Chrysler Concorde 1993 User manual

CHRYSLER
CORPORATION
1993
SERVICE MANUAL
CONCORDE
INTREPID
VISION
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, ME-
CHANICAL, 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 ob-
ligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1992 Chrysler Corporation 15M0692
NEXT PAGE ©

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system
to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the
form to provide Chrysler Corporation with your comments and suggestions.
To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group.
Throughout this manual, the vehicle family code, LH, is used when descriptions or procedures apply to all
three models, Concorde, Intrepid and Vision.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re-
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
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GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension and Driveshaft
5Brakes
7Cooling System
8Electrical
9Engines
11 Exhaust System and Intake Manifold
13 Frame and Bumpers
14 Fuel System
19 Steering
21 Transaxle
22 Wheels and Tires
23 Body Components
24 Heating and Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)

LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY .................... 15
DRIVETRAIN ........................... 13 ENGINE ................................ 7 GENERAL INFORMATION .................. 1
GENERAL INFORMATION
INDEX
page page
Classification of Lubricants .................. 1
Fluid Capacities .......................... 2
Fuel Usage .............................. 1
Hoisting Recommendations .................. 4
Introduction .............................. 1
Jump Starting Procedure .................... 4
Parts and Lubricant Recommendations ......... 1
Parts Requiring No Lubrication ............... 2
Severe Service ........................... 1
Towing Recommendations ................... 5
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures to help reduce premature wear or failure over
a broad range of operating conditions. When select-
ing the proper maintenance schedule, the climate
and operating conditions must be considered. A vehi-
cle subjected to severe usage requires more frequent
service than a vehicle used for general transporta-
tion.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation rec-
ommends that only Mopartbrand parts, lubricants
and chemicals be used. Mopar provides the best en-
gineered products for servicing Chrysler Corporation
vehicles.
SEVERE SERVICE
If a vehicle is operated under any of the following
conditions, it is considered severe service.
•Extremely dusty areas.
•50% or more of vehicle operation in 32°C (90°F) or
higher temperatures.
•Prolonged idling (such as, vehicle operation in stop
and go traffic).
•Frequent short running periods. Not allowing en-
gine to warm to operating temperatures.
•Police or taxi usage.
FUEL USAGE
All Chrysler Corporation engines require the use of
unleaded fuel to reduce exhaust emissions. See En-
gine section of this group and Group 14, Fuel for fuel
recommendations.
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organization should be used to service a Chrysler
Corporation vehicle.
•Society of Automotive Engineers (SAE)
•American Petroleum Institute (API)
•National Lubricating Grease Institute (NLGI)
ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
•SAE 30 = single grade engine oil.
•SAE 5W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION.
•SG service engine oil is a high quality crankcase
lubricant designed for use in all naturally aspirated
engines.
•SG/CD service engine oil is a high performance
crankcase lubricant designed for use in all gasoline
or diesel engines.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear lu-
bricants. In addition, API classification defines the
lubricants usage.
LUBRICATION AND MAINTENANCE 0 - 1

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol on the label.
At the bottom NLGI symbol is the usage and qual-
ity identification letters. Wheel bearing lubricant is
identified by the letter ‘‘G’’. Chassis lubricant is iden-
tified by the letter ‘‘L’’. The letter following the us-
age letter indicates the quality of the lubricant. The
following symbols indicate the highest quality.
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysler Corporation vehi-
cle require no periodic maintenance. Some compo-
nents are sealed and permanently lubricated. Rubber
bushings can deteriorate or limit damping ability if
lubricated. The following list of components require
no lubrication:
•Air Pump
•Generator Bushings
•Drive Belts
•Drive Belt Idler/Tensioner Pulley
•Wheel Bearings
•Rubber Bushings
•Starter Bearings/Bushings
•Suspension Strut Bearings
•Throttle Control Cable
•Throttle Linkage
•Water Pump Bearings
FLUID CAPACITIES
Fuel Tank..............................................68L (18 gal.)
Engine Oil
3.3L...........................................................4.7L (5 qts.)
3.5L........................................................5.2L (5.5 qts.)
Cooling System
3.3L................................................10.74L (10.17 qts.)
3.5L................................................12.46L (11.80 qts.)
Includes heater and coolant pressure bottle
Transmission ......................................9.4L (9.9 qts.)
Differential.................................................95L (1 qt)
NLGI SYMBOL
0 - 2 LUBRICATION AND MAINTENANCE

LUBRICATION AND MAINTENANCE SCHEDULES
LUBRICATION AND MAINTENANCE 0 - 3

JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDICA-
TOR DOT IS YELLOW OR BRIGHT COLOR.
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
ARCHING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT
BOOSTING DEVICE, DO NOT ALLOW DISABLED
VEHICLE’S BATTERY TO EXCEED 16 VOLTS. PER-
SONAL INJURY OR DAMAGE TO ELECTRICAL SYS-
TEM CAN RESULT.
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 in-
spect 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 dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake or equivalent and op-
erate engine at 1200 rpm.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake or equivalent. Turn
OFF all accessories (Keyless Entry system must be
turned OFF manually).
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at oppo-
site end of cables to touch, electrical arc will result
(Fig. 1). 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. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) 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 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
•Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
•When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
•Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
HOISTING RECOMMENDATIONS
Refer to Owner’s Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. 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 sus-
pension components, damage to vehicle can result.
Fig. 1 Jumper Cable Clamp Connections
0 - 4 LUBRICATION AND MAINTENANCE

TO HOIST OR JACK VEHICLE SEE FIG. 2
TOWING RECOMMENDATIONS
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 3) is
recommended. When using a wheel lift towing de-
vice, be sure the rear 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.
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 lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to in-
crease the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain braking discs.
SAFETY PRECAUTIONS
The following safety precautions must be consid-
ered when preparing for and during a vehicle towing
operation:
•Do NOT tow vehicle with front wheels on the
ground. The transaxle can be damaged.
•Secure loose and protruding parts from a disabled
vehicle.
•Always use a safety chain system that is indepen-
dent of the lifting and towing equipment.
•Do not allow any of the towing equipment to con-
tact the fuel tank of the vehicle being towed.
•Do not go under the vehicle while it is lifted by
the towing equipment.
•Do not allow passengers to ride in a vehicle being
towed.
•Always observe all state and local laws pertaining
to warning signals, night illumination,speed, etc.
•Do not attempt a towing operation that could jeop-
ardize the operator, bystanders or other motorists.
•Do not exceed a towing speed of 48 km/h (30mph).
•Avoid towing distances of more than 24 km
(15miles), whenever possible.
•Never attach tow chains or a tow sling to the
bumper, steering linkage, or constant velocity joints.
TIE DOWN LOCATIONS FOR FLAT BED
TOWING
There are three reinforced elongated holes on each
side of the vehicle designed to serve as hold down lo-
cations. These locations can safely hold the vehicle to
the towing device using T or R-hooks.
•Bottom of the front frame rail forward of the en-
gine cradle.
•Bottom of the forward torque box between the
front frame rail and the rocker panel.
•Bottom of the rearward torque box forward of the
rear wheel.
FRONT TOWING PROCEDURES
CAUTION: Do Not tow vehicle from the front with
sling type towing device. Damage to bumper fascia
will result.
Always tow vehicle with front wheels off the
ground as shown (Fig. 4).
Use a flat bed towing device when wheel lift tow-
ing device is not available.
Fig. 2 Hoisting and Jacking Points
Fig. 3 Recommended Towing Devices
LUBRICATION AND MAINTENANCE 0 - 5

REAR TOWING PROCEDURES
CAUTION: Do not tow vehicle with the rear end
lifted.
If damage to the vehicle prevents front towing, use
a flat bed towing device.
CAUTION: Do not push the vehicle with another ve-
hicle as damage to the bumper facia and transaxle
can result.
Fig. 4 Towing
0 - 6 LUBRICATION AND MAINTENANCE

ENGINE
INDEX
page page
Engine Oil Filter .......................... 8
Battery ................................ 12
Crankcase Ventilation System ............... 10
Drive Belts ............................. 11
Emission Control System ................... 11
Engine Air Cleaner ....................... 10
Engine Cooling System ..................... 9
Engine Oil ............................... 7
Frequency of Engine Oil and Filter Changes ..... 7
Fuel Filter .............................. 11
Fuel Recommendations .................... 11
Ignition Cables .......................... 11
Rubber and Plastic Component Inspection ...... 12
Spark Plugs ............................ 11
FREQUENCY OF ENGINE OIL AND FILTER
CHANGES
ENGINE OIL
Road conditions as well as your kind of driving af-
fect the interval at which your oil should be changed.
Check the following to determine if any apply to you:
•Frequent short trip driving less than 8 kilometers
(5 miles)
•Frequent driving in dusty conditions
•Frequent trailer towing
•Extensive idling (such as vehicle operation in stop
and go traffic)
•More than 50% of your driving is at sustained
high speeds during hot weather, above 32°C (90°F)
If any of these apply to you then change your en-
gine oil every 4 800 kilometers (3,000 miles) or 3
months, whichever comes first.
If none of these apply to you then change your oil
every 12 000 kilometers (7,500 miles) or 6 months,
whichever comes first.
If none of these apply and the vehicle is in com-
mercial type service such as, Police, Taxi or Limou-
sine used for highway driving of 40 kilometers (25
miles) or more between stations, the engine oil
should be changed every 8 000 kilometers (5,000
miles) or 6 months.
OIL FILTER
The engine oil filter should be replaced with a new
filter at every second oil change.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING 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 EX-
POSED SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR
GOVERNMENT AGENCY FOR LOCATION OF COL-
LECTION CENTER IN YOUR AREA.
BREAK-IN PERIOD
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
On a Chrysler Corporation vehicle an extended
break-in period is not required. Driving speeds of not
over 80-90 km/h (50-55 mph) for the first 100 km (60
miles) is recommended. Hard acceleration and high
engine rpm in lower gears should be avoided.
SELECTING ENGINE OIL
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine or Turbocharger failure can result.
The factory fill engine oil is a high quality, energy
conserving, crankcase lubricant. The Recommended
SAE Viscosity Grades chart defines the viscosity
grades that must be used based on temperature in
the region where vehicle is operated and optional
equipment.
Chrysler Corporation recommends that Mopar mo-
tor oil, or equivalent, be used when adding or chang-
ing crankcase lubricant. The API symbol (Fig. 1) on
the container indicates the viscosity grade, quality
and fuel economy ratings of the lubricant it contains.
Use ENERGY CONSERVING II motor oil with API
SERVICE SG or SG/CD classification.
•SG service engine oil is a high quality crankcase
lubricant designed for use in all naturally aspirated
engines.
•SG/CD service engine oil is a high quality crank-
case lubricant designed for use in most naturally as-
pirated and turbocharged gasoline or diesel engines.
•SAE 5W-30 engine oil is recommended for use in
3.3L engines in temperatures below 38°C (100°F) to
LUBRICATION AND MAINTENANCE 0 - 7

reduce low temperature cranking effort. SAE 5W-30
is recommended for use in 3.5L engines in tempera-
tures below 0°C (32°F). SAE 5W-30 engine oil is NOT
recommended for use in 3.5L engines in tempera-
tures above 0°C (32°F).
•SAE 10W-30 engine oil is recommended for use in
3.5L engine in temperatures above -18°C (0°F).
ENGINE OIL ADDITIVES
Chrysler Corporation recommends that Mopar En-
gine Oil Supplement or equivalent be used when fric-
tion and corrosion reducing materials added to the
crankcase lubricant is desired.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Position vehicle on level sur-
face. With engine OFF, allow enough time for oil to
settle to bottom of crankcase, remove engine oil level
indicator (dipstick) and wipe clean. Install dipstick
and verify it is seated in the tube. Remove dipstick,
with handle above tip, take oil level reading (Fig. 2).
Add oil only if level is below MIN or ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Lubrication and Maintenance Schedules.
TO CHANGE ENGINE OIL:
(1) Position the vehicle on a level surface.
(2) Hoist and support vehicle on safety stands. Re-
fer to Hoisting and Jacking Recommendations in this
group.
(3) Place a suitable 3.8 liter (4 qt.) drain pan un-
der crankcase drain.
(4) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(5) Install drain plug in crankcase.
(6) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(7) Start engine and inspect for leaks.
(8) Stop engine and inspect oil level.
ENGINE OIL FILTER
SELECTING OIL FILTER
Chrysler Corporation recommends a Mopar or
equivalent oil filter be used when replacement is re-
quired. A replacement filter must be designed to
withstand 1756 kPa (256 psi) of internal pressure.
OIL FILTER REMOVAL
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench (Fig. 3)
loosen filter.
(3) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(4) With a wiping cloth, clean the gasket sealing
surface (Fig. 4) of oil and grime. Wipe off oil residue
from below oil filter adapter.
OIL FILTER INSTALLATION:
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, tighten filter one
full turn. If necessary use a filter wrench, do not over
tighten.
(3) Add oil, verify crankcase oil level and start en-
gine. Inspect for oil leaks.
RECOMMENDED VISCOSITY GRADES
Fig. 1 API Symbol
Fig. 2 Oil Level Indicator Dipstick—Typical
0 - 8 LUBRICATION AND MAINTENANCE

ENGINE COOLING SYSTEM
WARNINGS AND PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO
NOT STORE IN OPEN OR UNMARKED CONTAIN-
ERS. WASH SKIN AND CLOTHING THOROUGHLY
AFTER COMING IN CONTACT WITH ETHYLENE
GLYCOL. KEEP OUT OF REACH OF CHILDREN.
DISPOSE OF GLYCOL BASE COOLANT PROP-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CEN-
TER IN YOUR AREA.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER-
SONAL INJURY CAN RESULT.
AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PER-
FORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures
can result.
Do not operate vehicle without proper concentra-
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal
pressure of 97 to 123 kPa (14 to 18 psi) at normal op-
erating temperature. Allow the vehicle approxi-
mately one half hour to cool off before opening the
cooling system. As an indicator of pressure, squeeze
the upper radiator hose between index finger and
thumb. If it collapses with little effort the system
would have low internal pressure and should be safe
to open to the first safety notch of the coolant pres-
sure bottle cap. Refer to Group 7, Cooling System.
COOLING SYSTEM INSPECTION
Coolant level (Fig. 5) should be inspected when
other engine compartment service is performed or
when coolant leak is suspected. Coolant pressure bot-
tle level should read between the MIN and MAX
marks, located on the side of pressure bottle, when
the engine is at normal operating temperature. Cool-
ing system freeze protection should be tested at the
onset of the winter season or every 12 months. Ser-
vice is required if coolant is low, contaminated, rusty
or freeze protection is inadequate. To properly test
cooling system, see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
Glycol base antifreeze with silicate inhibitor and 50%
water. Using a suitable hydrometer, measure anti-
freeze concentration in the coolant pressure bottle
when the engine is cool. If the cooling system has re-
cently been serviced, allow coolant to circulate for at
Fig. 3 Remove Oil Filter
Fig. 4 Install Oil Filter
Fig. 5 Coolant Pressure Bottle
LUBRICATION AND MAINTENANCE 0 - 9

least 20 minutes before taking hydrometer reading.
Properly mixed coolant will protect the cooling sys-
tem to -37°C (-35°F). If the freeze protection is above
-28°C (-20°F), drain enough coolant from the cooling
system to allow room to add antifreeze to achieve ad-
equate protection. A mix table on the coolant con-
tainer indicates the amount of antifreeze required to
winterize the cooling system based on the capacity,
see Capacity Chart in General Information section of
this group.
SELECTING ANTIFREEZE
Chrysler Corporation recommends Mopar Anti-
freeze/Summer Coolant, or equivalent be used to win-
terize and protect cooling system.
PRESSURE CAP
The pressure cap must be secure for the engine
cooling system to perform properly. Inspect and test
pressure cap when cooling system service is per-
formed or when a problem is suspected.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter-
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
ENGINE AIR CLEANER
The engine air cleaner should be serviced at the in-
tervals described in the Lubrication and Mainte-
nance Schedules. Refer to General Information
section of this group. Additional information can be
found in Group 14, Fuel System and Group 25, Emis-
sion System. Inspect all air cleaner hoses or tubes for
damage or leaks when other engine compartment
service is performed. Replace faulty components.
AIR CLEANER SERVICE
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con-
troller to function correctly.
Do not immerse paper air filter element or temper-
ature sensor in cleaning solvents, damage can re-
sult.
TO SERVICE AIR CLEANER
(1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment.
(2) Remove air cleaner lid (Fig. 6).
(3) Remove paper air filter element from air
cleaner body. Hold a shop light on throttle body side
of element. Inspect air intake side of element. If light
is visible through element, blow dust from element
(Fig. 7) and reuse. If element is saturated with oil or
light is not visible, replace filter. If element is satu-
rated with oil, perform crankcase ventilation system
tests. Refer to Group 25, Emission Control Systems
for proper procedure.
(4) Clean inside of air cleaner lid and body with
vacuum or compressed air. If oily, wash with solvent.
To Install, reverse the preceding operation.
CRANKCASE VENTILATION SYSTEM
Engine crankcase pressure and emissions are
vented into combustion chambers through the posi-
tive crankcase ventilation (PCV) system (Fig. 8 or 9).
The PCV system should have enough volume to over-
come crankcase pressure created by piston backwash.
If a PCV system becomes plugged, the crankcase
pressure will increase and force engine oil past the
piston rings creating oil consumption. Blockage of
PCV system can occur at the vacuum source cou-
pling, PCV valve or a collapsed hose.
Fig. 6 Air Cleaner
Fig. 7 Cleaning Air Filter Element
0 - 10 LUBRICATION AND MAINTENANCE

Chrysler Corporation recommends that a PCV
valve not be cleaned. A new Mopar or equivalent
PCV valve should be installed when servicing is re-
quired. Over a period of time, depending on the en-
vironment where vehicle is used, deposits build up in
the PCV vacuum circuit. PCV system should be in-
spected at every oil change. Service PCV system if
engine oil is discharged into air cleaner.
PCV SYSTEM TEST
Refer to group 25, Emission Control System for
proper procedures to test PCV system.
FUEL RECOMMENDATIONS
Use of mid-grade unleaded fuel with minimum oc-
tane rating of 89 is recommended. Regular unleaded
gasoline having a minimum octane rating of 87 can
be used. Regular fuel can reduce engine performance
and fuel mileage. Premium unleaded gasoline having
a minimum octane rating of 91 can be used if de-
sired. Refer to Group 14, Fuel for additional informa-
tion.
Chrysler Corporation recommends that only fuel
purchased from a reputable retailer be used. Use
high quality, unleaded gasoline to provide satisfac-
tory driveability and highest fuel economy. Gasoline
containing detergent and corrosion control additives
are desireable. If the engine develops spark knock
(audible ping), poor performance, hard starting or
stalling, purchase fuel from another source. Engine
performance can vary when using different brands of
gasoline with the same octane rating. Occasional
light engine spark knock under heavy acceleration,
at low speed or when vehicle is heavily loaded is not
harmful. Extended periods of spark knock under
moderate acceleration or at cruising speed can dam-
age the engine. The cause of excessive spark knock
condition must be diagnosed and corrected. For diag-
nostic procedures refer to Group 14, Fuel System and
Powertrain Diagnostic Procedures manual.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System,
IGNITION CABLES
Inspect and test ignition cables when the spark
plugs are replaced. Oil and grime should be cleaned
from the ignition cables and coil to avoid possible
spark plug fouling. Mopar Foamy Engine Degreaser,
or equivalent is recommended for cleaning the en-
gine compartment. For proper service and diagnostic
procedures refer to Group 8D, Ignition System.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
cedures refer to Group 8D, Ignition Systems.
DRIVE BELTS
Inspect and adjust drive belts at the interval de-
scribed in the Lubrication and Maintenance Sched-
ules. Refer to General Information section of this
group. For proper inspection and adjustment proce-
dures refer to Group 7, Cooling System.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
Fig. 8 PCV System—3.3L Engine
Fig. 9 PCV System—3.5L Engine
LUBRICATION AND MAINTENANCE 0 - 11

BATTERY
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result.
Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area.
All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EXHAUST SYSTEM ISOLATOR AND HANGER
The exhaust system should be inspected when un-
der vehicle service is performed. The exhaust system
should not make contact with under body, brake ca-
bles, brake/fuel lines, fuel tank or suspension compo-
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo-
nents must be replaced. For proper service proce-
dures see Group 11, Exhaust System and Intake
Manifold.
0 - 12 LUBRICATION AND MAINTENANCE

DRIVETRAIN
INDEX
page page
Automatic Transaxle ...................... 13
Differential .............................. 13
Drive Shaft Boots ........................ 14
Tires .................................. 14
Wheel Bearings .......................... 14
AUTOMATIC TRANSAXLE
The automatic transaxle should be inspected for
fluid leaks and proper fluid level when other under
hood service is performed.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill tube after fluid level
reading is taken.
TO INSPECT THE TRANSAXLE FLUID LEVEL:
(1) Position the vehicle on a level surface.
(2) Start engine and allow to idle in PARK for at
least 60 seconds. The warmer the transaxle fluid, the
more accurate the reading.
(3) While sitting in driver seat, apply brakes and
place gear selector in each position. Return gear se-
lector to park.
(4) Raise hood and remove transaxle fluid level in-
dicator (dipstick) and wipe clean with a suitable
cloth.
(5) Install dipstick and verify it is seated in fill
tube (Fig. 1).
CAUTION: Do not overfill automatic transaxle, fluid
leak or damage can result.
(6) Remove dipstick, with handle above tip, take
fluid level reading (Fig. 2). If the vehicle has been
driven for at least 15 minutes before inspecting fluid
level, transaxle can be considered hot and reading
should be above the WARM mark. If vehicle has run
for less than 15 minutes and more than 60 seconds
transaxle can be considered warm and reading
should be above ADD mark. Add fluid only if level is
below ADD mark on dipstick when transaxle is
warm.
The automatic transaxle does not require periodic
maintenance when used for general transportation. If
the vehicle is subjected to severe service conditions,
the automatic transaxle will require fluid/filter
change and band adjustments every 24 000 km
(15,000 miles). For additional information, refer to
Severe Service paragraph and Lubrication and Main-
tenance Schedules in General Information section of
this group. The fluid and filter should be changed
when water contamination is suspected. If fluid has
foamy or milky appearance, it is probably contami-
nated. If the fluid appears brown or dark and a foul
odor is apparent, the fluid is burned, transaxle re-
quires maintenance or service. A circular magnet lo-
cated in the transaxle pan, collects metallic particles
circulating in the oil. For proper diagnostic and ser-
vice procedures, refer to Group 21, Automatic Tran-
saxle.
SELECTING AUTOMATIC TRANSAXLE FLUID
Chrysler Corporation recommends Mopar ATF Plus
(automatic transmission fluid type 7176) be used to
a1dd to or replace automatic transaxle fluid. If ATF
Plus is not available use DexrontII or Dexron IIe
Automatic Transmission Fluid or equivalent.
DIFFERENTIAL
The differential should be inspected for oil leaks
and proper oil level when other under vehicle service
is performed. To inspect the differential oil level, po-
Fig. 1 Transaxle Fill tube
Fig. 2 Transaxle Dipstick—Typical
LUBRICATION AND MAINTENANCE 0 - 13

sition the vehicle on a level surface and remove fill
plug (Fig. 3). The oil level should be at the bottom
edge of oil fill opening.
The differential does not require periodic mainte-
nance when subjected to normal driving conditions.
The oil should be changed when water contamination
is suspected. If oil has foamy or milky appearance it
probably is contaminated. For proper diagnostic and
service procedures, refer to Group 21, Transaxle.
SELECTING LUBRICANT
Chrysler Corporation recommends Mopar Gear
Lube, SAE 80W-90, or equivalent, be used to fill the
differential.
DRIVE SHAFT BOOTS
The front drive shaft constant velocity and tripod
joint boots (Fig. 4) should be inspected when other
under vehicle service is performed. Inspect boots for
cracking, tears, leaks or other defects. If service re-
pair is required, refer to Group 2, Suspension.
WHEEL BEARINGS
The wheel bearings are permanently sealed, re-
quiring no lubrication. For proper diagnostic and ser-
vice procedures refer to Group 2, Suspension.
TIRES
The tires should be inspected at every engine oil
change for proper inflation and condition. The tires
should be rotated at the distance intervals described
in the Lubrication and Maintenance Schedules of the
General Information section in this group. For tire
inflation specifications refer to the Owner’s Manual.
A Tire Inflation sticker is located in the driver door
opening. For proper diagnostic procedures, see Group
22, Wheels and Tires.
TIRE ROTATION
The Forward Cross rotation method is recom-
mended for use on Chrysler Corporation vehicles
(Fig. 5). Other rotation methods can be used, but
may not have the benefits of the recommended
method. Only the four tire rotation method can be
used if the vehicle is equipped with a space saver
spare tire.
Fig. 3 Differential Fill Plug
Fig. 4 Drive Shaft Boots
Fig. 5 Tire Rotation
0 - 14 LUBRICATION AND MAINTENANCE

CHASSIS AND BODY
INDEX
page page
Body Lubrication ......................... 16
Brakes ................................ 15
Headlamps ............................. 16
Power Steering .......................... 15
Steering Linkage ......................... 15
Supplemental Airbag System ................ 16
Suspension Ball Joints .................... 15
STEERING LINKAGE
INSPECTION
The steering linkage and steering gear should be
inspected for wear, leaks or damage when other un-
der vehicle service is performed. The rack and pinion
steering gear end boots should not have excess oil or
grease residue on the outside surfaces or surrounding
areas. If boot is leaking, it should be repaired. For
proper service procedures refer to Group 19, Steering.
The tie rod end seal should fit securely between the
steering knuckle and tie rod end (Fig. 1). The steer-
ing linkage should be lubricated at the time and dis-
tance intervals described in the Lubrication and
Maintenance Schedules. Refer to General Informa-
tion section of this group.
TIE ROD END LUBRICATION
Lubricate the steering linkage with Mopar Multi-
mileage Lube or equivalent. Using a wiping cloth,
clean grease and dirt from around grease fitting and
joint seal. Using a grease gun, fill tie rod end until
lubricant leaks from around the tie rod end side of
the seal (Fig. 1). When lube operation is complete,
wipe off excess grease.
SUSPENSION BALL JOINTS
The ball joints are permanently sealed, requiring
no lubrication. For proper diagnostic and service pro-
cedures refer to Group 2, Suspension.
POWER STEERING
The power steering fluid level should be inspected
when other under hood service is performed. If the
fluid level is low and system is not leaking, use Mo-
par Power Steering Fluid or equivalent. The power
steering system should be inspected for leaks when
other under vehicle service is performed. For proper
service procedures refer to Group 19, Steering.
The power steering pump drive belt should be in-
spected at the time and distance interval described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re-
sult.
TO INSPECT FLUID LEVEL
(1) Position vehicle on a level surface with engine
at normal running temperature.
(2) Turn OFF engine and remove ignition key.
Fig. 1 Tie Rod End Lubrication
Fig. 2 Power Steering Reservoir Dipstick
LUBRICATION AND MAINTENANCE 0 - 15

(3) Using a wiping cloth, clean oil and dirt residue
from around power steering reservoir cap.
(4) Remove reservoir cap or dipstick and wipe off
fluid.
(5) Install cap or dipstick.
(6) Remove cap or dipstick. Holding handle or cap
above tip of dipstick, read fluid level (Fig. 2). Add
fluid if reading is below cold level mark on dipstick.
BRAKES
BRAKE PAD AND LINING INSPECTION
The brake pads and linings should be inspected at
distance intervals described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. If brake pads or linings
appear excessively worn, the brakes would require
service. For proper service procedures, refer to Group
5, Brakes.
BRAKE HOSE INSPECTION
WARNING: IF FRONT WHEEL, REAR AXLE, OR AN-
TI-LOCK UNIT BRAKE HOSE OUTER COVER IS
CRACKED, CHAFED, OR BULGED, REPLACE HOSE
IMMEDIATELY. BRAKE FAILURE CAN RESULT.
The front wheel, rear axle and anti-lock unit (if
equipped) brake hoses should be inspected at time
and distance intervals described in the Lubrication
and Maintenance Schedules. Refer to the General In-
formation section of this group. A hose must be re-
placed if it has signs of cracking, chafing, fatigue or
bulging. For proper service procedures, refer to
Group 5, Brakes.
BRAKE LINE INSPECTION
The metal brake lines should be inspected when
other under vehicle service is preformed. If a line is
pinched, kinked, or corroded, it should be repaired.
For proper service procedures, refer to Group 5,
Brakes.
BRAKE RESERVOIR LEVEL INSPECTION
WARNING: DO NOT ALLOW PETROLEUM OR WA-
TER BASE LIQUIDS TO CONTAMINATE BRAKE
FLUID, SEAL DAMAGE AND BRAKE FAILURE CAN
RESULT.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal
for the reservoir level to drop as disc brake pads
wear. When fluid must be added, use Mopar Brake
Fluid or equivalent. Use only brake fluid conforming
to DOT 3, Federal, Department of Transportation
specification. To avoid brake fluid contamination, use
fluid from a properly sealed container.
If fluid level should become low after several thou-
sand kilometers (miles), fill the reservoir to level
marks on the side of the reservoir (Fig. 3).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug-
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle
height change. For proper service procedures, refer to
Group 8L, Lamps.
SUPPLEMENTAL AIRBAG SYSTEM
WARNING: FAILURE TO HAVE THE AIRBAG SYS-
TEM PROMPTLY SERVICED BY AN AUTHORIZED
DEALER SHOULD ONE OF THE FOLLOWING CON-
DITIONS EXIST CAN LEAD TO POSSIBLE INJURY
IN THE EVENT OF AN ACCIDENT.
If the AIRBAG indicator lamp does not light at all,
stays lit or lights momentarily or continuously while
driving, a malfunction may have occurred. Prompt
service is required. Refer to Group 8M, Restraint
Systems for proper diagnostic procedures.
BODY LUBRICATION
Body mechanisms and linkages should be in-
spected, cleaned and lubricated as required to main-
tain ease of operation and to prevent corrosion and
wear.
Before a component is lubricated, oil, grease and
dirt should be wiped off. If necessary, use solvent to
clean component to be lubricated. After lubrication is
complete, wipe off excess grease or oil.
During winter season, external lock cylinders
should be lubricated with Mopar Lock Lubricant or
equivalent to assure proper operation when exposed
to water and ice.
To assure proper hood latching component opera-
tion, use engine oil to lubricate the latch, safety
Fig. 3 Brake Reservoir—Typical
0 - 16 LUBRICATION AND MAINTENANCE