Dodge Intrepid User manual

GROUP TAB LOCATOR
IN
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Driveline
5
Brakes
7
Cooling
8A
Audio
8B
Chime/Buzzer
8C
Clock
8E
Electronic Control Modules
8F
Engine Systems
8FS
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8LS
Lamps
8M
Message Systems
8N
Power Systems
8NS
Power Systems
8O
Restraints
8OS
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
11
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transaxle
22
Tires/Wheels
23
Body
23S
Body
24
Heating & Air Conditioning
25
Emissions Control
Component and System Index
Component and System Index-Police Package
Service Manual Comment Forms
NOTE: For New Vehicle Preparation information, see the separate
publication, 81-170-00003.
NOTE: Group names with the suffix (S(indicate groups pertaining to
Police Vehicles.

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATES
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................3
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE ........6
DESCRIPTION - THREADED HOLE REPAIR . . 6
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS
DESCRIPTION ..........................6
METRIC SYSTEM
DESCRIPTION ..........................7
TORQUE REFERENCES
DESCRIPTION ..........................9
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION .........................10
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION .........................11
E-MARK LABEL
DESCRIPTION .........................11
VECI LABEL
DESCRIPTION .........................11
MANUFACTURE PLATE
DESCRIPTION .........................12
BODY CODE PLATES
DESCRIPTION
LOCATION AND DECODING
The Body Code Plate (Fig. 1) is located in the
engine compartment on the battery tray front side
(Fig. 2). There are seven lines of information on the
body code plate. Lines 4, 5, 6, and 7 are not used to
define service 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 3
DIGITS 1, 2, AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary Paint (Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
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
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
LH INTRODUCTION 1

DIGITS 20, 21, AND 22
Engine Code
•EER = 2.7 L, Six Cylinder, 24 Valve, DOHC,
Gasoline, Aluminum Block (MPI)
•EGG = 3.5 L, Six Cylinder, 24 Valve, SOHC,
High Output, Gasoline, Aluminum Block (MPI)
•EGK = 3.5 L, Six Cylinder, 24 Valve, SOHC,
High Output, Gasoline, Aluminum Block (MPI)
•EGJ = 3.5 L, Six Cylinder, 24 Valve, SOHC,
High Output, Gasoline, Aluminum Block
•EGC = 3.5 L, Six Cylinder, 24 Valve, SOHC,
Magnum, Gasoline, Aluminum Block
DIGIT 23
Open Space
BODY CODE PLATE – LINE 2
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, THROUGH 15
Vinyl Roof Code
DIGITS 16 AND 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
•LH
DIGITS 20
Carline
•C = Chrysler
•D = Dodge
•Y = Chrysler
DIGIT 21
Price Class
•E = Economy
•H = High Line
•L = Low Line
•M = Mid Line
•P = Premium
•S = Special/Sport
•X = Performance Image
DIGITS 22 AND 23
Body Type
•41 = Four Door Sedan
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
•DGX = 42LE 4-Speed Electronic Automatic
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 DATA/VEHICLE INFOR-
MATION/VEHICLE IDENTIFICATION NUMBER -
DESCRIPTION) 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.
Fig. 2 BODY CODE PLATE LOCATION
1 - BODY COPY PLATE
2 - BATTERY TRAY
2 INTRODUCTION LH
BODY CODE PLATES (Continued)

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. 3) and (Fig. 4).
LH INTRODUCTION 3

Fig. 3 FASTENER IDENTIFICATION
4 INTRODUCTION LH
FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER STRENGTH
LH INTRODUCTION 5
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 VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 5) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 5 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
6 INTRODUCTION LH

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.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x
0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x
1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x
0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x
0.03937 = Inches
Feet x
0.3048 = Meters (M) M x 3.281 = Feet
Yards x
0.9144 = Meters M x 1.0936 = Yards
mph x
1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x
0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x
0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x
0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.) (Fig. 6).
LH INTRODUCTION 7

Fig. 6 METRIC CONVERSION CHART
8 INTRODUCTION LH
METRIC SYSTEM (Continued)

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
tions Chart for torque references not listed in the
individual torque charts (Fig. 7).
Fig. 7 TORQUE SPECIFICATIONS
LH INTRODUCTION 9