"GROUP TAB LOCATOR
Introduction
0 2 3 5 6 7 8A 8B 8E 8F 8G 8H 8I 8J 8L 8M 8N 8O 8P 8Q 8R 8W 9 11 13 14 19 21 22 23 24 25
Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering Transmission and Transfer Case Tires/Wheels Body Heating & Air Conditioning Emissions Control Component and System Index
Service Manual Comment Forms
(Rear of Manual)
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INTRODUCTION
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INTRODUCTION
TABLE OF CONTENTS
page FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE . . . . . DESCRIPTION - THREADED HOLE REPAIR INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . page
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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. 1) and (Fig. 2).
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INTRODUCTION
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FASTENER IDENTIFICATION (Continued)
Fig. 1 FASTENER IDENTIFICATION
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FASTENER IDENTIFICATION (Continued)
INTRODUCTION
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Fig. 2 FASTENER STRENGTH
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INTRODUCTION
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FASTENER USAGE
DESCRIPTION DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL 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 Helicoil . Follow the vehicle or Helicoil recommendations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 3) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
Fig. 3 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 2 3 4 5 6 7 8 9 10 11 12 High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper 13 14 15 16 17 18 19 20 21 22 23 24 Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter
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INTRODUCTION
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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 in-lbs ft-lbs Inches Hg (60° F) psi Inches Feet Yards mph Feet/Sec mph Kilometers/Hr. (Km/h) BY x 0.11298 x 1.3558 x 3.377 x 6.895 x 25.4 x 0.3048 x 0.9144 x 1.6093 x 0.3048 x 0.4470 x 0.27778 TO GET = Newton Meters (N·m) = Newton Meters (N·m) = Kilopascals (kPa) = Kilopascals (kPa) = Millimeters (mm) = Meters (M) = Meters = Kilometers/Hr. (Km/h) = Meters/Sec (M/S) = Meters/Sec (M/S) = Meters/Sec (M/S) MULTIPLY N·m N·m kPa kPa mm M M Km/h M/S M/S M/S BY x 8.851 x 0.7376 x 0.2961 x 0.145 x 0.03937 x 3.281 x 1.0936 x 0.6214 x 3.281 x 2.237 x 3.600 = in-lbs = ft-lbs = Inches Hg = psi = Inches = Feet = Yards = mph = Feet/Sec = mph Kilometers/Hr. (Km/h) TO GET
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Foot = 0.3 Meter 1 Yard = 0.9 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. 4). 1 Cubic Inch = 16 Cubic Centimeters 1 Cubic Foot = 0.03 Cubic Meter 1 Cubic Yard = 0.8 Cubic Meter
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INTRODUCTION
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METRIC SYSTEM (Continued)
Fig. 4 METRIC CONVERSION CHART
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INTRODUCTION
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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. 5).
Fig. 5 TORQUE SPECIFICATIONS
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INTRODUCTION
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VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL
DESCRIPTION
All models have a Vehicle Emission Control Information (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment (Fig. 6). The label cannot be removed without defacing label information and destroying label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label. The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. The VECI label contains the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Engine timing specifications (if adjustable) • Idle speeds (if adjustable) • Spark plug and gap
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is located on the lower left A-pillar and is visible through the windshield (Fig. 7). The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle.
Fig. 7 VIN NUMBER LOCATION
1 - A-PILLAR 2 - VIN CODE PLATE
Fig. 6 VECI LABEL LOCATION
1 - RADIATOR SUPPORT 2 - VECI LABEL
The Vehicle Identification Number is also imprinted on the: • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.
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VEHICLE IDENTIFICATION NUMBER (Continued)
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION 1 2 3 4 5 INTERPRETATION Country of Origin Make Vehicle Type Gross Vehicle Weight Rating Vehicle Line
INTRODUCTION
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CODE = DESCRIPTION 1 = Manufactured by DaimlerChrysler Corporation J = Jeep 4 = MPV W/O Side Airbags. 8 = MPV With Side Airbags. F = 4001 - 5000 lbs. G = 5001 - 6000 lbs. K = Liberty 4X2 (LHD) L = Liberty 4X4 (LHD) M = Cherokee 4X4 (RHD) 3 = Liberty Renegade 4 = Liberty Sport/Cherokee Sport 5 = Liberty Limited/Cherokee Limited 8 = Sport Utility - 4 Door K = 3.7L 6 cyl MPI Gasoline 1 = 2.4L 4 cyl MPI Gasoline 7 = 2.5L 4 cyl Diesel 0 through 9 or X 3=2003 W = Toledo North Assembly Plant Vehicle Build Sequence The label is located on the driver-side door shut-face.
6
Series
7 8
Body Style Engine
9 10 11 12 thru 17
Check Digit Model Year Assembly Plant
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 8) is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin.
Fig. 8 VEHICLE SAFETY CERTIFICATION LABEL TYPICAL
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LUBRICATION & MAINTENANCE
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LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . PARTS & LUBRICANT RECOMMENDATION DESCRIPTION DESCRIPTION - FLUID TYPES . . . . . . . . . DESCRIPTION - LUBRICANT RECOMMENDATIONS . . . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - FLUID TYPES . . . . . . . . . DESCRIPTION - AXLE . . . . . . . . . . . . . . . . DESCRIPTION - MANUAL TRANSMISSION DESCRIPTION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . DESCRIPTION - TRANSFER CASE - NV231 DESCRIPTION - TRANSFER CASE - NV242 DESCRIPTION - ENGINE COOLANT . . . . . DESCRIPTION - ENGINE OIL - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . page DESCRIPTION - POWER STEERING FLUID . . 5 OPERATION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6 FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HOISTING STANDARD PROCEDURE - HOISTING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 14 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14 TOWING STANDARD PROCEDURE - TOWING . . . . . . . . 15
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INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).
PARTS & LUBRICANT RECOMMENDATION
DESCRIPTION DESCRIPTION - FLUID TYPES
When service is required, DaimlerChrysler Corporation recommends that only Mopar brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined 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)
Fig. 1 INTERNATIONAL SYMBOLS
SAE VISCOSITY RATING
An SAE viscosity grade is used to specify the viscosity of engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Example SAE 5W-30 = multigrade engine oil. DaimlerChrysler Corporation only recommends multigrade engine oils.
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PARTS & LUBRICANT RECOMMENDATION (Continued)
API QUALITY CLASSIFICATION
This symbol (Fig. 2) on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the correct application of these lubricants.
DESCRIPTION - LUBRICANT RECOMMENDATIONS
Chassis
Component Steering Gear & Linkage, Ball Joints, Prop Shafts & Yokes, Wheel Bearings Fluid, Lubricant, or Genuine Part Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB
Fig. 2 API Symbol
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W90.
Body
Component Fluid, Lubricant, and Genuine Part Mopar Engine Oil Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB
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 indicate the highest quality. Hinges: Door & Hood Swing Gate Latches: Door, Hood/Safety Catch, Swing Gate Seat Regulator & Track Lock Cylinders
Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Mopar Lock Cylinder Lube
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS
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LUBRICATION & MAINTENANCE
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FLUID TYPES
DESCRIPTION DESCRIPTION - FLUID TYPES
When service is required, DaimlerChrysler Corporation recommends that only Mopar brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) (Fig. 4) • National Lubricating Grease Institute (NLGI) (Fig. 5)
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 5) 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 indicate the highest quality.
SAE VISCOSITY RATING
An SAE viscosity grade is used to specify the viscosity of engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Example SAE 5W-30 = multigrade engine oil. DaimlerChrysler Corporation only recommends multigrade engine oils.
Fig. 5 NLGI Symbol
1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the correct application of these lubricants.
API QUALITY CLASSIFICATION
This symbol (Fig. 4) on the front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by DaimlerChrysler Corporation.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality.
FRONT AXLE • 186FIA (Model 30) - Mopar Lubricant 75W-140
Synthentic Gear
REAR AXLE • 8 1/4 - Mopar Gear Lubricant 75W-90 (Trailer Towing - Mopar Synthentic Gear Lubricant 75W-140 Fig. 4 API Symbol
NOTE: Trac-lok equipped axles require 118 ml (4 ounces) of Limited Slip Additive be added to the lubricant.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W90.
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FLUID TYPES (Continued)
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. • NV1500 - Mopar cant • NV3550 - Mopar cant Manual Transmission LubriManual Transmission Lubri-
DESCRIPTION - TRANSFER CASE - NV242
Recommended lubricant for the NV242 transfer case is Mopar ATF+4, Automatic Transmission Fluid.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID
NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopar ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopar ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.
DESCRIPTION - TRANSFER CASE - NV231
Recommended lubricant for the NV231 transfer case is Mopar ATF +4, Automatic T..."
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