2003 Chrysler PT Cruiser Service Repair Manual

2003 PT Cruiser Service Manual

BODYCODEPLATE

DESCRIPTION

TheBodyCodePlate(Fig.1)islocatedinthe enginecompartmentontheplenumbehindtheright sidestruttower(Fig.2).Therearesevenlinesof informationonthebodycodeplate.Lines4,5,6,and 7arenotusedtodefineserviceinformation.Informationreadsfromlefttoright,startingwithline3in thecenteroftheplatetoline1atthebottomofthe plate.

BODYCODEPLATELINE2

DIGITS1,2,AND3

Paintprocedure

DIGIT4

OpenSpace

DIGITS5THROUGH7

Primarypaint (Referto23-BODY/PAINT-SPECIFICATIONS) forBodyColorCodes.

DIGIT8AND9

OpenSpace

DIGITS10THROUGH12

SecondaryPaint

DIGIT13AND14

OpenSpace

BODYCODEPLATE(Continued)

DIGIT5

MarketCode

• C=Canada

• B=International

• M=Mexico

• U=UnitedStates

DIGIT6

OpenSpace

DIGITS7THROUGH23

VehicleIdentificationNumber

• (RefertoVEHICLEDATA/VEHICLEINFORMATION/VEHICLEIDENTIFICATIONNUMBERDESCRIPTION)forproperbreakdownofVINcode.

IFTWOBODYCODEPLATESAREREQUIRED

1-BODYCODEPLATE

2-BODYCODEEMBOSS

DIGITS20,21,AND22

EngineCode

• EJD=1.6LFourCylinder16ValvesSOHCGasoline

• ECC=2.0LFourCylinder16ValvesDOHC Gasoline

• EDJ=2.2LFourCylinderTurboDieselEngine

• EDZ=2.4LFourCylinder16ValvesDOHCGasoline

• EDV=2.4LFourCylinder16ValvesDOHC H.O.TurboGasoline

DIGIT23

OpenSpace

BODYCODEPLATELINE1

DIGITS1,2,AND3

TransaxleCodes

• DGL=41TE4-SpeedElectronicAutomatic Transaxle

• DD5=NVT3505-SpeedManualTransaxle

• DDD=GETRAG2885-SpeedManualTransaxle

DIGIT4

OpenSpace

ThelastcodeshownoneitherplatewillbefollowedbyEND.Whentwoplatesarerequired,the lastcodespaceonthefirstplatewillindicate(CTD) Whenasecondplateisrequired,thefirstfour spacesofeachlinewillnotbeusedduetooverlapof theplates.

FASTENERIDENTIFICATION

DESCRIPTION

TheSAEboltstrengthgradesrangefromgrade2 tograde8.Thehigherthegradenumber,thegreater theboltstrength.Identificationisdeterminedbythe linemarksonthetopofeachbolthead.Theactual boltstrengthgradecorrespondstothenumberofline marksplus2.Themostcommonlyusedmetricbolt strengthclassesare9.8and10.9.Themetric strengthclassidentificationnumberisimprintedon theheadofthebolt.Thehighertheclassnumber, thegreatertheboltstrength.Somemetricnutsare imprintedwithasingle-digitstrengthclassonthe nutface.RefertotheFastenerIdentificationand FastenerStrengthCharts(Fig.3)and(Fig.4).

Fig.2BODYCODEPLATE2

Fig.4FASTENERSTRENGTH

FASTENERUSAGE

DESCRIPTION

DESCRIPTION-FASTENERUSAGE

WARNING:USEOFANINCORRECTFASTENER MAYRESULTINCOMPONENTDAMAGEORPERSONALINJURY.

Fastenersandtorquespecificationsreferencesin thisServiceManualareidentifiedinmetricandSAE format.

Duringanymaintenanceorrepairprocedures,itis importanttosalvageallfasteners(nuts,bolts,etc.) forreassembly.Ifthefastenerisnotsalvageable,a fastenerofequivalentspecificationmustbeused.

DESCRIPTION-THREADEDHOLEREPAIR

Moststrippedthreadedholescanberepairedusing aHelicoil .FollowthevehicleorHelicoil recommendationsforapplicationandrepairprocedures.

INTERNATIONALSYMBOLS

DESCRIPTION

Thegraphicsymbolsillustratedinthefollowing InternationalControlandDisplaySymbolsChart (Fig.5)areusedtoidentifyvariousinstrumentcontrols.Thesymbolscorrespondtothecontrolsanddisplaysthatarelocatedontheinstrumentpanel.

1HighBeam13RearWindowWasher

2FogLamps14Fuel

3Headlamp,ParkingLamps,PanelLamps15EngineCoolantTemperature

4TurnWarning16BatteryChargingCondition

5HazardWarning17EngineOil

6WindshieldWasher18SeatBelt

7WindshieldWiper19BrakeFailure

8WindshieldWiperandWasher20ParkingBrake

9WindscreenDemistingandDefrosting21FrontHood

10VentilatingFan22Rearhood(Decklid)

11RearWindowDefogger23Horn

12RearWindowWiper24Lighter

Fig.5INTERNATIONALCONTROLANDDISPLAYSYMBOLS

METRICSYSTEM

DESCRIPTION

Themetricsystemisbasedonquantitiesofone, ten,onehundred,onethousandandonemillion.

Thefollowingchartwillassistinconvertingmetric unitstoequivalentEnglishandSAEunits,orvise versa.

COMMONMETRICEQUIVALENTS

1inch=25Millimeters1CubicInch=16CubicCentimeters

1Foot=0.3Meter1CubicFoot=0.03CubicMeter

1Yard=0.9Meter1CubicYard=0.8CubicMeter

1Mile=1.6Kilometers

RefertotheMetricConversionCharttoconvert torquevalueslistedinmetricNewton-meters(N·m).

Also,usethecharttoconvertbetweenmillimeters (mm)andinches(in.)(Fig.6).

Fig.6METRICCONVERSIONCHART

TORQUEREFERENCES

DESCRIPTION

IndividualTorqueChartsappearwithinmanyor theGroups.RefertotheStandardTorqueSpecifica-

tionsChartfortorquereferencesnotlistedinthe individualtorquecharts(Fig.7).

Fig.7TORQUESPECIFICATIONS

VEHICLEIDENTIFICATION NUMBER

DESCRIPTION-VEHICLEIDENTIFICATION NUMBER

TheVehicleIdentificationNumber(VIN)islocated ontheupperleftcorneroftheinstrumentpanel, neartheleftA-Pillar.TheVINconsistsof17charactersinacombinationoflettersandnumbersthat providespecificinformationaboutthevehicle(Fig. 8).RefertoVINCodeDecodingChart.

Toprotecttheconsumerfromtheftandpossible fraudthemanufacturerisrequiredtoincludea CheckDigitattheninthpositionoftheVehicleIdentificationNumber.Thecheckdigitisusedbythe manufacturerandgovernmentagenciestoverifythe authenticityofthevehicleandofficialdocumentation.Theformulatousethecheckdigitisnot releasedtothegeneralpublic.

Fig.8VEHICLEIDENTIFICATIONNUMBER LOCATION

1-VehicleIdentificationNumber(VIN)

2-InstrumentPanel

VINCODEDECODING

POSITIONINTERPRETATIONCODE=DESCRIPTION

1CountryofOrigin1=BuiltinUnitedStatesbyDiamlerChrysler

3=BuiltinMexicobyDiamlerChryslerDeMexico

2MakeC=Chrysler

3VehicleType

4=Multi-purposePassengerVehicleLessSideAirBags

8=Multi-purposePassengerVehiclewithSideAirBags

4OtherF=1815-2267KG(4000-5000lbs.)

5LineY=Cruiser(LHD) 5-ExportLine

9=2.0L4Cyl.GasolineDOHC(MPI)

U=2.2L4Cyl.TurboDieselEngine(MPI)

9CheckDigitSeeexplanationinthissection.

10ModelYear3=2003

11AssemblyPlant

T=TolucaAssembly

U=GrazAssembly

12Though17VehicleBuildSequence6digitnumberassignedbyassemblyplant.

VEHICLESAFETY CERTIFICATIONLABEL

DESCRIPTION

Avehiclesafetycertificationlabelisattachedto therearshutfaceofthedriver’sdoor(Fig.9).This labelindicatesdateofmanufacture(monthand year),GrossVehicleWeightRating(GVWR),Gross AxleWeightRating(GAWR)front,GrossAxleWeight Rating(GAWR)rearandtheVehicleIdentification Number(VIN).TheMonth,DayandHourofmanufactureisalsoincluded.

Allcommunicationsorinquiriesregardingthe vehicleshouldincludetheMonth-Day-Hourand VehicleIdentificationNumber.

E-MARKLABEL

DESCRIPTION

AnE-markLabel(Fig.10)islocatedontherear shutfaceofthedriver’sdoor.Thelabelcontainsthe followinginformation:

• DateofManufacture

• Month-Day-Hour(MDH)

• VehicleIdentificationNumber(VIN)

• CountryCodes

• RegulationNumber

• RegulationAmendmentNumber

• ApprovalNumber

VECILABEL

DESCRIPTION

AllmodelshaveaVehicleEmissionControlInformation(VECI)Label.Chryslerpermanentlyattaches

thelabelintheenginecompartment.Itcannotbe removedwithoutdefacinginformationanddestroying thelabel.

Thelabelcontainsthevehicle’semissionspecificationsandvacuumhoseroutings.Allhosesmustbe connectedandroutedaccordingtothelabel.

MANUFACTURERPLATE

DESCRIPTION

TheManufacturerPlate(Fig.11)islocatedinthe enginecompartmentonthepassengersiderearcornerofthehood.Theplatecontainsfivelinesofinformation:

1.VehicleIdentificationNumber(VIN)

2.GrossVehicleMass(GVM)

3.GrossTrainMass(GTM)

4.GrossFrontAxleRating(GFAR)

5.GrossRearAxleRating(GRAR)

Fig.9VEHICLESAFETYCERTIFICATIONLABELTYPICAL

Fig.10E-MARKLABEL

Fig.11MANUFACTURERPLATE

LUBRICATION&MAINTENANCE

INTERNATIONALSYMBOLS

DESCRIPTION

DaimlerChryslerCorporationusesinternational symbolstoidentifyenginecompartmentlubricant andfluidinspectionandfilllocations(Fig.1).

FLUIDTYPES

DESCRIPTION

DESCRIPTION-ENGINEOILANDLUBRICANTS

WARNING:NEWORUSEDENGINEOILCANBE IRRITATINGTOTHESKIN.AVOIDPROLONGEDOR REPEATEDSKINCONTACTWITHENGINEOIL.

CONTAMINANTSINUSEDENGINEOIL,CAUSEDBY INTERNALCOMBUSTION,CANBEHAZARDOUSTO YOURHEALTH.THOROUGHLYWASHEXPOSED SKINWITHSOAPANDWATER.DONOTWASH SKINWITHGASOLINE,DIESELFUEL,THINNER,OR SOLVENTS,HEALTHPROBLEMSCANRESULT.DO NOTPOLLUTE,DISPOSEOFUSEDENGINEOIL PROPERLY.CONTACTYOURDEALERORGOVERNMENTAGENCYFORLOCATIONOFCOLLECTION CENTERINYOURAREA.

Whenserviceisrequired,DaimlerChryslerCorporationrecommendsthatonlyMopar brandparts, lubricantsandchemicalsbeused.Mopar provides thebestengineeredproductsforservicing DaimlerChryslerCorporationvehicles.

Onlylubricantsbearingdesignationsdefinedby thefollowingorganizationshouldbeused.

• SocietyofAutomotiveEngineers(SAE)

• AmericanPetroleumInstitute(API)

• NationalLubricatingGreaseInstitute(NLGI)

APISERVICEGRADECERTIFIED

UseanengineoilthatisAPICertified(GF-3). MOPAR providesengineoils,meetingMaterial StandardMS-6395,thatmeetorexceedthisrequirement.

Fig.1INTERNATIONALSYMBOLS

SAEVISCOSITY

AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.Useonlyengineoilswithmultipleviscositiessuchas5W-30or10W-30.Theseare specifiedwithadualSAEviscositygradewhichindicatesthecold-to-hottemperatureviscosityrange. Selectanengineoilthatisbestsuitedtoyourparticulartemperaturerangeandvariation(Fig.2).

• SAE5W-30 engineoilispreferred.SAE5W-30 engineoilsimprovelowtemperaturestartingand helpsvehiclefueleconomy.

SYNTHETICENGINEOILS

Thereareanumberofengineoilsbeingpromoted aseithersyntheticorsemi-synthetic.Ifyouchoseto usesuchaproduct,use only thoseoilsthatmeetthe AmericanPetroleumInstitute(API)andSAEviscositystandard.Followtheserviceschedulethat describesyourdrivingtype.

MATERIALSADDEDTOENGINEOIL

Themanufacturer doesnotrecommend theadditionofanyadditivetothespecifiedengineoil.

GEARLUBRICANTS

SAEratingsalsoapplytomultigradegearlubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.SuchasAPIGL-5andSAE75W90.

LUBRICANTSANDGREASES

ENERGYCONSERVINGOIL

AnEnergyConservingtypeoilisrecommendedfor gasolineengines.ThedesignationofENERGYCONSERVINGislocatedonthelabelofanengineoilcontainer.

CONTAINERIDENTIFICATION

Standardengineoilidentificationnotationshave beenadoptedtoaidintheproperselectionofengine oil.Theidentifyingnotationsarelocatedonthefront labelofengineoilplasticbottlesandthetopof engineoilcans(Fig.3).

Thissymbolmeansthattheoilhasbeencertified bytheAmericanPetroleumInstitute(API).DiamlerChrysleronlyrecommendsAPICertified(GF-3) engineoilsthatmeettherequirementsofMaterial StandardMS-6395.UseMoparoranequivalentoil meetingthespecificationMS-6395.

Lubricatinggreaseisratedforqualityandusage bytheNLGI.AllapprovedproductshavetheNLGI symbol(Fig.4)onthelabel.AtthebottomNLGI symbolistheusageandqualityidentificationletters. Wheelbearinglubricantisidentifiedbytheletter “G”.Chassislubricantisidentifiedbythelatter“L”. Theletterfollowingtheusageletterindicatesthe qualityofthelubricant.Thefollowingsymbolsindicatethehighestquality.

SPECIALIZEDLUBRICANTSANDOILS

Somemaintenanceorrepairproceduresmay requiretheuseofspecializedlubricantsoroils.Consulttheappropriatesectionsinthismanualforthe correctapplicationoftheselubricants.

Fig.2TEMPERATURE/ENGINEOILVISCOSITY

Fig.3APISYMBOL

Fig.4NLGISYMBOL

DESCRIPTION-ENGINECOOLANT

WARNING:ANTIFREEZEISANETHYLENEGLYCOL BASECOOLANTANDISHARMFULIFSWALLOWEDORINHALED.IFSWALLOWED,DRINK TWOGLASSESOFWATERANDINDUCEVOMITING.IFINHALED,MOVETOFRESHAIRAREA. SEEKMEDICALATTENTIONIMMEDIATELY.DONOT STOREINOPENORUNMARKEDCONTAINERS. WASHSKINANDCLOTHINGTHOROUGHLYAFTER COMINGINCONTACTWITHETHYLENEGLYCOL. KEEPOUTOFREACHOFCHILDREN.DISPOSEOF GLYCOLBASECOOLANTPROPERLY,CONTACT YOURDEALERORGOVERNMENTAGENCYFOR LOCATIONOFCOLLECTIONCENTERINYOUR AREA.DONOTOPENACOOLINGSYSTEMWHEN THEENGINEISATOPERATINGTEMPERATUREOR HOTUNDERPRESSURE,PERSONALINJURYCAN RESULT.AVOIDRADIATORCOOLINGFANWHEN ENGINECOMPARTMENTRELATEDSERVICEIS PERFORMED,PERSONALINJURYCANRESULT.

CAUTION:UseofPropyleneGlycolbasedcoolants isnotrecommended,astheyprovidelessfreeze protectionandlessboilingprotection.

Thecoolingsystemisdesignedaroundthecoolant. Thecoolantmustacceptheatfromenginemetal,in thecylinderheadareaneartheexhaustvalvesand engineblock.Thencoolantcarriestheheattothe radiatorwherethetube/finradiatorcantransferthe heattotheair.

Theuseofaluminumcylinderblocks,cylinder heads,andwaterpumpsrequiresspecialcorrosion protection.Mopar Antifreeze/Coolant,5 Year/100,000MileFormula(MS-9769),ortheequivalentethyleneglycolbasecoolantwithhybridorganic corrosioninhibitors(calledHOAT,forHybridOrganic AdditiveTechnology)isrecommended.Thiscoolant offersthebestenginecoolingwithoutcorrosionwhen mixedwith50%EthyleneGlycoland50%distilled watertoobtainafreezepointof-37°C(-35°F).Ifit losescolororbecomescontaminated,drain,flush, andreplacewithfreshproperlymixedcoolantsolution.

Thegreencoolant MUSTNOTBEMIXED with theorangeormagentacoolants.Whenreplacingcoolantthecompletesystemflushmustbeperformed beforeusingthereplacementcoolant.

CAUTION:Mopar Antifreeze/Coolant,5 Year/100,000MileFormula(MS-9769)maynotbe mixedwithanyothertypeofantifreeze.Doingso willreducethecorrosionprotectionandmayresult inprematurewaterpumpsealfailure.Ifnon-HOAT coolantisintroducedintothecoolingsysteminan

emergency,itshouldbereplacedwiththespecified coolantassoonaspossible.

DESCRIPTION-TRANSMISSIONFLUID

NOTE:Refertothemaintenanceschedulesinthe Owner’sManualfortherecommendedmaintenance (fluid/filterchange)intervalsforthistransaxle.

NOTE:Alltransaxleshaveacommontransmission anddifferentialsump.Fillingthetransaxleaccommodatesthedifferentialaswell.

TRANSMISSIONFLUID

Mopar ATF+4(AutomaticTransmissionFluidType9602)isrequiredinthe41TEautomatic.Substitutefluidscaninducetorqueconverterclutch shudder.

Mopar ATF+4(AutomaticTransmissionFluidType9602)whennewisredincolor.TheATFisdyed redsoitcanbeidentifiedfromotherfluidsusedin thevehiclesuchasengineoilorantifreeze.Thered colorisnotpermanentandisnotanindicatoroffluid condition.Asthevehicleisdriven,theATFwillbegin tolookdarkerincolorandmayeventuallybecome brown. Thisisnormal. Adarkbrown/blackfluid accompaniedwithaburntodorand/ordeterioration inshiftqualitymayindicatefluiddeteriorationor transmissioncomponentfailure.

G288andT350Manualtransaxlesrequiretheuse ofMopar ATF+4(AutomaticTransmissionFluid)

FLUIDADDITIVES

DaimlerChryslerstronglyrecommendsagainstthe additionofanyfluidstothetransmission,otherthan thoseautomatictransmissionfluidslistedabove. Exceptionstothispolicyaretheuseofspecialdyes toaidindetectingfluidleaks.

Various“special”additivesandsupplementsexist thatclaimtoimproveshiftfeeland/orquality.These additivesandothersalsoclaimtoimproveconverter clutchoperationandinhibitoverheating,oxidation, varnish,andsludge.TheseclaimshavenotbeensupportedtothesatisfactionofDaimlerChryslerand theseadditives mustnotbeused. Theuseoftransmission“sealers”shouldalsobeavoided,sincethey mayadverselyaffecttheintegrityoftransmission seals.

DESCRIPTION-FUELREQUIREMENTS

Yourengineisdesignedtomeetallemissionsregulationsandprovideexcellentfueleconomyandperformancewhenusinghighqualityunleadedgasoline havinganoctaneratingof87.Theuseofpremium gasolineisnotrecommended.Theuseofpremium

0-4LUBRICATION&MAINTENANCE PT FLUIDTYPES(Continued)

gasolinewillprovidenobenefitoverhighqualityregulargasoline,andinsomecircumstancesmayresult inpoorerperformance.

Lightsparkknockatlowenginespeedsisnot harmfultoyourengine.However,continuedheavy sparkknockathighspeedscancausedamageand immediateserviceisrequired.Enginedamageresultingfromoperationwithaheavysparkknockmay notbecoveredbythenewvehiclewarranty.

Poorqualitygasolinecancauseproblemssuchas hardstarting,stallingandhesitations.Ifyouexperiencethesesymptoms,tryanotherbrandofgasoline beforeconsideringserviceforthevehicle.

Over40automanufacturersworld-widehave issuedandendorsedconsistentgasolinespecifications (theWorldwideFuelCharter,WWFC)todefinefuel propertiesnecessarytodeliverenhancedemissions, performanceanddurabilityforyourvehicle.WerecommendtheuseofgasolinesthatmeettheWWFC specificationsiftheyareavailable.

REFORMULATEDGASOLINE

Manyareasofthecountryrequiretheuseof cleanerburninggasolinereferredtoas“reformulated”gasoline.Reformulatedgasolinecontainoxygenates,andarespecificallyblendedtoreducevehicle emissionsandimproveairquality.

Westronglysupporttheuseofreformulatedgasoline.Properlyblendedreformulatedgasolinewillprovideexcellentperformanceanddurabilityforthe engineandfuelsystemcomponents.

GASOLINE/OXYGENATEBLENDS

Somefuelsuppliersblendunleadedgasolinewith oxygenatessuchas10%ethanol,MTBE,andETBE. Oxygenatesarerequiredinsomeareasofthecountry duringthewintermonthstoreducecarbonmonoxide emissions.Fuelsblendedwiththeseoxygenatesmay beusedinyourvehicle.

CAUTION:DONOTusegasolinecontainingMETHANOL.Gasolinecontainingmethanolmaydamage criticalfuelsystemcomponents.

MMTINGASOLINE

MMTisamanganese-containingmetallicadditive thatisblendedintosomegasolinetoincreaseoctane. GasolineblendedwithMMTprovidenoperformance advantagebeyondgasolineofthesameoctanenumberwithoutMMT.GasolineblendedwithMMT reducesparkpluglifeandreduceemissionsystem performanceinsomevehicles.Werecommendthat gasolinefreeofMMTbeusedinyourvehicle.The MMTcontentofgasolinemaynotbeindicatedonthe gasolinepump;therefore,youshouldaskyourgaso-

lineretailerwhetherornothis/hergasolinecontains MMT.

ItisevenmoreimportanttolookforgasolinewithoutMMTinCanadabecauseMMTcanbeusedat levelshigherthanallowedintheUnitedStates. MMTisprohibitedinFederalandCaliforniareformulatedgasoline.

SULFURINGASOLINE

IfyouliveinthenortheastUnitedStates,your vehiclemayhavebeendesignedtomeetCalifornia lowemissionstandardswithCleaner-BurningCaliforniareformulatedgasolinewithlowsulfur.Ifsuch fuelsarenotavailableinstatesadoptingCalifornia emissionstandards,yourvehicleswilloperatesatisfactorilyonfuelsmeetingfederalspecifications,but emissioncontrolsystemperformancemaybe adverselyaffected.GasolinesoldoutsideofCalifornia ispermittedtohavehighersulfurlevelswhichmay affecttheperformanceofthevehicle’scatalyticconverter.ThismaycausetheMalfunctionIndicator Lamp(MIL),CheckEngineorServiceEngineSoon lighttoilluminate.Werecommendthatyoutryadifferentbrandofunleadedgasolinehavinglowersulfur todetermineiftheproblemisfuelrelatedpriorto returningyourvehicletoanauthorizeddealerfor service.

CAUTION:IftheMalfunctionIndicatorLamp(MIL), CheckEngineorServiceEngineSoonlightisflashing,immediateserviceisrequired;seeon-board diagnosticssystemsection.

MATERIALSADDEDTOFUEL

AllgasolinesoldintheUnitedStatesandCanada arerequiredtocontaineffectivedetergentadditives. Useofadditionaldetergentsorotheradditivesisnot neededundernormalconditions.

FUELSYSTEMCAUTIONS

CAUTION:Followtheseguidelinestomaintainyour vehicle’sperformance:

• TheuseofleadedgasisprohibitedbyFederal law.Usingleadedgasolinecanimpairengineperformance,damagetheemissioncontrolsystem,and couldresultinlossofwarrantycoverage.

• Anout-of-tuneengine,orcertainfuelorignition malfunctions,cancausethecatalyticconverterto overheat.Ifyounoticeapungentburningodoror somelightsmoke,yourenginemaybeoutoftuneor malfunctioningandmayrequireimmediateservice. Contactyourdealerforserviceassistance.

• Whenpullingaheavyloadordrivingafully loadedvehiclewhenthehumidityislowandthetem-

peratureishigh,useapremiumunleadedfuelto helppreventsparkknock.Ifsparkknockpersists, lightentheload,orenginepistondamagemayresult.

• Theuseoffueladditiveswhicharenowbeing soldasoctaneenhancersisnotrecommended.Most oftheseproductscontainhighconcentrationsof methanol.Fuelsystemdamageorvehicleperformanceproblemsresultingfromtheuseofsuchfuels oradditivesisnottheresponsibilityof DaimlerChryslerCorporationandmaynotbecovered underthenewvehiclewarranty.

NOTE:Intentionaltamperingwithemissionscontrol systemscanresultincivilpenaltiesbeingassessed againstyou.

FLUIDCAPACITIES

SPECIFICATIONS-FLUIDCAPACITIES DESCRIPTIONSPECIFICATION FuelTank57L(15gal.)

EngineOil*-1.6L4.3L(4.5qts.)

FLUIDFILL/CHECK LOCATIONS

DESCRIPTION

Thefluidcheck/fillpointlocationsarelocatedin eachapplicableservicemanualsection.

LUBRICATIONPOINTS

DESCRIPTION

Lubricationpointlocationsarelocatedineach applicableSections.

MAINTENANCESCHEDULES

DESCRIPTION

MaintenanceScheduleInformationnotincludedin thissection,islocatedintheappropriateOwner’s Manual.

Therearethreemaintenanceschedulesthatshow required serviceforyourvehicle.

FirstisSchedule “B”—ALLENGINES.Itisfor vehiclesthatareoperatedundertheconditionsthat arelistedbelowandatthebeginningoftheschedule.

• Dayornighttemperaturesarebelow0°C (32°F).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan16km(10miles).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C (90°F).†

• Trailertowing.†

• Taxi,police,ordeliveryservice(commercialservice).†

• Off-roadordesertoperation.

• IfequippedforandoperatingwithE-85 (ethanol)fuel.

*(includesnewfilter)

2.2LTurboDiesel:2.0L (2.1qts.)

2.4LTurbo:1.8L(1.9 qts.)

**(Includesheaterandcoolantrecoverybottlefilledto MAXlevel.)

NOTE:MostvehiclesareoperatedundertheconditionslistedforSchedule B .

SecondisSchedule “A”—NONTURBO CHARGEDENGINES.Itisforvehiclesthatarenot operatedunderanyoftheconditionslistedunder Schedule B —ALLENGINES.

SecondisSchedule “A”—TURBOCHARGED ENGINES.Itisforvehiclesthatarenotoperated underanyoftheconditionslistedunderSchedule B —ALLENGINES.

Usetheschedulethatbestdescribesyourdriving conditions.Wheretimeandmileagearelisted,follow theintervalthatoccursfirst.

MAINTENANCESCHEDULES(Continued)

CAUTION:Failuretoperformtherequiredmaintenanceitemsmayresultindamagetothevehicle.

AtEachStopforFuel

• Checktheengineoillevelabout5minutesafter afullywarmedengineisshutoff.Checkingtheoil levelwhilethevehicleisonlevelgroundwill improvetheaccuracyoftheoillevelreading.Addoil onlywhenthelevelisatorbelowtheADDorMIN mark.

• Checkthewindshieldwashersolventandaddif required.

OnceaMonth

• Checktirepressureandlookforunusualwear ordamage.

• Inspectthebatteryandcleanandtightenthe terminalsasrequired.

• Checkthefluidlevelsofcoolantreservoir,brake mastercylinder,powersteeringandtransaxleand addasneeded.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

• Checkrubbersealsoneachsideoftheradiator forproperfit.

AtEachOilChange

• Changetheengineoilfilter.

• Inspecttheexhaustsystem.

• Inspectthebrakehoses.

• InspecttheCVjointsandfrontsuspensioncomponents.

• Checktheautomatictransaxlefluidlevel.

• Checkthemanualtransaxlefluidlevelandfill plugcondition.

• Checkthecoolantlevel,hoses,andclamps.

• Rotatethetiresateachoilchangeinterval shownonSchedule“A”—NONTURBOCHARGED ENGINES10000km(6,000miles),Schedule“A”— TURBOCHARGEDENGINES8000km(5,000 miles),oreveryotherintervalshownonSchedule “B”—ALLENGINES10000km(6,000miles).

SCHEDULE“B”—ALLENGINES

Followschedule“B”—AllEnginesifyouusually operateyourvehicleunderoneormoreofthefollowingconditions.Changetheautomatictransmission fluidandfilterevery77000km(48,000miles)ifthe vehicleisusuallyoperatedunderoneormoreofthe conditionsmarkedwithan

Changethemanualtransaxlefluidevery77000 km(48,000miles)ifthevehicleisusuallyoperated underoneormoreoftheconditionsmarkedwithan †.

• Dayornighttemperaturesarebelow0°C (32°F).

• Stopandgodriving.

• Extensiveengineidling.

• Drivingindustyconditions.

• Shorttripsoflessthan16.2km(10miles).

• Morethan50%ofyourdrivingisatsustained highspeedsduringhotweather,above32°C (90°F).†

• Trailertowing.†

• Taxi,police,ordeliveryservice(commercialservice).†

• Off-roadordesertoperation.

• IfequippedforandoperatingwithE-85 (ethanol)fuel.

Miles3,0006,0009,00012,00015,00018,000 (Kilometers)(5000)(10000)(14000)(19000)(24000)(29000)

PT LUBRICATION&MAINTENANCE0-7

MAINTENANCESCHEDULES(Continued)

Miles21,00024,00027,00030,00033,00036,000 (Kilometers)(34000)(38000)(43000)(48000)(53000)(58000)

Miles39,00042,00045,00048,00051,00054,000 (Kilometers)(62000)(67000)(72000)(77000)(82000)(86000)

0-8LUBRICATION&MAINTENANCE PT MAINTENANCESCHEDULES(Continued)

Miles57,00060,00063,00066,00069,00072,000 (Kilometers)(91000)(96000)(101000)(106000)(110000)(115000)

Miles75,00078,00081,00084,00087,00090,000 (Kilometers)(120000)(125000)(130000)(134000)(139000)(144000)

MAINTENANCESCHEDULES(Continued)

*Thismaintenanceisrecommendedbythemanufacturertotheownerbutisnotrequiredtomaintain theemissionswarranty.

‡Thismaintenanceisnotrequiredifpreviously replaced.

Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. Retainallreceipts.

0-10LUBRICATION&MAINTENANCE PT MAINTENANCESCHEDULES(Continued)

SCHEDULE“A”—NONTURBOCHARGEDENGINES

Miles6,00012,00018,00024,00030,00036,000 (Kilometers)(10000)(19000)(29000)(38000)(48000)(58000) [Months][6][12][18][24][30][36]

Miles42,00048,00054,00060,00066,000 (Kilometers)(67000)(77000)(86000)(96000)(106000) [Months][42][48][54][60][66]

MAINTENANCESCHEDULES(Continued)

*Thismaintenanceisrecommendedbythemanufacturertotheownerbutisnotrequiredtomaintain theemissionswarranty.

‡Thismaintenanceisnotrequiredifpreviously replaced.

Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. Retainallreceipts.

SCHEDULE“A”—2.4LTURBOCHARGEDENGINES

Miles5,00010,00015,00020,00025,00030,000 (Kilometers)(8000)(16000)(24000)(32000)(40000)(48000) [Months][6][12][18][24]

Miles35,00040,00045,00050,00055,000 (Kilometers)(56000)(64000)(72000)(80000)(88000)

Miles60,00065,00070,00075,00080,00085,000 (Kilometers)(96000)(104000)(112000)(120000)(128000)(136000) [Months][48][54][60][66]

MAINTENANCESCHEDULES(Continued)

*Thismaintenanceisrecommendedbythemanufacturertotheownerbutisnotrequiredtomaintain theemissionswarranty.

‡Thismaintenanceisnotrequiredifpreviously replaced.

Inspectionandserviceshouldalsobeperformed anytimeamalfunctionisobservedorsuspected. Retainallreceipts.

WARNING:Youcanbebadlyinjuredworkingonor aroundamotorvehicle.Doonlythatservicework forwhichyouhavetheknowledgeandtheright equipment.Ifyouhaveanydoubtaboutyourability toperformaservicejob,takeyourvehicletoa competentmechanic.

HOISTING

STANDARDPROCEDURE-HOISTING

RefertoOwner’sManualprovidedwithvehiclefor properemergencyjackingprocedures.

WARNING:THEHOISTINGANDJACKLIFTING POINTSPROVIDEDAREFORACOMPLETEVEHICLE.WHENTHEENGINEORREARSUSPENSION ISREMOVEDFROMAVEHICLE,THECENTEROF GRAVITYISALTEREDMAKINGSOMEHOISTING CONDITIONSUNSTABLE.PROPERLYSUPPORTOR SECUREVEHICLETOHOISTINGDEVICEWHEN THESECONDITIONSEXIST.

CAUTION:Donotpositionhoistingdeviceonsuspensioncomponents,damagetovehiclecanresult. Donotattempttoraiseoneentiresideofthevehiclebyplacingafloorjackmidwaybetweenthe frontandrearwheels.Thispracticemayresultin permanentdamagetothebody.

Whenproperlypositioned,afloorjackcanbeused toliftthevehicleandsupporttheraisedvehiclewith jackstands(Fig.5).

Afloorjackoranyliftingdevice,mustneverbe usedonanypartoftheunderbodyotherthenthe describedareas.

JUMPSTARTING

STANDARDPROCEDURE-JUMPSTARTING

WARNING:REVIEWALLSAFETYPRECAUTIONS ANDWARNINGSINBATTERY/STARTING/CHARGINGSECTIONS.DONOTJUMPSTARTAFROZEN BATTERY,PERSONALINJURYCANRESULT.DO NOTJUMPSTARTWHENMAINTENANCEFREE BATTERYINDICATORDOTISYELLOWORBRIGHT COLOR.DONOTJUMPSTARTAVEHICLEWHEN THEBATTERYFLUIDISBELOWTHETOPOFLEAD PLATES.DONOTALLOWJUMPERCABLE CLAMPSTOTOUCHEACHOTHERWHENCONNECTEDTOABOOSTERSOURCE.DONOTUSE OPENFLAMENEARBATTERY.REMOVEMETALLIC JEWELRYWORNONHANDSORWRISTSTOAVOID INJURYBYACCIDENTALARCINGOFBATTERY CURRENT.WHENUSINGAHIGHOUTPUTBOOSTINGDEVICE,DONOTALLOWBATTERYVOLTAGE TOEXCEED16VOLTS.REFERTOINSTRUCTIONS PROVIDEDWITHDEVICEBEINGUSED.

CAUTION:Whenusinganothervehicleasa booster,donotallowvehiclestotouch.Electrical systemscanbedamagedoneithervehicle.

TOJUMPSTARTADISABLEDVEHICLE:

(1)Raisehoodondisabledvehicleandvisually inspectenginecompartmentfor:

• Batterycableclampcondition,cleanifnecessary.

• Frozenbattery.

• Yelloworbrightcolortestindicator,ifequipped.

• Lowbatteryfluidlevel.

• Generatordrivebeltconditionandtension.

• Fuelfumesorleakage,correctifnecessary.

CAUTION:Ifthecauseofstartingproblemondisabledvehicleissevere,damagetoboostervehicle chargingsystemcanresult.

(2)Whenusinganothervehicleasabooster source,parktheboostervehiclewithincablereach. Turnoffallaccessories,settheparkingbrake,place theautomatictransmissioninPARKorthemanual transmissioninNEUTRALandturntheignition OFF.

1-DRIVEONLIFT

2-FRAMECONTACTLIFT(SINGLEPOST)

2-CHASSISLIFT(DUALPOST)

2-OUTBOARDLIFT(DUALLIFT)

2-FLOORJACK

(3)Ondisabledvehicle,placegearselectorinpark orneutralandsetparkbrake.Turnoffallaccessories.

(4)Connectjumpercablestoboosterbattery.RED clamptopositiveterminal(+)orremoteterminal. BLACKclamptonegativeterminal(-).DONOT allowclampsatoppositeendofcablestotouch,elec-

Fig.5HoistingandJackingPoints

tricalarcwillresult.Reviewallwarningsinthisprocedure.

(5)OndisabledvehicleconnectREDjumpercable clamptopositive(+)remoteterminal.Connect BLACKjumpercableclamptoenginegroundas closetothegroundcableattachingpointaspossible (Fig.6).

(a)Pulltheprotectivesleevefromtheremote positiveterminal.

(b)ConnectREDjumpercableclamptopositive (+)remoteterminal.ConnectBLACKjumpercable clamptoenginegroundasclosetotheground cableattachingpointaspossible(Fig.6).

(6)Starttheengineinthevehiclewhichhasthe boosterbattery,lettheengineidleafewminutes, thenstarttheengineinthevehiclewiththedischargedbattery.

TOWING STANDARDPROCEDURE-TOWING

WARNING:DONOTALLOWTOWINGATTACHMENT DEVICESTOCONTACTTHEFUELTANKORLINES, FUELLEAKCANRESULT.DONOTLIFTORTOW VEHICLEBYFRONTORREARBUMPER,OR BUMPERENERGYABSORBERUNITS.DONOT VENTUREUNDERALIFTEDVEHICLEIFNOTSUPPORTEDPROPERLYONSAFETYSTANDS.DONOT ALLOWPASSENGERSTORIDEINATOWEDVEHICLE.USEASAFETYCHAINTHATISINDEPENDENT FROMTHETOWINGATTACHMENTDEVICE.

CAUTION:Donotdamagebrakelines,exhaustsystem,shockabsorbers,swaybars,oranyother undervehiclecomponentswhenattachingtowing devicetovehicle.Donotattachtowingdeviceto frontorrearsuspensioncomponents.Donot securevehicletotowingdevicebytheuseoffront orrearsuspensionorsteeringcomponents. Removeorsecurelooseorprotrudingobjectsfrom adamagedvehiclebeforetowing.Refertostateand localrulesandregulationsbeforetowingavehicle. Donotallowweightoftowedvehicletobearon lowerfascia,airdams,orspoilers.

Toavoiddamagetobumperfasciaandairdams useofawheelliftorflatbedtowingdevice(Fig.7)is recommended.Whenusingawheellifttowingdevice, besuretheunliftedendofdisabledvehiclehasat least100mm(4in.)groundclearance.Ifminimum groundclearancecannotbereached,useatowing dolly.Ifaflatbeddeviceisused,theapproachangle shouldnotexceed15degrees.

CAUTION:Donotcrankstartermotorondisabled vehicleformorethan15seconds,starterwilloverheatandcouldfail.

(7)Allowbatteryindisabledvehicletochargeto atleast12.4volts(75%charge)beforeattemptingto startengine.Ifenginedoesnotstartwithin15seconds,stopcrankingengineandallowstartertocool (15minutes),beforecrankingagain.

DISCONNECTCABLECLAMPSASFOLLOWS:

• DisconnectBLACKcableclampfromengine groundondisabledvehicle.

• DisconnectREDcableclampfrombatterypositiveremoteterminal.

Fig.6POSITIVEJUMPERCABLECLAMP CONNECTION

Fig.7RecommendedTowingDevices

FRONTSUSPENSION

DESCRIPTION-FRONTSUSPENSION

ThisvehiclehasagaspressurizedMacPherson struttypefrontsuspensiondesign(Fig.1).

Thefrontsuspensionconsistsofthesemajorcomponents:

• Hub(pressedintobearing)

• Bearing(pressedintosteeringknuckle)

• Lowercontrolarm(2)

• Stabilizerbar

• Steeringknuckle(2)

• Strutassembly(2)

Refertoindividualcomponentsforadditionalinformation.

OPERATION-FRONTSUSPENSION

Thefrontsuspensionallowseachfrontwheelona vehicletoadapttodifferentroadsurfacesandconditionswithoutgreatlyaffectingtheoppositewheel andtheabilitytocontrolthevehicle.Eachsideofthe frontsuspensionisallowedtopivotsothevehiclecan besteeredinthedirectionpreferred.

Whenavehiclestrikesabump,theforceistransferredthroughthehub,bearing,andknuckle,into thestrutassemblytoabsorbtheforceanddampenit. Duringsteeringmaneuvers,thestrutassembly (throughapivotbearingintheupperstrutmount) andsteeringknuckle(throughthelowerballjoint mountedonthelowercontrolarm)turnasanassembly.

WARNING

WARNINGSANDCAUTIONS

WARNING:DUSTANDDIRTACCUMULATINGON BRAKEPARTSDURINGNORMALUSEMAYCONTAINASBESTOSFIBERSFROMPRODUCTIONOR AFTERMARKETLININGS.BREATHINGEXCESSIVE CONCENTRATIONSOFASBESTOSFIBERSCAN CAUSESERIOUSBODILYHARM.EXERCISECARE WHENSERVICINGBRAKEPARTS.DONOTSAND, ORGRINDBRAKELININGUNLESSEQUIPMENT USEDISDESIGNEDTOCONTAINTHEDUSTRESIDUE.DONOTCLEANBRAKEPARTSWITHCOMPRESSEDAIRORBYDRYBRUSHING.CLEANING SHOULDBEDONEBYDAMPENINGTHEBRAKE COMPONENTSWITHAFINEMISTOFWATER, THENWIPINGTHEBRAKECOMPONENTSCLEAN WITHADAMPENEDCLOTH.DISPOSEOFCLOTH ANDALLRESIDUECONTAININGASBESTOS FIBERSINANIMPERMEABLECONTAINERWITH THEAPPROPRIATELABEL.FOLLOWPRACTICES PRESCRIBEDBYTHEOCCUPATIONALSAFETY

ANDHEALTHADMINISTRATION(OSHA)ANDTHE ENVIRONMENTALPROTECTIONAGENCY(EPA) FORTHEHANDLING,PROCESSING,ANDDISPOSITIONOFDUSTORDEBRISTHATMAYCONTAIN ASBESTOSFIBERS.

WARNING:DONOTREMOVETHESTRUTSHAFT NUTWHILESTRUTASSEMBLYISINSTALLEDIN VEHICLE,ORBEFORETHECOILSPRINGISCOMPRESSEDWITHACOMPRESSIONTOOL.THE SPRINGISHELDUNDERHIGHPRESSURE.

CAUTION:Onlyframecontacthoistingequipment canbeusedonthisvehicle.Itcannotbehoisted usingequipmentdesignedtoliftavehiclebythe rearaxle.Ifthistypeofhoistingequipmentisused, damagetorearsuspensioncomponentswilloccur.

CAUTION:Atnotimewhenservicingavehiclecan asheetmetalscrew,bolt,orothermetalfastenerbe installedintheshocktowertotaketheplaceofan originalplasticclip.Itmaycomeintocontactwith thestrutorcoilspring.

CAUTION:Wheelbearingdamagewillresultifafter looseningthehubnut,thevehicleisrolledonthe groundortheweightofthevehicleisallowedtobe supportedbythetiresforalengthoftime.

STANDARDPROCEDURE-LUBRICATION

Therearenoserviceablelubricationpointsonthe frontsuspension.Thefrontlowerballjointshave greasefittingswhichhavehadtheheadsnappedoff bythemanufactureraftertheyhavebeenfilled.This hasbeendonetoeliminatethepossibilityofdamagingthenon-ventedseals.Greasewillnotleakfrom thebrokengreasefittings.Theballjointsaresealed forlifeandrequirenomaintenance.

CAUTION:Noattemptshouldbemadetoreplace theballjointgreasefittingwithanewfitting,then fillingtheballjointwithgrease.Damagetothe greasesealcanresult.

Fig.1FrontSuspensionSystem

FRONTSUSPENSION(Continued)

1-UPPERMOUNT

2-VEHICLESTRUTTOWER

3-OUTERTIEROD

4-JAMNUT

5-STEERINGGEAR

6-CROSSMEMBER

7-STABILIZERBAR

8-STABILIZERBARCUSHIONANDRETAINER

9-BALLJOINT

10-STABILIZERBARLINK

SPECIFICATIONS

FRONTSUSPENSIONFASTENERTORQUE DESCRIPTIONN·m

BallJointStudPinchBolt9570—

HubNut244180—

DiscBrakeCaliperAdapter

KnuckleBolts 10477—

LowerControlArmFront PivotBolt 170125—

LowerControlArmRear PivotBolt 250185—

StabilizerBarCushion

RetainerBolts 2821250

StabilizerBarLinkNuts2821250

StrutClevis-to-KnuckleNuts54+ 90° turn

40+ 90° turn

StrutShaftNut7555—

Strut-to-TowerNuts3425—

TieRodAdjusterJamNut7555—

TieRodEnd-to-KnuckleNut5440—

WheelBearingRetainer

PlateBolts 2821250

WheelMounting(Lug)Nuts135100—

SPECIALTOOLS FRONTSUSPENSION

Splitter,Bearing1130

Installer,Bearing5052

Remover/Installer6644(-2)

Installer6758

Installer6760

Remover6804

Socket/WrenchStrutNut6864

RemoverC-4150A

Press,BallJointC-4212F

Remover/Installer6908(–2)

InstallerAdapterC-4698-2

RemoverMB-990799

Remover/Installer8373

RemoverMB991113

HUB/BEARING

DESCRIPTION

Thewheelbearingandhubarepressedintothe steeringknuckle.(Referto2-SUSPENSION/ FRONT/KNUCKLE-DESCRIPTION)

OPERATION

Thewheelbearingandhubarepressedintothe steeringknuckle.(Referto2-SUSPENSION/ FRONT/KNUCKLE-OPERATION)

DIAGNOSISANDTESTING-WHEELBEARING ANDHUB

Thewheelbearingisdesignedforthelifeofthe vehicleandrequiresnotypeofperiodicmaintenance. Thefollowingproceduremaybeusedfordiagnosing theconditionofthewheelbearingandhub.

Withthewheel,discbrakecaliper,andbrakerotor removed,rotatethewheelhub.Anyroughnessor resistancetorotationmayindicatedirtintrusionora failedhubbearing.Ifthebearingexhibitsanyof theseconditionsduringdiagnosis,thehubbearing willrequirereplacement.Donotattempttodisassemblethebearingforrepair.Ifthewheelbearingis disassembledforanyreason,itmustbereplaced.

Damagedbearingsealsandtheresultingexcessive greaselossmayalsorequirebearingreplacement. Moderategreaseweapagefromthebearingisconsiderednormalandshouldnotrequirereplacementof thewheelbearing.

Todiagnoseabenthub,(Referto5-BRAKES/HYDRAULIC/MECHANICAL/ROTORS-DIAGNOSIS ANDTESTING)fortheprocedureonmeasuringhub runout.

REMOVAL

Thewheelbearingandhubarepressedintothe knuckle.(Referto2-SUSPENSION/FRONT/ KNUCKLE-REMOVAL)

INSTALLATION

Thewheelbearingandhubarepressedintothe knuckle.(Referto2-SUSPENSION/FRONT/ KNUCKLE-INSTALLATION)

KNUCKLE DESCRIPTION-STEERINGKNUCKLE

Thesteeringknuckleisasinglecastingwithlegs machinedforattachmenttothefrontstrutassembly onthetop,lowercontrolarmballjointonthebottom,andsteeringlinkageonthetrailingend(Fig.1). Thesteeringknucklealsohastwomachined,drilled

andtappedlegsontheleadingendcastingtosupport andalignthefrontdiscbrakecaliperadapter.

Theknucklesupportsthewheelbearingandhub (Fig.1).Thewheelhubispressedintoasealed-forlifewheelbearingthatispressedintothesteering knuckle.Aretainerplatealsoholdsthebearingin place.Thehubsupportsthedriveshaftouterconstant velocity(C/V)joint.Eachissplinedandmeshesin thecenterofthehub.TheouterC/Vjointisretained tothehubusinganut.Thenutislockedtotheouter C/Vstubshaftusinganutretainerandcotterpin.

ThewheelbearingisaUnit1typecartridgebearingthatrequiresnomaintenance.Thewheelbearing canbeservicedseparatelyfromthehub.

Thehubhasfivestudspressedintoitsflange.

OPERATION-STEERINGKNUCKLE

Thesteeringknucklepivotswiththestrutassemblybetweenthelowerballjointandthepivotbearing inthestrutassembly.Thesteeringgearoutertierod endconnectstothetrailingendofeachknuckle, allowingthevehicletobesteered.

Thecenteroftheknucklesupportsthehub,wheel bearingandaxleshaft.

Thehubandwheelbearingworktogether.The wheelbearinghasinternalbearingsthatallowthe hubtorotatewiththedriveshaftandthetireand wheelassembly.Thehub’sfivestudsmountthetire andwheeltothevehicle.

DIAGNOSISANDTESTING-STEERING KNUCKLE

Thefrontsuspensionsteeringknuckleisnota repairablecomponentofthefrontsuspension.It mustbereplacediffoundtobedamagedinanyway. Ifitisdeterminedthatthesteeringknuckleisbent whenservicingthevehicle,noattemptistobemade tostraightenthesteeringknuckle.

REMOVAL-STEERINGKNUCKLE

NOTE:Beforeproceeding,reviewallWarningsand Cautions.(Referto2-SUSPENSION/FRONTWARNING)

(1)Applythebrakesandholdinplace.

(2)Raisethevehicle.(RefertoLUBRICATION& MAINTENANCE/HOISTING-STANDARDPROCEDURE)

(3)Removethefronttireandwheelassembly.

(4)Removethecotterpin,locknutandspring washerfromthehubnut(Fig.2).

(5)Whilethebrakesareapplied,loosenand removethehubnutontheendofthedriveshaft(Fig. 2).

(6)Releasethebrakes.

(7)Removethefrontdiscbrakecaliperand adapterasanassembly,andthebrakerotorfromthe steeringknuckle.RefertoBRAKEROTORinthe BRAKEsectionfortheprocedure.

(8)Removethenutattachingtheoutertierodto thesteeringknuckle.Todothis,holdthetierodend studwithawrenchwhilelooseningandremovingthe nutwithastandardwrenchorcrowfootwrench(Fig. 3).

(10)Removethetierodheatshield.

(11)Removethenutandpinchboltclampingthe balljointstudtothesteeringknuckle(Fig.5).

(9)Removethetierodendfromthesteering knuckleusingRemover,SpecialToolMB991113(Fig. 4).

CAUTION:Thestrutassembly-to-steeringknuckle attachingboltsareserratedandmustnotbeturned duringremoval.Holdtheboltsstationaryinthe steeringknuckleswhileremovingthenuts,thentap theboltsoutusingapinpunch.

(12)Removethetwoboltsattachingthestrutto thesteeringknuckle.

NOTE:Usecautionwhenseparatingtheballjoint studfromthesteeringknuckle,sotheballjointseal doesnotgetcut.

Fig.2HubNut

Fig.3TieRodNutRemoval/Installation

Fig.4TieRodRemoval

Fig.5BallJointBoltAndNut

(13)Separatetheballjointstudfromthesteering knucklebypryingdownonlowercontrolarmandup againsttheballjointbossonthesteeringknuckle (Fig.6).

(1)Removesteeringknuckle,hub,andwheelbearingasanassemblyfromthevehicle.(Referto2SUSPENSION/FRONT/KNUCKLE-REMOVAL)

(2)Threewheelstudsacrossfromoneanother requireremovalfromthehubflange.Rotatethehub toaligneachwheelmountingstudwiththenotchin thebearingretainerplatebeforeremoval.Using Remover,SpecialToolC–4150A(Fig.7),pressthe threewheelmountingstudsoutofthehubflange. Removethewheelmountingstudsfromthehub throughtheopennotch(Fig.8).

NOTE:Donotallowthedriveshafttohangbythe innerC/Vjoint;itmustbesupportedtokeepthe jointfromseparatingduringthisoperation.

(14)Pullthesteeringknuckleoffthedriveshaft outerC/Vjointsplinesandremovethesteering knuckle.

NOTE:Thecartridgetypefrontwheelbearingused onthisvehicleisnottransferabletothereplacementsteeringknuckle.Ifthereplacementsteering knuckledoesnotcomewithawheelbearing,anew bearingmustbeinstalledinthesteeringknuckle. Installationofthenewwheelbearingandhubmust bedonebeforeinstallingthesteeringknuckleon thevehicle.

(15)Ifthewheelbearingandhubneedremoval, (Referto2-SUSPENSION/FRONT/KNUCKLEDISASSEMBLY).Donotreusethewheelbearing.

DISASSEMBLY-STEERINGKNUCKLE(WHEEL BEARINGANDHUB)

NOTE:Theremovalandinstallationofthewheel bearingandhubfromthesteeringknuckleisonly tobedonewiththesteeringknuckleremovedfrom thevehicleusingthefollowingprocedure.

(3)Rotatethehubsothestudmountingholesin thehubarefacinginthedirectionshowninthefigure(Fig.9).

Fig.6SeparateBallJointFromKnuckle

Fig.7SpecialToolC-4150A

Fig.8StudRemovalFromHub

(4)InstalltheBearingSplitter,SpecialTool1130, betweenthehubandthebearingretainerplateas shown(Fig.9).Absenceofthethreewheelmounting studsallowsthebearingsplittertobeinstalled behindtheflange.Handtightenthenutstohold bearingsplitterinplaceonsteeringknuckle.

(8)Removethethreeboltsmountingthebearing retainerplatetothesteeringknuckle(Fig.11). Removethebearingretainerplatefromthesteering knuckle.

(5)Placethesteeringknucklefacedowninan arborpresssupportedbythebearingsplitteras shown(Fig.10).

(9)Placethesteeringknucklebackinthearbor pressfacedownasshown(Fig.12).Thepresssupportblocksmustnotobstructthebearingwhileitis beingpressedoutofthesteeringknuckle.

(10)PlaceRemover/Installer,SpecialTool MB-990799ontheouterraceofthewheelbearing (Fig.12).Pressthewheelbearingoutofthesteering knuckle.

(6)PositionRemover/Installer,SpecialTool6644-2, onthesmallendofthehub(Fig.10).Usingthearbor press,removethehubfromthewheelbearing.The bearingracewillnormallycomeoutofthewheel bearingwiththehubasitispressedoutofthebearing.

(7)Removethebearingsplitterfromthesteering knuckle.

(11)Removethebearingracethatisstillpressed ontothehub.Todoso,installBearingSplitter,SpecialTool1130,betweenthehubflangeandthebearingrace(Fig.13).Placethehub,bearingraceand bearingsplitterinanarborpressasshown(Fig.13).

Fig.9BearingSplitterProperlyInstalled

Fig.12WheelBearingRemoval

PlaceRemover/Installer,SpecialTool6644-2onend ofhub.Pressthehuboutofthebearingrace.

6-SPECIALTOOL6644–2

NOTE:Forsteeringknucklereassembly,(Referto2 -SUSPENSION/FRONT/KNUCKLE-ASSEMBLY).

ASSEMBLY-STEERINGKNUCKLE(WHEEL BEARINGANDHUB)

(1)Wipetheboreofthesteeringknucklecleanof anygreaseordirtwithaclean,dryshoptowel.

(2)Placethesteeringknuckleinanarborpress withInstaller,SpecialToolC-4698-2,supportingthe steeringknuckle(Fig.14).

(3)PlacetheNEWwheelbearingintotheboreof thesteeringknuckle.Besurethewheelbearingis placedsquarelyintothebore.

(4)PlaceInstaller,SpecialTool5052,ontheouter raceofthewheelbearing(Fig.14).Pressthewheel bearingintothesteeringknuckleuntilitisfullybottomedintheboreofthesteeringknuckle.

(5)Removetheknucklefromthepress.

NOTE:Useonlytheoriginaloridenticalreplacementboltstomountthebearingretainerplateto thesteeringknuckle.

(6)Notingthenotchlocation,installthebearing retainerplateonthesteeringknuckleasshown(Fig.

11).Installthethreebearingretainermounting bolts.Tightenthebearingretainerplatemounting boltstoatorqueof28N·m(250in.lbs.).

(7)Installthepreviouslyremovedwheelmounting studsbackintothehubflange.Todoso:

(a)Placethestudsinthethreeholesinthehub flange.

(b)Placethehubinthearborpresssupported bySpecialToolC-4698-1,allowingthefirststudto extenddownintothetool(Fig.15).

(c)Pressthewheelmountingstudintothehub flangeuntilitisfullyseatedagainstthebackside onthehubflange.

(d)Removethehubandtoolfromthepress.

(e)Repeatthesteps(b),(c)and(d)onthe remainingtwostuds.

1-ARBORPRESSRAM

2-HUB

3-SPECIALTOOLC-4698–1

4-NOGAPISALLOWEDBETWEENSTUDFLANGEANDHUB HERE

5-WHEELMOUNTINGSTUD

Fig.13BearingRaceRemovalFromHub

Fig.14WheelBearingInstallation

Fig.15WheelMountingStudInstallation

(8)Placethesteeringknucklewiththewheelbearinginstalledbackinthearborpresswiththesmaller endofRemover/Installer,SpecialToolMB-990799, supportingtheinnerraceofthewheelbearingas shown(Fig.16).

(9)Placethehubinthewheelbearingmaking sureitissquarewiththebearinginnerrace(Fig. 16).Pressthehubintothewheelbearinguntilitis fullybottomedinthewheelbearing.

onceinstalled.Installthenuts.Holdingtheboltsin placetightenthenutstoatorqueof53N·m(40ft. lbs.)plusanadditional90°turnafterthespecified torqueismet.

(5)Placethetierodheatshieldonthesteering knucklearmsothattheshieldispositionedstraight awayfromthesteeringgearandtierodendonce installed.Aligntheholeintheshieldwiththeholein thesteeringknucklearm.

(6)Installtheoutertierodballstudintothehole inthesteeringknucklearm.Startthetierodattachingnutontothestud.Holdthetierodendstudwith awrenchwhiletighteningthenutwithastandard wrenchorcrowfootwrench(Fig.3).Tofullytighten thenuttospecifications,useacrowfootwrenchona torquewrenchtoturnthenut,andawrenchonthe stud.Tightenthenuttoatorqueof55N·m(40ft. lbs.).

(7)Installthebrakerotor,discbrakecaliperand adapter.(Referto5-BRAKES/HYDRAULIC/MECHANICAL/ROTOR-INSTALLATION)

(8)Cleanallforeignmatterfromthethreadsof thedriveshaftouterC/Vjoint.

(9)Installthehubnutintheendofthedriveshaft andsnugit(Fig.2).

(10)Haveahelperapplythebrakes.Withvehicle brakesappliedtokeepbrakerotorandhubfrom turning,tightenthehubnuttoatorqueof244N·m (180ft.lbs.)

(10)Removethesteeringknuckleandtoolsfrom thepress.

(11)Verifythehubturnssmoothlywithoutrubbingorbinding.

(12)Installthesteeringknuckleonthevehicle. (Referto2-SUSPENSION/FRONT/KNUCKLEINSTALLATION)

INSTALLATION-STEERINGKNUCKLE

(1)Slidethehubofthesteeringknuckleontothe splinesonthedriveshaftC/Vjoint.

(2)Installthesteeringknuckleontotheballjoint studaligningtheboltholeintheknucklebosswith thenotchformedinthesideoftheballjointstud.

(3)Installanewballjointstudpinchboltandnut (Fig.5).Tightenthenuttoatorqueof95N·m(70ft. lbs.).

CAUTION:Thestrutassembly-to-steeringknuckle attachingboltsareserratedandmustnotbeturned duringinstallation.Installthenutswhileholdingthe boltsstationaryinthesteeringknuckle.

(4)Positionthelowerendofthestrutassemblyin linewiththeupperendofthesteeringknuckleand alignthemountingholes(Fig.1).Installthetwo attachingbolts.Theboltsshouldbeinstalledwithso thatthenutsfacetowardsthefrontofthevehicle

(11)Installthespringwasher,locknutandcotter pinonthehubnut(Fig.2).Wrapthecotterpinends tightlyaroundthelocknut(Fig.17).

(12)Installthetireandwheelassembly.Install thewheelmountingnutsandtightenthemtoa torqueof135N·m(100ft.lbs.).

(13)Lowerthevehicle.

(14)Setthefronttoeonthevehicletorequired specification.(Referto2-SUSPENSION/WHEEL ALIGNMENT-STANDARDPROCEDURE)

Fig.16HubInstallation

Fig.17CorrectlyInstalledCotterPin

LOWERBALLJOINT

DIAGNOSISANDTESTING-BALLJOINT

Withtheweightofthevehiclerestingontheroad wheels,grasptheheadlessgreasefittingasshown (Fig.18).Withnomechanicalassistanceoradded force,attempttomovethegreasefitting.Iftheball jointisworn,thegreasefittingwillmove.Ifmovementisnoted,replacetheballjoint.

CAUTION:Noattemptshouldbemadetoservice theheadlessgreasefittingontheballjoint.Ithas beenpurposelysnappedoffbythemanufacturerto avoidover-greasing.

LOWERBALLJOINTSEAL BOOT REMOVAL

(1)Removesteeringknucklefromvehicle.(Refer to2-SUSPENSION/FRONT/KNUCKLEREMOVAL)

(2)Usingascrewdriverorothersuitabletool,pry sealbootoffofballjoint(Fig.19).

INSTALLATION

(1)Wipeoffusedgreasearoundballjointstem.

CAUTION:Wheninstallingthesealingbootonthe balljoint,positiontheupwardliponthesealboot outsideperimeteroutward,awayfromthecontrol armonceinstalled(Fig.20).Itistheretohelpshield heatfromthesealingboot.

(2)PlaceNEWballjointsealbootoverballjoint stem.Upwardliplocatedonoutsideperimeterofseal bootmustpointoutward,awayfromcontrolarm onceinstalled(Fig.20).

(3)Byhand,startsealingbootoversidesofthe balljoint.

(4)PositionInstaller,SpecialTool6758,oversealingbootouterdiameterasshown(Fig.20).Byhand, applypressuretotopofInstalleruntilsealbootis pressedsquarelydownagainsttopsurfaceoflower controlarm.

(5)Removetool.

(6)Removeheadlessgreasefittingonballjoint andreplaceitwithstandardzirc-typegreasefitting. Donotdiscardheadlessgreasefitting.

Fig.18CheckingBallJointWear

Fig.19SealBootRemoval

Fig.20SealBootInstallation

LOWERBALLJOINTSEALBOOT(Continued)

CAUTION:Itisimportanttolubricatetheballjoint beforeinstallationofsteeringknuckletoallow properventingwhenthesealisfilled.Iftheball jointislubricatedafterinstallationtoknuckle,damagetothesealcanoccur.

(7)Usingahandoperatedpumpgreasegun,fill theballjointsealbootwithMopar Multi-Mileage Lubeorequivalentuntilgreasepushesoutpastball jointstem.Wipeoffoverfill.

(8)Removestandardzirc-typegreasefittingand reinstallheadlessgreasefittingonballjointtopreventfuturelubricating.Seeabovecaution.

(9)Installsteeringknuckle.(Referto2-SUSPENSION/FRONT/KNUCKLE-INSTALLATION)

LOWERCONTROLARM DESCRIPTION

Thereisonelowercontrolarmoneachsideofthe vehicle.Eachlowercontrolarmisastampedsteel unitusingrubberisolatedpivotbushingstoisolateit fromthefrontsuspensioncrossmemberandframeof thevehicle(Fig.1).Therearbushingcanbeservicedseparately.

Thefrontofthelowercontrolarmisboltedtothe frontcrossmemberusingaboltthroughthecenterof therubberpivotbushing.Therearofthelowercontrolarmismountedtoboththefrontcrossmember andtheframerailofthevehicleusingathru-bolt. Thethru-boltgoesthroughboththecrossmember andrearlowercontrolarmbushing,threading directlyintoacagednutintheframerailofthevehicle.

Theleftandrightlowercontrolarmsareinterconnectedthroughalinkedrubberisolatedstabilizer bar.

Theoutboardendofeachlowercontrolarmconnectstothesteeringknuckleusingaballjoint.

Thelowercontrolarmconnectstothesteering knucklethroughaballjointmountedattheoutboard endofthearm(Fig.1).Theballjointispressedinto thelowercontrolarmandhasanon-taperedstud withanotchforsteeringknucklepinchboltclearance.Theballjointstudisclampedandlockedtothe steeringknucklelowerlegusingapinchbolt.

Theballjointislubricatedforlifeduringthemanufacturingprocess.Oncelubricatedforlife,the greasefittingheadissnappedoffbythemanufacturer.Thisisdonetoeliminatethepossibilityof lubricationlaterintheballjointslifethusdamaging thenon-ventedballjointsealboot.

Theballjointusedonthisvehicleisreplaceable andcanbeservicedasaseparatecomponentofthe lowercontrolarm.

OPERATION

Thelowercontrolarmsupportsthelowerendof thesteeringknuckleandallowsfortheupanddown movementofthesuspensionduringthejounceand reboundtravel.Thelowercontrolarmballjointconnectsthearmtothesteeringknuckle.

Theballjointisapivotaljointonthelowercontrol armthatallowstheknuckletomoveupanddown, andturnwithease.

DIAGNOSISANDTESTING-LOWERCONTROL ARM

Inspectthelowercontrolarmforsignsofdamage fromcontactwiththegroundorroaddebris.Ifthe lowercontrolarmshowsanysignofdamage,lookfor distortion.Donotattempttorepairorstraightena brokenorbentlowercontrolarm.Ifdamaged,the lowercontrolarmstampingisservicedonlyasa completecomponent.

Theserviceablecomponentsofthelowercontrol armare:theballjoint,theballjointgreasesealand thelowercontrolarmrearisolatorbushing.

Inspectbothlowercontrolarmisolatorbushings forseveredeteriorationandreplaceasrequired. Inspecttheballjointpertheinspectionprocedurein thissectionoftheservicemanualandreplaceas required.(Referto2-SUSPENSION/FRONT/ LOWERBALLJOINT-DIAGNOSISANDTESTING).

REMOVAL-LOWERCONTROLARM

NOTE:Beforeproceeding,(Referto2-SUSPENSION/FRONT-WARNING).

(1)Raisethevehicle.(RefertoLUBRICATION& MAINTENANCE/HOISTING-STANDARDPROCEDURE)

(2)Removethefronttireandwheelassembly.

(3)Removebothstabilizerbarlinksfromthevehicle(Fig.21).Removeeachlinkbyholdingtheupper retainer/nutwithawrenchandturningthelinkbolt.

(4)Rotatetheforwardendsofthestabilizerbar downward.Itmaybenecessarytoloosenthestabilizerbarcushionretainerboltsalittletoeaseany turningresistance.

(5)Removethenutandpinchboltclampingthe balljointstudtothesteeringknuckle(Fig.22).

CAUTION:Afterremovingthesteeringknucklefrom theballjointstud,donotpulloutwardonthe knuckle.Pullingthesteeringknuckleoutwardat thispointcanseparatetheinnerC/Vjointonthe driveshaft.RefertoFRONTDRIVESHAFTSinthe DIFFERENTIALANDDRIVELINEgroupforfurther information.