Chrysler neon 1997 User manual

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1997 Neon
(RHD & LHD)
Interactive Electronic Service Manual!
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LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION .................. 1
JUMP STARTING, TOWING AND HOISTING ... 7 MAINTENANCE SCHEDULES ............... 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS .......... 1
FLUID CAPACITIES ...................... 2
INTERNATIONAL SYMBOLS ............... 1
INTRODUCTION ........................ 1
PARTS AND LUBRICANT
RECOMMENDATIONS .................. 1
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule—A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule— A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule— B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopartbrand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
Fig. 1 International Symbols
ENGINE OILAUTOMATICTRANSMISSIONFLUIDENGINE COOLANT BRAKE FLUIDPOWER STEERINGFLUIDWINDSHIELDWASHER FLUID
PL LUBRICATION AND MAINTENANCE 0 - 1

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) (Fig. 2)
•National Lubricating Grease Institute (NLGI)
(Fig. 3)
ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
•SAE 30 = single grade engine oil.
•SAE 10W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use engine oils that are API Service Certified.
5W-30 and 10W-30 MOPAR engine oils conform to
specifications.
Refer to Group 9, Engine for engine oil specifica-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
FLUID CAPACITIES
FUEL TANK
All .........................47.3 L (12.5 gal.)
ENGINE OIL W/FILTER CHANGE
All ..........................4.25 L (4.5 qts.)
ENGINE OIL W/OUT FILTER CHANGE
All ...........................3.8L(4.0 qts.)
COOLING SYSTEM
All* ...........................6L(6.5 qts.)
*Includes heater and coolant recovery bottle
AUTOMATIC TRANSAXLE
NOTE: Overhaul Fill Capacity with Torque Con-
verter Empty
31TH ........................8.4L(8.9 qts.)
31 TH (Fleet Vehicles) ............8.7L(9.2 qts.)
MANUAL TRANSAXLE
NV T350 ................1.9-2.2 L (4.0-4.6 pts.)
POWER STEERING
All ..........................0.95 L (2.0 pts.)
Fig. 2 API Symbol Fig. 3 NLGI Symbol
WHEELBEARINGS CHASSIS LUBRICA-TION CHASSIS ANDWHEEL BEARINGS
0 - 2 LUBRICATION AND MAINTENANCE PL
GENERAL INFORMATION (Continued)

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION ........................ 3
SCHEDULE—A ......................... 3
SCHEDULE—B ......................... 4
UNSCHEDULED INSPECTION .............. 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule—A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to. Use the schedule that best
describes these conditions.
Schedule— A, lists maintenance recommended for
vehicles used for general transportation.
Schedule— B, lists maintenance recommended for
vehicles used under the following conditions:
•Frequent short trip driving less than 5 miles (8
km)
•Frequent driving in dusty conditions
•Frequent trailer towing
•Extensive idling
•More than 50% of your driving is at sustained
high speeds during hot weather, above 90°F (32°C)
Where time and mileage are listed, follow the
interval that occurs first.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
•Check engine oil level, add as required.
•Check windshield washer solvent and add if
required.
Once A Month
•Check tire pressure and look for unusual wear
or damage.
•Inspect battery, clean, and tighten terminals as
required.
•Check fluid levels of coolant reservoir, power
steering and automatic transmission and add as
required.
•Check all lights and all other electrical items for
correct operation.
At Each Oil Change
•Inspect exhaust system.
•Inspect brake hoses.
•Inspect the CV joints and front suspension com-
ponents.
•Rotate the tires at each oil change interval
shown on Schedule—A (7,500 miles) or every other
interval shown on schedule—B (6,000 miles).
•Check coolant level, hoses and clamps.
•Check the manual transaxle fluid level.
•If the mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
SCHEDULE—A
7,500 Miles (12 000 km) or at 6 months
•Change engine oil.
15,000 Miles (24 000 km) or at 12 months
•Change engine oil.
•Replace engine oil filter.
•Adjust drive belt tension.
22,500 Miles (36 000 km) or at 18 months
•Change engine oil.
•Inspect the front brake pads and rear brake lin-
ings.
30,000 Miles (48 000 km) or at 24 months
•Change engine oil.
•Replace engine oil filter.
•Lubricate front suspension ball joints.
•Adjust drive belt tension.
PL LUBRICATION AND MAINTENANCE 0 - 3

•Replace air cleaner element.
•Replace spark plugs.
37,500 Miles (60 000 km) or at 30 months
•Change engine oil.
45,000 Miles (72 000 km) or at 36 months
•Change engine oil.
•Replace engine oil filter.
•Inspect front brake pads and rear brake linings.
•Adjust drive belt tension.
•Flush and replace engine coolant at 36 months,
regardless of mileage.
52,500 Miles (84 000 km) or at 42 months
•Change engine oil.
•Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
•Change engine oil.
•Replace engine oil filter.
•Check and replace, if necessary***, the
PCV valve.**
•Lubricate front suspension upper ball joints.
•Replace drive belts.
•Replace air cleaner element.
•Replace ignition cables.
•Replace spark plugs.
67,500 Miles (108 000 km) or at 54 months
•Change engine oil.
•Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km) or at 60 months
•Change engine oil.
•Replace engine oil filter.
•Adjust drive belt tension.
•Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
•Change engine oil.
•Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
•Change engine oil.
•Replace engine oil filter.
•Check and replace, if necessary***, the
PCV valve.**
•Lubricate front suspension upper ball joints.
•Inspect front brake pads and rear brake linings.
•Adjust drive belt tension.
•Replace air cleaner air cleaner element.
•Replace spark plugs.
97,500 Miles (156 000 km) or at 78 months
•Change engine oil.
105,000 Miles (168 000 km)
•Change engine oil.
•Replace engine oil filter.
•Replace engine timing belt
•Adjust drive belt tension.
SCHEDULE—B
3,000 Miles (5 000 km)
•Change engine oil
6,000 Miles (10 000 km)
•Change engine oil
•Replace engine oil filter.
9,000 Miles (14 000 km)
•Change engine oil
•Inspect front brake pads and rear brake lining.
12,000 Miles (19 000 km)
•Change engine oil
•Replace engine oil filter.
15,000 Miles (24 000 km)
•Change engine oil
•Adjust drive belt tension.
•Inspect and replace, if required, the air
cleaner element.
•Change automatic transaxle fluid and filter.
Adjust the bands.*
18,000 Miles (29 000 km)
•Change engine oil
•Replace engine oil filter.
•Inspect front brake pads and rear brake linings.
21,000 Miles (34 000 km)
•Change engine oil
24,000 Miles (38 000 km)
•Change engine oil
•Replace engine oil filter.
27,000 Miles (43 000 km)
•Change engine oil
•Inspect front brake pads and rear brake linings.
30,000 Miles (48 000 km)
•Change engine oil
•Replace engine oil filter.
•Check and replace, if necessary, the PCV
valve.**
0 - 4 LUBRICATION AND MAINTENANCE PL
GENERAL INFORMATION (Continued)

•Lubricate front suspension upper ball joints.
•Adjust drive belt tension.
•Replace air cleaner element.
•Replace spark plugs.
•Change automatic transmission fluid and filter.
Adjust the bands.*
33,000 Miles (53 000 km)
•Change engine oil.
36,000 Miles (58 000 km)
•Change engine oil.
•Replace engine oil filter.
•Flush and replace engine coolant.
•Inspect front brake pads and rear brake linings.
39,000 Miles (62 000 km)
•Change engine oil.
42,000 Miles (67 000 km)
•Change engine oil.
•Replace engine oil filter.
45,000 Miles (72 000 km)
•Change engine oil.
•Inspect front brake pads and rear brake linings.
•Inspect and replace, if necessary, the air
cleaner element.
•Adjust drive belt tension.
•Change automatic transaxle fluid and filter.
Adjust the bands.*
48,000 Miles (77 000 km)
•Change engine oil.
•Replace engine oil filter.
51,000 Miles (82 000 km)
•Change engine oil.
•Flush and replace engine coolant.
54,000 Miles (86 000 km)
•Change engine oil.
•Replace engine oil filter.
•Inspect front brake pads and rear brake linings.
57,000 Miles (91 000 km)
•Change engine oil.
60,000 Miles (96 000 km)
•Change engine oil.
•Replace engine oil filter.
•Check and replace, if necessary***, the
PCV valve.**
•Lubricate front suspension upper ball joints.
•Replace drive belts.
•Replace air cleaner element.
•Replace ignition cables.
•Replace spark plugs.
•Change automatic transaxle fluid and filter.
Adjust the bands.*
63,000 Miles (101 000 km)
•Change engine oil.
•Inspect front brake pads and rear brake linings.
66,000 Miles (106 000 km)
•Change engine oil.
•Replace engine oil filter.
69,000 Miles (110 000 km)
•Change engine oil.
72,000 Miles (115 000 km)
•Change engine oil.
•Replace engine oil filter.
•Inspect front brake pads and rear brake linings.
75,000 Miles (120 000 km)
•Change engine oil.
•Adjust drive belt tension.
•Inspect and replace, if necessary, the air
cleaner element.
•Change automatic transaxle fluid and filter.
Adjust the bands.*
78,000 Miles (125 000 km)
•Change engine oil.
•Replace engine oil filter.
81,000 Miles (130 000 km)
•Change engine oil.
•Flush and replace the engine coolant.
•Inspect front brake pads and rear brake linings.
84,000 Miles (134 000 km)
•Change engine oil.
•Replace engine oil filter.
87,000 Miles (139 000 km)
•Change engine oil.
90,000 Miles (144 000 km)
•Change engine oil.
•Replace engine oil filter.
•Inspect front brake pads and rear brake linings.
•Check and replace, if necessary***, the
PCV valve.**
•Lubricate front suspension upper ball joints.
•Adjust drive belt tension.
•Replace air cleaner element.
•Replace spark plugs.
•Change automatic transaxle fluid and filter.
Adjust the bands.*
PL LUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

93,000 Miles (149 000 km)
•Change engine oil.
96,000 Miles (154 000 km)
•Change engine oil.
•Replace engine oil filter.
99,000 Miles (158 000 km)
•Change engine oil.
•Inspect front brake pads and rear brake linings.
102,000 Miles (163 000km)
•Change engine oil.
•Replace engine oil filter.
105,000 Miles (168 000km)
•Replace the engine timing belt
•Change engine oil.
•Replace engine oil filter.
•Adjust drive belt tension.
•Inspect and replace, if necessary, the air
cleaner element.
*Police, taxi, or delivery service usage and trailer
towing require the more frequent transaxle service
indicated witha*inschedule—B. Perform these ser-
vices if the vehicle is usually operated under these
conditions.
NOTE: **This maintenance is recommended by
Chrysler to the owner but is not required to main-
tain the warranty on the PCV valve.
NOTE: ***This maintenance is not required if the
PCV valve was previously replaced.
0 - 6 LUBRICATION AND MAINTENANCE PL
GENERAL INFORMATION (Continued)

JUMP STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS ........... 9 JUMP STARTING PROCEDURE ............. 7 TOWING RECOMMENDATIONS ............. 8
SERVICE PROCEDURES
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, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
•Battery cable clamp condition, clean if necessary.
•Frozen battery.
•Yellow or bright color test indicator, if equipped.
•Low battery fluid level.
•Generator drive belt condition and tension.
•Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
ENGINE GROUNDNEGATIVE JUMPER CABLEBATTERY NEGATIVE CABLEPOSITIVE JUMPER CABLEBATTERY POSITIVE CABLEBATTERYTEST INDICATOR
PL LUBRICATION AND MAINTENANCE 0 - 7

DISCONNECT CABLE CLAMPS AS FOLLOWS:
•Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
•When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
•Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR
TOW VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust
system, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do not
secure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
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
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
•3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
•5-speed manual transaxle vehicles can be flat
towed at any legal highway speed for extended dis-
tances. The gear selector must be in the neutral posi-
tion.
TOWING—FRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible.
TOWING—REAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
•Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
•Verify that front drive line and steering compo-
nents are in good condition.
•5-speed manual transaxle vehicles can be towed
at any legal highway speed for extended distances.
The gear selector must be in the neutral position.
•3-speed automatic transaxle vehicles can be
towed at speeds not to exceed 40 km/h (25 mph) for
Fig. 2 Recommended Towing Devices
WHEEL LIFTFLAT BED
0 - 8 LUBRICATION AND MAINTENANCE PL
SERVICE PROCEDURES (Continued)

not more than 25 km (15 miles). The gear selector
must be in the neutral position.
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.
Do not attempt to raise one entire side of the
vehicle by placing a floor jack midway between the
front and rear wheels. This practice may result in
permanent damage to the body.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a PL vehicle (Fig. 3). Support the vehicle in the
raised position with jack stands.
A floor jack must never be used on any part of the
underbody.
HOIST
A vehicle can be lifted with:
•A single-post, frame-contact hoist.
•A twin-post, chassis hoist.
•A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 3).
Fig. 3 Hoisting and Jacking Points
PL LUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)

SUSPENSION
CONTENTS
page page
FRONT SUSPENSION ..................... 9
REAR SUSPENSION ..................... 36 WHEEL ALIGNMENT ..................... 1
WHEEL ALIGNMENT
INDEX
page page
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT GENERAL INFORMATION
....................................... 1
DIAGNOSIS AND TESTING
PRE-ALIGNMENT VEHICLE INSPECTION ..... 4
SUSPENSION AND STEERING DIAGNOSIS . . . 3
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT PROCEDURE ............. 5
SPECIFICATIONS
VEHICLE ALIGNMENT SPECIFICATIONS AT
CURB HEIGHT ........................ 8
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT GENERAL INFORMATION
Proper vehicle wheel alignment is the proper
adjustment of all interrelated front and rear suspen-
sion angles (Fig. 1). These angles are what affects
the handling and steering of the vehicle when it is in
motion.
The method of checking a vehicle’s front and rear
wheel alignment will vary depending on the type and
manufacturer of the equipment being used. Instruc-
tions furnished by the manufacturer of the equip-
ment being used should always be followed to ensure
accuracy of the alignment, except alignment specifi-
cations recommended by Chrysler Corporation
MUST ALWAYS be used.
CAUTION: Do not attempt to modify any suspen-
sion or steering components by heating or bending
of the component.
Wheel alignment adjustments should be made in
the following sequence, to ensure that an accurate
alignment is performed.
(1) Rear Wheel Toe Adjustment within specifica-
tions for both total toe and thrust angle.
(2) Front Wheel Toe Adjustment within specifica-
tions for total toe.
PL SUSPENSION 2 - 1

(3) Toe is measured in degrees or inches and is
the distance that the front edges of the tires are
closer (or farther apart) than the rear edges (Fig. 1).
See Front Wheel Drive Specifications for correct front
and rear wheel Toe specifications.
(4) Thrust Angle is defined as the average of the
Toe settings on each rear wheel. If this measurement
is out of specification, re-adjust rear wheel Toe so
that each wheel has 1/2 of the total Toe measure-
ment. When re-adjusting, do not exceed the total Toe
specification.
Fig. 1 Alignment Camber/Toe
2 - 2 SUSPENSION PL
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel
Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or Grinding On
Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Engine Mount Grounding
Against Frame Or Body Of Vehicle. 2. Check For Motor Mount Hitting Frame Rail And Reposition Engine
As Required
3. Worn Or Broken C/V Joint 3. Replace C/V Joint
4. Loose Wheel Lug Nuts 4. Verify Wheel Lug Nut Torque
5. Incorrect Wheel Alignment 5. Check And Reset Wheel
Alignment
6. Worn Tires 6. Replace Tires
Front End Clunk Or Snap On
Turns 1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
3. Worn Or Loose Tie Rod Or Ball
Joint 3. Tighten Or Replace Tie Rod End Or Ball Joint
4. Worn Control Arm Bushing 4. Replace Control Arm Bushing
5. Loose Sway Bar Or Upper Strut
Attachment 5. Tighten Sway Bar Or Upper Strut Attachment To Specified Torque
Front End Whine With Vehicle
Going Straight At A Constant
Speed
1. Defective Wheel Bearing 1. Replace Wheel Bearing
2. Incorrect Wheel Alignment 2. Check And Reset Wheel
Alignment
3. Worn Tires 3. Replace Tires
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed
1. Engine Mount Grounding 1. Reposition Engine As Required
2. Worn Or Broken C/V Joint 2. Replace C/V Joint
Front End Whine When
Accelerating Or Decelerating 1. Worn Or Defective Transaxle Gears Or Bearings 1. Replace Transaxle Gears Or Bearings
Front End Clunk When
Accelerating Or Decelerating 1. Worn Or Broken Engine Mount 1. Replace Engine Mount
2. Worn Or Defective Transaxle
Gears Or Bearings 2. Replace Transaxle Gears Or Bearings
3. Loose Wheel Lug Nuts 3. Verify Wheel Lug Nut Torque
4. Worn Or Broken C/V Joint 4. Replace C/V Joint
5. Worn Or Loose Ball Joint 5. Tighten Or Replace Ball Joint
6. Worn Or Loose Control Arm
Bushing 6. Tighten To Specified Torque Or Replace Control Arm Bushing
7. Loose Crossmember Bolts 7. Tighten Crossmember Bolts To
Specified Torque
PL SUSPENSION 2 - 3

CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
Road Wander 1. Incorrect Tire Pressure 1. Inflate Tires To Rcommended
Pressure
2. Incorrect Front Or Rear Wheel
Toe 2. Check And Reset Front Wheel Toe
3. Worn Wheel Bearings 3. Replace Wheel Bearing
4. Worn Control Arm Bushings 4. Replace Control Arm Bushing
5. Excessive Friction In Steering
Gear 5. Replace Steering Gear
6. Excessive Friction In Steering
Shaft Coupling 6. Replace Steering Coupler
7. Excessive Friction In Strut Upper
Bearing 7. Replace Strut Bearing
Lateral Pull 1. Unequal Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Radial Tire Lead 2. Perform Lead Correction
Procedure
3. Incorrect Front Wheel Camber 3. Check And Reset Front Wheel
Camber
4. Power Steering Gear Imbalance 4. Replace Power Steering Gear
5. Wheel Braking 5. Correct Braking Condition
Causing Lateral Pull
Excessive Steering Free Play 1. Incorrect Steering Gear
Adjustment 1. Adjust Or Replace Steering Gear
2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends
3. Loose Steering Gear Mounting
Bolts 3. Tighten Steering Gear Bolts To The Specified Torque
4. Loose Or Worn Steering Shaft
Coupler 5. Replace Steering Shaft Coupler
Excessive Steering Effort 1. Low Tire Pressure 1. Inflate All Tires To Recommended
Pressure
2. Lack Of Lubricant In Steering
Gear 2. Replace Steering Gear
3. Low Power Steering Fluid Level 3. Fill Power Steering Fluid
Reservoir To Correct Level
4. Loose Power Steering Pump Belt 4. Correctly Adjust Power Steering
Pump Drive Belt
5. Lack Of Lubricant In Steering Ball
Joints 5. Lubricate Or Replace Steering Ball Joints
6. Steering Gear Malfunction 6. Replace Steering Gear
7. Lack Of Lubricant In Steering
Coupler 7. Replace Steering Coupler
PRE-ALIGNMENT VEHICLE INSPECTION
CAUTION: If the front suspension crossmember
shows any sign of impact damage, the steering col-
umn to steering gear coupling must be inspected.
Refer to Group 19 Steering in this service manual
for the inspection procedure.
Before any attempt is made to change or correct
the wheel alignment factors, the following inspection
and necessary corrections must be made on those
parts which influence the steering of the vehicle.
(1) Be sure the fuel tank is full when the wheel
alignment specifications are checked and or adjusted.
A full tank of fuel weighs approximately 75 pounds,
if the fuel tank is not full this reduction in weight
will affect the curb height of the vehicle and the
alignment specifications.
(2) Alignment specifications of a vehicle can be the
most accurately checked and set when the passenger
2 - 4 SUSPENSION PL
DIAGNOSIS AND TESTING (Continued)

compartment and trunk of the vehicle are vacant
with the exception of the spare tire. People, luggage,
and any other appreciable weight will adversely
affect the checking and setting of the camber specifi-
cation.
(3) Check and if required, inflate all of the tires to
the recommended air pressure. All tires must be of
the same size and in good condition and have approx-
imately the same tread wear. Note the type of
tread wear on the tire, this will aid in diagnos-
ing problems. Refer to Group 22 Tires And
Wheels in this service manual for the tire wear
diagnosis.
(4) Check the front tire and wheel assemblies for
radial runout.
(5) Before beginning the alignment process,
inspect all suspension component fasteners for loose-
ness and/or loss of specified torque.
(6) Inspect the lower front ball joints and all steer-
ing linkage for looseness and any signs of wear and
or damage.
(7) Inspect the tie rod ends for looseness and any
signs of wear and or damage.
(8) Inspect the rubber bushings on all suspension
components for signs of wear or deterioration. If any
bushings show signs of wear or deterioration they
should be replaced prior to aligning the vehicle.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER CAMBER
Front and rear Caster and Camber settings on this
vehicle are determined at the time the vehicle is
designed, by the location of the vehicle’s suspension
components. This is called a Net Build vehicle and
results in no required adjustment of Caster and
Camber after vehicle is built or when servicing the
suspension components. Thus Caster and Camber are
not normally considered an adjustable specification
when performing an alignment on this vehicle.
Though Caster and Camber are not adjustable they
must be checked to ensure they meet vehicle specifi-
cations.
If front and or rear camber is found not to meet
the vehicle alignment specifications, it can be
adjusted using a Mopar Service Kit developed to
allow for camber adjustment. If a vehicle’s front or
rear camber is found to be outside the specifications,
the vehicles suspension components should be
inspected for any signs of damage on bending. This
must be done before using the Mopar Service
Kit for setting camber to meet required specifi-
cation.
If a vehicles caster is not within manufacturers
alignment specifications, check for damaged suspen-
sion components or body parts. This type of damage
can cause component locations to move affecting
vehicle alignment. No adjustment can be made
for the Caster setting on this vehicle.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or any other
modification of the suspension components.
(1) Correctly position vehicle on alignment rack
and install all required equipment on vehicle, per the
alignment equipment manufacturers specifications.
(2) Center the steering wheel and lock in place
using a steering wheel clamp.
NOTE: Prior to reading each alignment specifica-
tion, jounce the front and rear of the vehicle an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Correctly jounce vehicle and read front and
rear alignment settings and compare to vehicle spec-
ifications for Camber, Caster and Toe. See Alignment
Specifications in this group of the service manual for
required specifications. If front and rear camber
readings are within required specifications pro-
ceed to step Step 3 in the Front And Rear Toe
Setting procedure. If Camber readings are not
within specifications refer to step Step 1 in the
following camber adjustment bolt package
installation procedure, for the front and rear
Camber adjustment procedure.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
PROCEDURE
(1) If front and or rear camber readings obtained
are not within the required specification range, a
Mopar Service Kit is available to provide the
required adjustment. The kit contains new bolts and
nuts for the strut clevis bracket to steering knuckle
attachment. The bolts contained in the service kit,
are slightly undersize allowing for movement
between the strut clevis bracket and steering
knuckle. The movement allowed by the undersize
bolts will provide approximately 2 degrees of camber
adjustment per side of vehicle. To install new bolts in
service kit follow the procedure below.
PL SUSPENSION 2 - 5
DIAGNOSIS AND TESTING (Continued)

CAUTION: The Mopar Service Kit for allowing
adjustment of front and rear camber are different
for the front and rear of the vehicle. When using the
service kits be sure that the front and rear strut
attaching bolts are always used in the right location
on the vehicle.
(2) Raise front and or rear of vehicle until tires are
not supporting the weight of the vehicle.
CAUTION: The steering knuckle and rear knuckle
to strut assembly attaching bolts are serrated and
must not be turned during removal. Remove nuts
while holding bolts stationary in the steering knuck-
les.
(3) Remove original upper bolt attaching the front
or rear strut clevis bracket to the steering knuckle or
rear knuckle (Fig. 2) or (Fig. 3).
(4) Loosen lower bolt attaching strut clevis bracket
to steering knuckle or rear knuckle ONLY enough to
allow knuckle to move in clevis bracket.
(5) Install bolt from service kit into the upper
strut clevis bracket to steering knuckle or rear
knuckle mounting hole.
CAUTION: Only the nuts supplied in the service
kits MUST be used with the service kit replacement
bolts. The original nuts will not properly secure the
strut clevis bracket to steering knuckle or rear
knuckle.
(6) Install nut provided in service kit on the
replacement bolt.
(7) Tighten upper bolt and nut from service kit
until snug, but still allowing movement between
strut clevis bracket and knuckle.
(8) Remove original lower bolt. Install bolt from
service kit into the bottom hole of the strut clevis
bracket. Install nut and snug.
(9) Lower vehicle until full weight of vehicle is
supported by the suspension and then jounce front
and rear of vehicle an equal amount of times.
(10) Adjust front and or rear camber to the pre-
ferred setting by pushing or pulling on the top of the
front or rear tire. When camber is correctly set
tighten upper and lower strut clevis bracket bolts.
Again jounce front and rear of vehicle an equal
amount of times and verify front and rear camber
setting. See Alignment Specifications in this group of
the service manual for required specifications.
(11) When vehicle is at correct camber setting
torque both front strut clevis bracket to steering
knuckle attaching bolts to 53 N·m (40 ft. lbs.) plus an
additional 1/4 turn after required torque is met.
Torque rear strut clevis bracket to rear knuckle
attaching bolts to 95 N·m (70 ft. lbs.).
(12) If Toe readings obtained are not within the
required specification range, adjust Toe to meet the
preferred specification setting. Toe is adjustable
using the following Toe setting procedure.
FRONT AND REAR TOE SETTING PROCEDURE
(1) Prepare vehicle as described in the Pre-Align-
ment Vehicle Inspection procedure.
(2) Center steering wheel and lock in place using a
steering wheel clamp.
(3) When performing the Toe setting procedure, set
rear wheel Toe to preferred specification first, then
set front wheel Toe to the preferred specification.
(4) Loosen nuts on attaching bolts, for the left and
right rear lateral links to rear crossmember (Fig. 4).
(5) Rotate lateral link adjustment cams (Fig. 5)
until the preferred rear Toe specification is obtained.
See Alignment Specifications in this group of the ser-
vice manual for preferred specification.
Fig. 2 Front Strut Clevis Bracket To Steering
Knuckle Attaching Bolts
STRUT CLEVISBRACKET STRUT CLEVIS BRACKET TOSTEERING KNUCKLEATTACHING BOLTSSTEERINGKNUCKLELOOSEN THISBOLTREMOVE AND REPLACETHIS BOLT
Fig. 3 Rear Strut Clevis Bracket Attaching Bolts
KNUCKLESTRUT ASSEMBLY CLEVISBRACKET CLEVIS BRACKET TOKNUCKLE ATTACHINGBOLTS
2 - 6 SUSPENSION PL
SERVICE PROCEDURES (Continued)

(6) While holding Toe adjustment cams from turn-
ing, tighten left and right lateral links to rear cross-
member attaching bolt nuts. This will securely hold
adjustment cams in position. Then while holding lat-
eral link attaching bolt and adjustment cam from
turning, torque nut of lateral link attaching bolt to
95 N·m (70 ft. lbs.) (Fig. 6).
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(7) Loosen inner to outer tie rod end jam nuts (Fig.
7). Grasp inner tie rods at serrations and rotate tie
rods (Fig. 7) to set the front wheel Toe to the pre-
ferred specification. See Alignment Specifications in
this group of the service manual for preferred speci-
fication.
(8) Tighten tie rod locknuts to 54 N·m (40 ft.lbs.)
torque.
(9) Adjust steering gear to tie rod boots at tie rod.
(10) Remove steering wheel clamp.
Fig. 4 Rear Lateral Link To Crossmember Attaching
Bolts
FUEL TANK
REAR CROSSMEMBERREAR LATERAL LINKSNUTS
Fig. 5 Rear Wheel Toe Adjustment Cams
REAR LATERAL LINKADJUSTMENT CAMSREAR LATERAL LINKS
Fig. 6 Torquing Rear Lateral Link Attaching Bolts
ATTACHING BOLT NUTSLATERAL LINKSTOE ADJUSTMENTCAMS
Fig. 7 Front Wheel Toe Adjustment
PL SUSPENSION 2 - 7
SERVICE PROCEDURES (Continued)

SPECIFICATIONS
VEHICLE ALIGNMENT SPECIFICATIONS AT CURB
HEIGHT
FRONT WHEEL ALIGNMENT ACCEPTABLE ALIGNMENT
RANGE AT CURB HEIGHT PREFERRE SETTING
CAMBER ................... -0.4° to +0.4° +0.0°
TOTALTOE.................
Specified In Degrees (See Note) 0.3°in to 0.1°out 0.1° in
CASTER* .................. +1.8° to +3.8°
1.0° or less +2.8°
*Side To Side Caster Difference
Not To Exceed ...............
REAR WHEEL ALIGNMENT ACCEPTABLE ALIGNMENT
RANGE AT CURB HEIGHT PREFERRE SETTING
CAMBER ................... -.75° to +0.25° -0.25°
TOTALTOE.................
Specified In Degrees (See Note)
TOE OUT: When Backed On
Alignment Rack Is TOE In When
Driving
0.3° in to 0.1° out 0.1° in
THRUST ANGLE ............. -0.10° to +0.10°
Note: Total Toe is the arithmetic sum of the left and right wheel Toe settings. Positive is Toe-in, negative is
Toe-out. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after
setting Toe. Left and Right Toe
must be equal to within 0.02 degrees.
2 - 8 SUSPENSION PL

FRONT SUSPENSION
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION ................. 9
DESCRIPTION AND OPERATION
BALL JOINT ........................... 13
COIL SPRING ......................... 13
FRONT SUSPENSION .................... 9
FRONT WHEEL HUB BEARING ............ 13
LOWER CONTROL ARM ................. 12
McPHERSON STRUT ASSEMBLY .......... 12
STABILIZER BAR ....................... 12
STEERING KNUCKLE ................... 12
WHEEL MOUNTING STUDS .............. 13
DIAGNOSIS AND TESTING
BALL JOINT ASSEMBLY .................. 14
HUB/BEARING ......................... 14
LOWER CONTROL ARM ................. 14
MCPHERSON STRUT ASSEMBLY .......... 13
STABILIZER BAR ....................... 14
STEERING KNUCKLE ................... 13
REMOVAL AND INSTALLATION
FRONT WHEEL MOUNTING STUDS ........ 25
HUB BEARING ......................... 23
LOWER CONTROL ARM ................. 20
MCPHERSON STRUT ................... 15
STABILIZER BAR ....................... 22
STEERING KNUCKLE ................... 16
DISASSEMBLY AND ASSEMBLY
BALL JOINT ........................... 29
LOWER CONTROL ARM FRONT ISOLATOR
BUSHING ........................... 31
LOWER CONTROL ARM REAR ISOLATOR
BUSHING ........................... 32
McPHERSON STRUT .................... 27
SPECIFICATIONS
FRONT SUSPENSION FASTENER
TORQUES .......................... 33
SPECIAL TOOLS
FRONT SUSPENSION ................... 34
GENERAL INFORMATION
GENERAL INFORMATION
CAUTION: ONLY FRAME CONTACT HOISTING
EQUIPMENT CAN BE USED ON THIS VEHICLE. All
vehicles have a fully independent rear suspension.
The vehicles can not be hoisted using equipment
designed to lift a vehicle by the rear axle. If this
type of hoisting equipment is used, damage to rear
suspension components will occur.
CAUTION: At no time when servicing a vehicle,
can a sheet metal screw, bolt or other metal fas-
tener be installed in the shock tower to take the
place of an original plastic clip. Also, NO holes can
be drilled into the front shock tower in the area
shown in (Fig. 1), for the installation of any metal
fasteners into the shock tower.
Because of the minimum clearance in this area
(Fig. 1) installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failure
of the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
DESCRIPTION AND OPERATION
FRONT SUSPENSION
This vehicle has a gas pressurized MacPherson
strut front suspension design (Fig. 2).
A MacPherson strut assembly is used in place of
the front suspension upper control arm and upper
ball joint. The bottom of the MacPherson strut,
mounts directly to the steering knuckle using 2
attaching bolts and nuts going through the clevis
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
SHOCKTOWERNO SHEET METAL SCREWS,BOLTS, OR ANY OTHERMETAL FASTENERS ARE TOBE INSTALLED INTO SHOCKTOWER IN THIS AREA.ALSO, NO HOLES ARE TOBE DRILLED INTO SHOCKTOWER IN THIS SAMEAREA. COILSPRING
PL SUSPENSION 2 - 9