Chrysler Sebring 2004 User manual

SERVICE MANUAL
2004
SEBRING/STRATUS SEDAN
SEBRING CONVERTIBLE
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Copyright © 2003 DaimlerChrysler Corporation

FOREWORD
This manual is designed as a supplement to be used along with the 2004 Sebring/Stratus Service Manual,
81-270-04025. For diagnosis or service procedures relating to other components or systems not in this manual,
refer to the 2004 Sebring/Stratus Service Manual.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. 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 description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator by clicking to 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. If you are not sure which Group contains
the information you need, look up the Component/System in the alphabetical index located in the rear of this
manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
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
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

Welcome
2004 JR Sebring/Stratus Sedan and Convertible
Technical Publications
Click on the icon for the desired manual
Service Manual
Gas Powertrain
Body
Chassis
Transmission

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................2
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE ........5
DESCRIPTION - THREADED HOLE REPAIR . . 5
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................5
METRIC SYSTEM
DESCRIPTION ..........................5
TORQUE REFERENCES
DESCRIPTION ..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................9
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION .........................10
E-MARK LABEL
DESCRIPTION .........................10
VECI LABEL
DESCRIPTION .........................11
MANUFACTURER PLATE
DESCRIPTION .........................11
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the driver side strut tower.
There are seven lines of information on the body code
plate. Lines 4, 5, 6, and 7 are not used to define ser-
vice information. Information reads from left to right,
starting with line 3 in the center of the plate to line
1 at the bottom of the plate.
BODY CODE PLATE LINE 2
DIGITS 1, 2, AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary paint
(Refer to 23 - BODY/PAINT - SPECIFICATIONS)
for Body Color Codes.
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
•ECC = 2.0L Four Cylinder 16 Valves DOHC
Gasoline
Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
JR INTRODUCTION 1

•EDV = 2.4L Four Cylinder 16 Valves DOHC
Gasoline TURBO
•EDZ = 2.4L Four Cylinder 16 Valves DOHC Gas-
oline
•EEE = 2.7L Six Cylinder 24 Valves FFV
•EER = 2.7L Six Cylinder 24 Valves DOHC Gas-
oline
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
•DGL = 41TE 4-Speed Electronic Automatic
Transaxle
•DD5 = NV T350 5-Speed Manual Transaxle
•DDR = NV T850 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
•C = Canada
•B = International
•M = Mexico
•U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
•Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
2 INTRODUCTION JR
BODY CODE PLATE (Continued)

Fig. 2 FASTENER IDENTIFICATION
JR INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH
4 INTRODUCTION JR
FASTENER IDENTIFICATION (Continued)

FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
JR INTRODUCTION 5