gas—Automatic or Manual Transaxle • EDS = 2.2 L, 4 cylinder, 16 valve Turbo III—Manual Transaxle • EDT = 2.5 L, 4 cylinder, Turbo I—Automatic or Manual Transaxle • EFA = 3.0 L, V6 Gas (EFI)—Automatic or Manual Transaxle • EGA = 3.3 L, V6 Gas (EFI)—Automatic • EGH = 3.8 L, V6 Gas (EFI)—Automatic
BODY CODE PLATE LINE 2 DIGIT BOXES 19 THROUGH 30—Vehicle Order Number DIGIT BOXES 31, 32 AND 33—Vinyl Roof Code DIGIT BOXES 34, 35 AND 36—Vehicle Shell Car Line • APD = Shadow • APP = Sundance • AAC = Lebaron Sedan • AAD = Spirit • AAP = Acclaim • AGV = Daytona, IROC R/T • AJC = LeBaron Coupe/Convertible
• ACC = New Yorker—New Yorker Landau—Dynasty (Canada) • ACD = Dynasty • ACY = New Yorker Fifth Avenue—Imperial DIGIT BOX 37—Price Class • E = Economy • H = High Line • L = Low Line • M = Maximum • P = Premium • S = Special/Sport • X = Performance Image DIGIT • 21 • 24 • 27 • 41 • 44
BOXES 38 AND 39—Body Type = Two Door Sedan = Two Door Hatchback = Two Door Convertible = Four Door Sedan = Four Door Hatchback
BODY CODE PLATE LINE 1 DIGIT BOXES 40, 41, AND 42—Transaxle Codes • DDM = 5-speed Manual Transaxle • DDN = 5-speed Manual Transaxle • DDV = 5-speed Manual Transaxle • DGC = 3-speed Automatic Transaxle • DGB = 4-speed Std. Duty Automatic Transaxle • DGL = 4-speed Automatic Transaxle DIGIT BOX 43—Market Code • U = United States • C = Canada • B = International • M = Mexico DIGIT BOXES 44 THROUGH 60—Vehicle Identification Number (VIN) Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will show CTD (for continued). When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.
STANDARD BODY DIMENSIONS
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INTRODUCTION
TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifications and Bolt Identification Chart in this Group for torques not listed in the individual torque charts (Fig. 4).
Common metric fastener strength classes are 9.8 and 12.9 with the class identification embossed on the head of each bolt (Fig. 6). Some metric nuts will be marked with a single digit strength number on the nut face.
Fig. 6 Metric Bolt Identification SAE strength classes range from grade 2 to 8 with line identification embossed on each bolt head. Markings corresponding to two lines less than the actual grade (Fig. 7). For Example: Grade 7 bolt will exhibit 5 embossed lines on the bolt head.
Fig. 4 Grade 5 and 8 Standard Torque Specifications Torque specifications on the Bolt Torque chart are based on the use of clean and dry threads. Reduce the torque by 10% when the threads are lubricated with engine oil and by 20% if new plated bolts are used. Various sizes of Torx head fasteners are used to secure numerous components to assemblies. Due to ever changing usage of fasteners, Torx head fasteners may not be identified in art or text.
METRIC THREAD AND GRADE IDENTIFICATION Metric and SAE thread notations differ slightly. The difference is illustrated in Figure 5.
Fig. 7 SAE Bolt Identification
INTERNATIONAL SYMBOLS Some International Symbols are used to identify controls and displays in this vehicle. These symbols are applicable to those controls which are displayed on the instrument panel or in the immediate vicinity of the driver (Fig. 8).
METRIC SYSTEM Fig. 5 Thread Notation (Metric and SAE)
Figure art, specifications, and tightening references in this Service Manual are identified in the metric system and in the SAE system.
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INTRODUCTION
Fig. 8 International Symbols During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification should be used. WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. The metric system is based on quantities of one, ten, one hundred, one thousand, and one million (Fig. 9).
Fig. 9 Metric Prefixes The following Tables will assist you in conversion procedures.
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INTRODUCTION CONVERSION TABLES
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INTRODUCTION CONVERSION TABLES
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BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
8A - 1
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS CONTENTS page
page
ALTERNATOR TEST PROCEDURES ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 17 BATTERY TEST PROCEDURES ON-VEHICLE . . . 2 FAULT CODES—ON BOARD DIAGNOSTICS . . . 20
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 IGNITION OFF DRAW (IOD) . . . . . . . . . . . . . . . . 7 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 25 STARTER TEST PROCEDURES ON VEHICLE . . . 9
GENERAL INFORMATION • For Battery, Starter or Alternator replacement refer to Group 8B, Battery/Starter/Alternator Service. This Group 8A will cover diagnostics only. The Battery, Starting, and Charging Systems operate with one another, and must be thoroughly tested as a complete system. To enable the vehicle to start and charge properly, it must have a battery that will perform to specifications. The starter motor, alternator, wiring, and electronics also must perform within specifications. Group 8A will cover Starting (Fig. 1) and Charging System (Fig. 2) diagnostic procedures. These will be covered from the most basic conventional methods to On Board Diagnostics (OBD) built into the vehicle’s electronics. The need for conventional testing equipment has not been eliminated by the introduction of OBD. Frequent use of an ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12 volt (low wattage) test light will be required.
Fig. 2 Charging System Components Fig. 1 Starting System Components All front wheel drive vehicles are equipped with OBD and all OBD sensing systems are monitored by the Engine Control computer. The Engine Control computer will store in electronic memory, any detectable failure within the monitored circuits. It will retain this information for a period of 50 engine starts, then erase the memory if the failure does not reoccur during that period. This also will translate a moni-
tored failure as a FAULT CODE when a readout command is given. A readout command can be made by turning the ignition switch to ON-OFF-ONOFF-ON without starting the engine. The CHECK ENGINE LAMP on the instrument cluster will flash in preset sequences to show Fault Codes. However, the Check Engine Lamp cannot express fault codes for all failures. Fault codes are easier to obtain and more complete with the use of Diagnostic Tool (DRB II). This tool is plugged into the diagnostic connector
8A - 2
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BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
located in the engine compartment (Fig. 2). Refer to the instructions provided with the (DRB II) tool being used. For numbered Fault Codes pertaining to components within this Group, refer to Failure Codes—On
Board Diagnostics in Group 8A. For other Fault Codes which, do not pertaining to this Group 8A, refer to Group 14, Fuel System, On Board Diagnostics.
BATTERY TEST PROCEDURES ON-VEHICLE INDEX page Battery Charging . . . . . . . . . . . Battery Load Test . . . . . . . . . . . Battery Open Circuit Voltage Test Causes of Battery Discharging .
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page General Information . . . . . . . . . . . . . . . . . . . . . . . . 2 State of Charge Tests . . . . . . . . . . . . . . . . . . . . . . 3 Test Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION The battery stores, stabilizes, and produces electrical current to operate various electrical systems in the vehicle. The determination of whether a battery is good or bad is made by the battery’s ability to accept a charge. It also must produce high amperage current output over an extended period to be able to start the vehicle. The capability of the battery to store electrical current comes from a chemical reaction. This reaction takes place between the sulfuric acid solution electrolyte and the lead +/- plates in each cell of the battery. As the battery discharges, the plates react with the acid from the electrolyte. When the charging system charges the battery, the water is converted to sulfuric acid in the battery. The amount of acid, specific gravity in the electrolyte can be measured with a hydrometer. The factory installed battery is equipped with a built in hydrometer as a test indicator (Figs. 3, 4 and 5) to help in determining the battery’s state of charge. The factory installed battery also is sealed. Water cannot and should not be added.
Fig. 4 Built in Test Indicator
Fig. 5 Test Indicator Sight Glass The battery is vented to release gases that is created when the battery is being charged and discharged. The battery top, posts, and terminals should be cleaned when other under hood maintenance is performed (Fig. 3). WARNING: DO NOT ASSIST BOOST, CHARGE, ADD WATER, OR LOAD TEST BATTERY WHEN ELECTROLYTE LEVEL IS BELOW THE TOP OF THE PLATES. PERSONAL INJURY MAY OCCUR.
Fig. 3 Battery Construction and Test Indicator
When the electrolyte level is below the top of the plates a yellow or bright color indicator in sight glass
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BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
(Figs. 4 and 5), the battery must be replaced. Refer to Test Indicator. The battery must be completely charged with a green color in sight glass. The top, posts, and terminals should be properly cleaned before diagnostic procedures are performed. Also refer to Group 8B, Battery/Starter/Alternator Service.
TEST INDICATOR The test indicator a hydrometer is viewed through a sight glass, it is built into the top of battery case (Figs. 3, 4 and 5). This provides visual information for battery testing. The test indicator sight glass is to be used with diagnostic procedures described in this Group. It is important when using the Test Indicator that the battery be level and have a clean top to see the correct indications. A light may be required to view the Indicator.
8A - 3
CAUSES OF BATTERY DISCHARGING It is normal to have a small 5 to 30 milliamperes continuous electrical draw from the battery. This draw will take place with the ignition in the OFF position, and the courtesy, dome, storage compartments, and engine compartment lights OFF. The continuous draw is due to various electronic features or accessories that require electrical current with the ignition OFF to function properly. When a vehicle is not used over an extended period approximately 20 days the Main Fusible Link Connector (Fig. 6) should be disconnected. This is located near the battery on the engine wiring harness. Disconnection of this connector will help prevent battery discharging.
WARNING: DO NOT USE OPEN FLAME NEAR BATTERY BECAUSE OF EXPLOSIVE GASES AT FORM ABOVE BATTERY.
STATE OF CHARGE TESTS USING TEST INDICATOR The built in test hydrometer (Figs. 3, 4 and 5) measures the specific gravity of the electrolyte. Specific Gravity (SG) of the electrolyte will show state of charge voltage. The test indicator WILL NOT show cranking capacity of the battery. Refer to Battery Load. Look into the sight glass (Figs. 4 and 5) and note the color of the indicator (Fig. 5). Refer to the following description of colors: • GREEN = 75 to 100 degree state of charge The battery is adequately charged for further testing and may be returned to use. If the vehicle will not crank for a maximum 15 seconds, refer to Battery Load Test in this Group for more information. • BLACK OR DARK = 0 to 75 degree state of charge The battery is INADEQUATELY charged and must be charged until green dot is visible, (12.4 volts or greater) before the battery is tested or returned to use. Refer to Causes of Battery Discharging. • YELLOW OR BRIGHT COLOR = Battery must be replace WARNING: DO NOT CHARGE, ASSIST BOOST, LOAD TEST, OR ADD WATER TO THE BATTERY WHEN YELLOW OR BRIGHT COLOR DOT IS VISIBLE. PERSONAL INJURY MAY OCCUR. A yellow or bright color dot shows electrolyte level in battery is below the test indicator (Fig. 5). Water cannot be added to a maintenance free battery. The battery must be replaced. A low electrolyte level may be caused by an over charging condition. Refer to Alternator Test Procedures on Vehicle.
Fig. 6 Main Fusible Link Connector ABNORMAL BATTERY DISCHARGING (1) Corroded battery posts, cables or terminals. (2) Loose or worn alternator drive belt. (3) Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery. (4) Slow driving speeds in heavy traffic conditions or prolonged idling with high-amperage electrical systems in use. (5) Defective electrical circuit or component causing excess Ignition Off Draw (IOD). Refer to Ignition OFF Draw (IOD). (6) Defective charging system. (7) Defective battery.