Chrysler 1991 Stealth Technical document

SAFETY NOTICE
CAUTION
on component!; or
applic~lions should rep~ired in ~ccord~nce with
supplied by the manufacturer of the lotal product.
,
instructions
Proper service and repair i. importanl to the safe. reliable, operation of ~ll motor vehicles.
The service procedur es recomme nded A nd described in this publication were dev ~ loped
for professional servic~ peroonnel and are effeclive m et hods for performing vehide
repair. Following these procedures will help assure efficient economical vehicle
performance and service reliability. Some of these service procedur e. require the use of
special lools designed for specific procedures. These special tools should be used when
recommended throughout Ihi. publication.
Sped~l ~ltenlion should be exen:ised when working with spring or tension loaded
fasteners and devices such ~s E-Clips, Cin:lips, Sn~p rings, etc., as careless removal
may cause personal injury. Always wear safety goggles whenever working on
vehicles or vehicle components.
It is important 10 note that this publication contains various Cautions and Warnings.
T he,e should be c~rc(ully r~ad in order to minimize the ri,k of pe rs onal injury. or the
possibility that
improper service methods may dam " ge the vehide or tender it umafc'. It i.
important to note that the,e Cautions ~nd Warning. cover only the ,il1lOtions ~nd
proc~x1urc, Chrysler Corpo'''lion has enc ountered and recommended. Chrysler Corpora_
tion could not possibly know, ev"luate, ~nd odvise the service trade of ~ll concej,,~ble
ways that service m~y be p<'rformed, or of the possible haards of corh. Consequently,
Chrysler Corpor ation has nOt ulUknaken any such brood service review. Accordingly,
anyone
who uses ~ ",rvice proc,'dure" or tool, that is not recommended in this publicotion.
must assure oneself thoroughly that neither personal .,fety , nor vehicle s.{ely. bc
j~..,pardilcd by the service methods they select.
I
THROUGH
AS:
CERTtFlED

Stealth
TECHNICAL
INFORMATION
MANUAL
FOREWARD
Thi S ma nus! ha s been prepar ed as an in tr od llCtion
10 the sp ec if ica tions. featur e~ , construction arn;l
fll nCliorlS of the n ewly developed STEALTH.
Plea 5e ,e&<! this manual carefully as ~ will be 01
assj'la.nce for S$rvice and sales actMlie$.
Please note t hlt 1M se rvIce "",nuet, are also
available and 5houkl be used in COIIjunc tion with
II 1IS manual
All onformal;')n, ill ustf~ t jons and p'odu C:1
o;k!s~ fiP l ior>s cont ai nw in this menual are current
as al the time of pub1icatiO{1 . We, however,
re serve the right to make ch a ng es al any time
with ou t prior no tice or oblig<l tion.
GROUP INDEX
General ..........................................
Fr ont Suspension .........................
Rear AlII........................................
...... . ..... . ..............
Clutch .............................................
Cooling ........................................ ..
El ectricil ........................................
Engine ............................................
Intlke and Exhaust .................... ..
Fuel System ........... .. .....................
Propeller Shaft and Universal
Jo int
....
Rear SuspltRsion .. ...................... ..
P owe r Steering ........................... ..
4-Wheel Steeri ng System 14WS) ..
Transexle - ~:t~~~tiC .................
Wheels and Tir es .........................
Body
.............. .................................
Restraint
........ ..... ..
Heater. and Air Conditioning ....
Em ission Control Sys tem s .........
o
2
3
5
6
7
8
9
11
14
16
17
19A
19B
21
22
23A
23B
24
25

MODEL INDICATIONS
The following abbreviatioos are USM in this manual for classilication of model types.
MrT: Indicates the manual transaxle. 01 models equipped with the manual transaxle.
AIT: IndicaleS Ihe automatic transaxle. or models eQuipped with the automatic transaxle.
MPI: Indicates the multi1X'int injection. or engines equipped with the multi-point injection.
DOHC: Indicates an engi"", with Ihe double overhead camsha ft. or a model equipped with such an engine.
Turbo: Ind icates an engi"", wilh turbocharger, or a model equipped with such an engine.
Non·Turbo: Indicate. an engi"", without turbocharger, or a model equipped with such an engine.
FWD, Indi~tes the front wheel·drive vehicles.
AWD: Indicates the aU wheel·drive vehicles.
HOW TO READ A CIRCUIT DIAGRAM
Circuit diagrams are preparoo as lollows using these
symbols:
eooo . ",o rI", eqUip '
"",n! ",.(h .ttoohe<l no<·
~"
NOTE
For specilic details concerning the interpretation 01
circuit diagrams. reler to the separatefy bound
Service Manual.
.,~
_ .. _.
n "" ••ymboI> >how their>p!Jt 10
and output from i<ir9<tion 01
ou"",,1 flow 10 and.f,oml an
eiec'","",cootroi OOt.
(61 ond.,..t .. thot c",,,,nt flows
~rd .
·W
."
1_, Ou",,",! output
! L--L,
L:.-°$ i
, ,

UNITED STATES
Th e ~ periaJ ..,rvire tool. r e f~ .... d to m.ffin .... nq ulnd for «lr!.&in ...... io:<l operations. Tbeili: ~J ",d .l .., rvi,e t ool .
(M'" their ""'I uivalent. if IlOl obt.oi""ble th"""h • \00:1.1 ""',..,. n. a nila"'-lloroulh Ihe follo" 'i", oul.let.
82t115 Pa rk I...ane ,GardenCIty. Mithipn 48 t U. U.S.A.
TRIANGLE SP£CIAL PRODUCTS GROUP
Il,!ll l ER SP£ CI .... l TOOl.$)
DlVI5OO101 Of THE TRIANG LI GOAPO~ o\TI O N
CANADA
floe .peciaI....-vioe t ools ldernd to Mrftn _ requ i red """ .. rtaia .. moe openticms. Thnt .ptcial..,....;.., ......
... theirequiVlllent. ifnot o bu inable throu!!h ...... 1 ~ .... . n i ~ lhl'OUlh the foUo..in& outlet.
. Box 24" ... mhentbu ..... On t.orio N9V zz.t
INTERNATIONAL
no. ,ped. l..,rv io e tool ... de","" to tM.ffin a .. requi red for ... rtain ..... ·io:. operotion... T ..... ~ped. 1 u rvio. toolt
orlhoi. equivalent. if root oblainable th rough. 10 .. 1"",,1'<'*'" .. &i able IIorou Rh tbe loIlo,,·inR ou tlot.
3216 15 ParlILaM . Gank ft City, Midoigan -48 t $. U.S.A.
A
TRIANGLE SPECIAL PRODUCTS GROUP
1 0.4I LL ER SPECI Al TOOL$!
DIV ISION O~ THE TRIANGLl! CO "PO~ATION
Te le phone (a13) 52~67 17 "AX (313) 52 ~ 65(}~

0-1
GENERAL
CONTENTS
GENE R AL D AT A AND S PE CI FIC A TIONS ...... 21 VEHIC LE IDENTIFICATION ....... . ........... . ..... 17
TeCHNICAL FE AT U RES ................................2 Chassis N....-nber . ... .. ..... ...... ... . ... . ... . ... .. . ... .. ....... 19
Active Exhaust <Turbo>. ........ . .......... . ... . .... ...........9 Eng i ne Model Stamping .... .. .... . .......... . .............. 20
Chassis ,..... ... .. ...... .. . .. ........ .. ....... ___ __ __ ___ __ ___ _ 10
Vehicle Identificati on C ode Chart P I ~ l e ........... 17
Clutch Booster <Turbo> .. .. ... __ . .... ._. ,_.... .. _,....... .. .9 Vehicle Identification Number List
.. ...... . .... . .... . 18
Eng in a .._._.. _ ___ _ __ , __ ,_,.., _, ,_,.. ... _,_...... .... ... .. ... .... ... ..4 Vehicle Identificati
on Number
Exterior ..", ___ __ __ _ __ _, ._._.
... .... ... .. ..............,... .... .. 2 Location
................................. . .... .... . .. __ ...... __ . _' . .. 17
Interior .,_ .. .......... .... ......... .. ...... .. .... ... . .. ... ... , .... .. ... .. .. ..3 Vehicle Informll1ion
Code Pill1e ... .. . .. .... ... ". .. .. .19
Small Amount Refrigerant System Vehicle
Sa f €ltY C€lrt ification Label .. ". .. ". .. .. . ...... 20
(Air Corlditior\e') . .. .... ....... .. . ... ... .... .. .. ........"........ .. ,15
Supplemental Restraint System {SRS) ........". ,1 4
Theft·alarm System. ...... ....... .. . ... .. ... .... .. ........ "". 16
Transax le .......... .... . .. .... ....... ...... ........ . .... .... . .. . .. ....... .8

0-2 GENERAL -
Techn ica l Fe a tur es
TECHNICAL FEATURES
E XTER I OR
Dynamic spons car proportions with wide tr ead
and tight in terior.
'0.
Feat ur es
,
Th<I forward passenger compa rl menl l ooh like a c",,"ule, U"irIg lila"" ""';th complex ClJrve •.
0''''''
, Sports car proportions and
~u p" rio' ""adynamic ch"'"cteristics matched with" super or9"'nic s o.rl ~ c e .
, , T al
uminum wheel and wide t re ed tire to cre8 1e th eifmge oi a high performlO!1Ce sport. "'"
<DOHC-Turbo>
--
, A large
solt -f ~ bumper !with bU~l·ir1 i)umper 8bsorber) th&t gives the feeli ng oj being "" • ...,;1with th"
"'"
" -Pop-up
type heodli t" with optical horn lens_
-Black
poi n ted h<Iad ighl 000ds charnel"';,,, the front face.
• 3.ffimensklnal ta
ill ig ht characterizes the rear corners.
,
Boomerang type ,ear spoiler to match the aero form.
,
Rear pillar that is elegant and creetes an aerodynamic i mage .

GENERAL - T. c:hn l c:.1 F eat ures
INTERIOR
I nte rior IIwII er Nte ! ~ .eel 1001i "9 (ll " o.:o<:kpJt
centering around the dr Ntw _
No
FM 1...."
, ArI!nstrumenl
pao>eI Itlel ~siles . . .... ng <J1 ~
,
~3 .... oe\eO ..... ..... ',.m that lO'oducesa sporty~ .
,
Etw-~ gogvko lyp9 mB[ .. ~W _
•
MA 'ound 000r !rim that see"" to be 0<I4i ..... , w;m the InS lf\.IIYIefI1 pwoel .
,
Supi-rloi & 1)OrIy I\1>e .r ont $HI!6-wey PO"" SNtlINI gives. 'Hling of suppo<t.
, H
;gh. wide a nd large jlo« eoosole .
,
Sporty s lee,jnQ wtlu lwi th bui lt -in air bag.
0-3
... 0 . ..
I

0-4 GENERAL -Tlchnlcal Features
ENGINE
There are three types of engines for the
STEALTH: 3.0l SOHC engine. 3 .0l DOHC Non·
Turbo engine and 3,Ol OOHC Twin-Turbofrwin-
Intercooler engine. Al l three features high
performance, low vibration. low noise and low fuel
SPECIFICATIONS
Eng;ne mode l Dispillcement
C<; Icu. in.!
0072-S0HC 2972 (181,41
6G72-DOHC (NI)I1 ·T <JI'bo) 2972(181,41
6G72·DOHC (Turl>o)
I 2972 (181,.41
FEATURES
High performance and low fuel consumption
consumption. The 3,OL DOHC Twin-Tur bolTwin-
Intercooler engine, in panicular. is ideal for a high
performance AWD sports CBr because of its
overwhelmin\l power,
Max. output (SAE net) Mil)(, torqUOi ISAE ntit)
HP /rpm ft,I b$ Jrpm
164/5.&lO
18514,000
222/6.000 201/4,500
I 300/6,000
307/2 , 500
• The roller rOCKer ~rm fedoces lha valve-actuation torque as well as fuel consumption.
• Vari3ble induction
contrc> system <OOHC Non-Turbo> for f l~t torqu(l perform~nC(l from low speed
to high speed.
• Improved response and fuel consumption have been achieved by electronic control multi-point
fuel
in ject ion.
• EI(lctronic control
of fuel pump fuel discharge for high response and low fuel consumption
<DOHC-Turbo>.
•
Overwhelmin~ acceleration due to combination of the twin-turbocharger and twin-intercooler.

GENERAL Technieal Feetures
-
05
-
Qu iltt operation
-Noise and vibration h",,&been decreased
by th e adopti on of r ol ler roc ke r arms.
• Noi
se g enera ted by the valve m echan ism has been decreased by th 8 hyd r au l ic aUIO la sh ad juster s.
• Both powerful exhaust sound fitting a high performance vehid", and quietness due
to the active
ft xhaust system <DO HC- Turoo>.
• Reduction in noise
and vibration by implOving the rigidity of the cy lin der block.
• Vi
bre tions have been decreased by the adoption of bea ri ng caps with beams which incI\lase the
rigidity of th o> c ra nkshah su pport rx:o ints.
• Major reducti
on of vibrat iQn when sh ift inQ and a mild acceleration feeling due to u Sfl of total con tr ol
between t!'le automatic tfMS<lxle control un it and engine control uni t.
• Reduction in vibration due to
the use of ij cran ks ha ft pu ll ey with torsion damper arid. becouse of t ha t.
improvement in the du r abi lity of the belts <DO H C> . .
Servlc.ability
• Complete
se l f~ i agrlOsis fUrlCtions.
•
EnharlCed re li ability through the adoption of gold-plated co nnector te rminals_
• U
se of an auto te ns kmer ach ieves maintenance-free. automatic adjustment of ti min g belt tension.
• U
se of the ~ uto- I ash ad justers ach ieves mainterwnce-free, au tomatic adjustment of va l ve clear arlC e.
•
The 3-coil ignit ion system w it hout a distributor supp li es sufficient i gn ition ef1ergy even during high
speed operMi on .

0-6
GENERAL -Teehnieal Features
<6G72-DOHC (Non-Turbo»
V •• I.b l. Induction CMI'roI Systom
11gr ."t ly irnpr"" e, tol qoe., medium . pe ed ,r.;j ,M dr iv ing /eeiog bV gradual ly op_ning tn " i r<JuctOn
contr ol vo",," who" t ho ~ng ' w i. , "~ " mWi "" rpm o< cordirIQ to t he ;"O "",M io oogino rpm_
low IPHd rpm
Induction control . " ' . ~
II; ,eno or
,
_.

GENERAL -Technical Features 0-7
<6G12·DOHC (Turbo»
ide. 1
to achiorM
Twin·tu,boch.,g. , . nd Twln·ln",~'
' " '~ "," .' [LX )
, D
front

0-8 GENERAL - Te chn ic al Features
TRANSAXLE
WSMG1 TYPE MANUAL TRANSAXLE
The W5MGl type manual transaxle is II fu ll·time
4WD manLJa I transaxle made by GETRAG' and
1. Sportiar dr iving is poss ible by using II center
di ifera nt;al method w ith viscous coupli ng for
distributi rJg Ifront 45: rear 55) front and rear
torqoo unevenly.
2. A double-cone synchronizer for lsi lind 2nd
speeds lind a reverse synchronizer are used
arid, in addition to su r f! shifting performance.
the shift feeling is also improved.
new ly developed 10 ma tch the high output and
high torque 01 the 6G72..[)()HC [Turbo) ,,"'gine.
3. Low vibration and l ow noi se ar e rea lized by
the use of h
ig h precision gears and high
rigidi ty shaft.
-GETRAG is a special
West Germany
manufacturer
and develops and manufactures
high performance transaxles especially in
Eu rope.

GENERAL - Technical Feature, 0-9
ACTIVE EXHAUST <Turbo>
Active exh~ust is ~n exh~ust system that can be
switched between two modes
by operating the
mode changeover switch; the normal mode for
improved power performance and fuel
: :
Moin m utf~ r
CLUTCH BOOSTER <Turbo>
A 4" single type clutch booster is used 10 reduw
the forca needed to depress the clutch pedal.
consumption, and the silent mode for improved
silence in the low rpm range.
Furthermore, the exhaust hils a rea l poweriul
sporty sound.
Ch " \l"""'" volv .
-
II I
r -
•
M"," rrufflor
811_ "''''''''--7
C
::::
, -
..
..
.. ,,",,'

0-10
CHASSIS
Stettlng
•
•
•
•
•
•
•
•
•
•
GENERAL - Technical Features
R.ar I oil ~
fro nt Axle
• B.J.TJ typo con. ",n, ~ty joint w it h higI> 'ran,mi •• oo etfici.,..-.:;y ond "' Ol mcm VibrlltlDfl ond
""'M .
• I ."."."ic d,; ve .haft for , odu~ vib/'tion. """e ond tor qv<o sle ..-.
• A unit b.al beari ng ODflsislinQ of Ih o hub ond "".,in g for good .er.i"",bility ond lit"" ,oI ing
r~oi.ta"" . ,

GENERAL -Technical Features 0-11
X _ ~~nt 01 l in .. t ha t
maintoin.
bo la nc . d ""'ing
in f,oot ond ,_ ."" n if th b
hyd ratJ 'ic S'/ s \em i. lost.
D ual proPOrtioning y."' ~
f Of cootrol of "' " who ol braking,
Ii
Propene, Shllft
. ~
• J .. "" ",,, 4· join t typo propel le , &hat! wi th two ""n ,er bo or i ng •.
RN ' Suop. n oi on
-Oooble wi.hI>one type indep<ndent ' " 'pi n. ioo lor
oot ." ", ding riding c omfort "AW D> ,
• Eleotroo lo cont<ol . " .pen .i oo l EeS ) lor be th .t_
L-'Ch ondli "!,l a nd li di "!,l oomf ort .
_,Axl.
o BJ- TJ type CO ' '''"nt "" Iocitv join t with high
tr. n. m "si on ~ ff icioo<:y and minimum vi "'o'ion
noise.
Vi$cw. ~ "!,l type imi to d- . lip d iffo , en , ioI .
• R 1>I>r o joint to "b oom l &ngt hwi •• • od " "!,l ui .' o ha roge and p, w"" t t ra n. mission of
vi br01ions.
• Anti-vibtolion type propel lo , . holt (, .or pr ope~ ' '' fij 10 ,eduoe "i "'ation " od """, e from
' 00 drivtt 'rW,

0-12
GENERAL -Technical Featurea
<FWD>
SI_rlng
• Lil11~ oompoct integral type ra o'< ond pi";"" typo po~ ' l _itt~ with "","'to"""" """';"1)
,. """n •• .
• Tut .t ee ring m.<h.n i .m for id elll drWing "" s it ;,""
• $AS i. w i' into til< ""''''ino whe el to prowct the df"'o r.
.-------
FrOn! Suoponllon
• Vo ", l i!,I ht . no r igid McPh .. """ .trut t~po "><IopeOOIln l
""pM'''' '' .
• l.ary<I d iomo .. , off_ coil .pring lor "UP '" ;''' ';di ng <omlor!_
• Anti-dr.irl\l ge<>me t"l for outstanding h. ndii rl{,l .tability.
• Ne g. tiw off.o, ~ try for oo", .nding br. ~ir\Q ''''bi i l')'.
• Electronic CDIltroi .u.pen.ion lEeS) for both """'- h<IndIing
ond 'i(j;ng comfort_
• L <l llkl fil .d bu ." "Il for impr""ed handf;ng stability and r 'l ing
comfor t.
Fro'" Axle
• lsome!r;'; drill. 'h o lt 10< re du "" d 'oit.'"tioo. 00; ... and (orQ ,,"
.-
• BJ-TJ Wpt con sta nt •• Iodty joint with high t ra n smission
~ff~y ond minimum vibrotio<1 an d oo i$e .
• ~ r <onto ot bal ~ring feo- <;IOOd .orvic eo bi i ty..,d littl .
roIiog ,.,; ott "" •.
.,~

GeNERAL -Technic_I Fntur ..
_ ... ·0 'a .
7. 8 or 8. 9 inch """'" t;nI<.
_ ... ..,.--
, 11<1«1 to de9o ." tn~
-
"'~1\'
• lie .. ", do•• I.,..... .......... * """ ""'_ tho! .... ,Gin •• "'" fulUJWo
of U .. oIOuI)If .... ~!VI» "" ,,,,,,, lion ond tt. l "" "'" oype
""- ""'-
• Too """Ir", dYr"" O\J~ otrol<e far both ' Iable "",din g..-.:j ridin!l
cormi on .
• Eloctronic
00 '11[01 SUIP8Mion lEGS) fot both . t.bI . clrM"Il 0Ild .
<omlon .~ .. ,~ .
0-'3
........

0-14 GENERAl- Technical F .. tur.s
SUPPl£'-'ENTAL RESTRAINT SYSTEM ISRSI
SRS is II $y$wm tha I works with the seat ba ll and
is du lgned a~ auxil i! ry equ i pment to the se 81
be ll.
It onty I Ur'lC lions to protect 111$ upper body 01 t~
driver when a shod: thaI is over the design value
Ideeel ar .l ion GI ;s added \0 the entire vehicle
from the Iron l.
" On "

GENERAL - Technical Features 0-15
SMALL AMOUNT REFRIGERANT SYSTEM (AIR CONDITIONER)
In order to protect the alOne I~yer, the small
amount refrigerant system was developed by
improving the structural parts of the air
to reduce as much as possible the amount of
chloro-fluoro carbon used as the refrigerant in
automobile ~ ir conditioners.
conditioner, mak i r.g it more compact, etc. in 0c'd"'-'c. __ ,- __ -:__ cc __
4-ioyer 'YP" "" .. to '~du<:e , ~ f, ige '''''t
perm""100 in ,ho rubM, hosa
M LJ 'i·flow tvJ>O
oornpact ooncifln, e,
Up •• 01 typo beoring a' conditione'
compre •• or
,
A "" e ivf>r with butJble prevention cove' to control
bubbli ng in t ho ",c_ by u'i:!g • """""