Chrysler Intrepid User manual

SERVICE MANUAL

2004

300M, CONCORDE

AND INTREPID

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.

7.0M0203

CAUTION

ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN

ARE

APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE

ONLY. All test and repair procedures on components or assemblies in

non-auto-

motive applications should be repaired in accordance with instructions supplied by

the manufacturer of the total product.

Proper service and repair is important to the safe, reliable, operation of all motor vehi-

cles. The service procedures recommended and described in this publication were

developed for professional service personnel and are effective methods for perform-

ing vehicle repair. Following these procedures will help assure efficient economical

vehicle performance and service reliability. Some of these service procedures require

the use of special tools designed for specific procedures. These special tools should

be used when recommended throughout this publication.

Special attention should be exercised when working with spring or tension loaded fas-

teners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may

cause personal injury. Always wear safety goggles whenever working on vehicles or vehi-

cle components.

It is important to note that this publication contains various Cautions and Warnings.

These should be carefully read in order to minimize the risk of personal injury, or the

possibility that improper service methods may damage the vehicle or render it unsafe.

It is important to note that these Cautions and Warnings cover only the situations and

procedures DaimlerChrysler Corporation has encountered and recommended.

DaimlerChrysler Corporation could not possibly know, evaluate, and advise the

service trade of all conceivable ways that service may be performed, or of the possi-

ble hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken

any such broad service review. Accordingly, anyone who uses a service procedure, or

tool, that is not recommended in this publication must assure oneself thoroughly that

neither personal safety, nor vehicle safety, be jeopardized by the service methods they

select.

For other Service and Owner Manuals for Chrysler, Plymouth,

Dodge, Dodge Truck, and Jeep

T

vehicles, Call (800) 890-4038 or

FAX (440) 572-0815 to place an order. Or, visit our website at

techauthority.daimlerchrysler.com. Tech Authority Online at our

website offers you service information on a subscription basis.

DaimlerChrysler Corporation

UNITED STATES and CANADA

The special service tools referred to herein are required for certain service oper-

ations. These special service tools or their equivalent, if not obtainable through a

local source, are available through the following outlet.

28635 Mound Road, Warren, Michigan 48092, U.S.A.

MILLER SPECIAL TOOLS

SPX Corporation

Telephone 1-800-801-5420 FAX 1-800-578-7375

INTERNATIONAL

The special service tools referred to herein are required for certain service oper-

ations. These special service tools or their equivalent, if not obtainable through a

local source, are available through the following outlet.

28635 Mound Road, Warren, Michigan 48092, U.S.A.

MILLER SPECIAL TOOLS

SPX Corporation

Telephone 1-507-455-7320 FAX 1-800-578-7375

FOREWORD

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 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. If you are not sure which Group contains the infor-

mation 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.

GROUP TAB LOCATOR

Introduction

0

Lubrication & Maintenance

2

Suspension

3

Driveline

5

Brakes

7

Cooling

8A

Audio/Video

8B

Chime/Buzzer

8C

Clock

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

9

Engine

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 PLATES

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 ..........................6

TORQUE REFERENCES

DESCRIPTION ..........................8

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION ..........................9

VEHICLE SAFETY CERTIFICATION LABEL

DESCRIPTION .........................10

E-MARK LABEL

DESCRIPTION .........................10

VECI LABEL

DESCRIPTION .........................10

MANUFACTURER PLATE

DESCRIPTION .........................11

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

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)

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

• 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.

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).

Fig. 2 BODY CODE PLATE LOCATION

1 - BODY COPY PLATE

2 - BATTERY TRAY

2 INTRODUCTION LH

BODY CODE PLATES (Continued)

Fig. 3 FASTENER IDENTIFICATION

LH INTRODUCTION 3

FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER STRENGTH

4 INTRODUCTION LH

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 Helicoilt recommen-

dations for application and repair procedures.

INTERNATIONAL 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

LH INTRODUCTION 5

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).

6 INTRODUCTION LH

Fig. 6 METRIC CONVERSION CHART

LH INTRODUCTION 7

METRIC SYSTEM (Continued)

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear within many or the

Groups. Refer to the Standard Torque Specifications

Chart for torque references not listed in the individual

torque charts (Fig. 7).

Fig. 7 TORQUE SPECIFICATIONS

8 INTRODUCTION LH

VEHICLE IDENTIFICATION

NUMBER

DESCRIPTION

The Vehicle Identification Number (VIN) is located

on the upper left corner of the upper plenum, near

the left windshield pillar (Fig. 8). The VIN consists of

17 characters in a combination of letters and num-

bers that provide specific information about the vehi-

cle. Refer to VIN Code Breakdown table for decoding

information.

VIN CODE BREAKDOWN CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 2 = Manufactured By DaimlerChrysler Canada Inc.

2 Make B = Dodge

C = Chrysler

3 Vehicle Type 3 = Passenger Car

4 Passenger Safety A = Restraint System - Active Driver and Side Airbags

H = Restraint System - Active Driver and Passenger Airbags

5 Car Line D = Concord (U.S.,Canada, Mexico, Bux)

D = Intrepid (U.S., Mexico)

E = 300M (U.S.,Canada, Mexico, Bux)

H = Intrepid (Canada)

6 Series 3 = Medium

4 = High Line

5 = Premium

6 = Sport

7 = Special

Transmission Table For Bux

W/DGL, DGX

B = 4 Speed Automatic

7 Body Style 6 = 4 Door Sedan

8 Engine G = 3.5L V6 Cyl 24 Valve SOHC (MPI)

K = 3.5L V6 Cyl 24 valve (MPI)

M = 3.5L V6 Cyl 24 valve SOHC

R = 2.7L V6 Cyl 24 Valve DOHC (MPI)

V = 3.5L V6 Cyl 24 Valve SOHC

9 Check Digit See explanation in this section.

10 Model Year 4 = 2004

11 Assembly Plant H = Bramalea Assembly

12 through 17 Sequence Number Six digit number assigned by assembly plant

Fig. 8 VEHICLE IDENTIFICATION NUMBER (VIN PLATE)

1 - INSTRUMENT PANEL

2 - V.I.N.

3 - WINDSHIELD OPENING

LH INTRODUCTION 9

VIN CHECK DIGIT

DESCRIPTION

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 Iden-

tification Number. The check digit is used by the

manufacturer and government agencies to verify the

authenticity of the vehicle and official documenta-

tion. The formula to use the check digit is not

released to the general public.

VEHICLE SAFETY

CERTIFICATION LABEL

DESCRIPTION

A vehicle safety certification label is attached to

the rear shutface of the driver’s door (Fig. 9). This

label indicates date of manufacture (month and

year), Gross Vehicle Weight Rating (GVWR), Gross

Axle Weight Rating (GAWR) front, Gross Axle Weight

Rating (GAWR) rear and the Vehicle Identification

Number (VIN). The Month, Day and Hour of manu-

facture is also included.

All communications or inquiries regarding the

vehicle should include the Month-Day-Hour and

Vehicle Identification Number.

E-MARK LABEL

DESCRIPTION

An E-mark Label (Fig. 10) is located on the rear

shut face of the driver’s door. The label contains the

following information:

• Date of Manufacture

• Month-Day-Hour (MDH)

• Vehicle Identification Number (VIN)

• Country Codes

• Regulation Number

• Regulation Amendment Number

• Approval Number

VECI LABEL

DESCRIPTION

All models have a Vehicle Emission Control Infor-

mation (VECI) Label. Chrysler permanently attaches

the label in the engine compartment. It cannot be

removed without defacing information and destroying

the label.

The label contains the vehicle’s emission specifica-

tions and vacuum hose routings. All hoses must be

connected and routed according to the label.

Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL -

TYPICAL

Fig. 10 E-MARK LABEL

1 - COUNTRY CODE

2 - REGULATION NUMBER

3 - APPROVAL NUMBER

4 - AMENDMENT NUMBER

10 INTRODUCTION LH

VEHICLE IDENTIFICATION NUMBER (Continued)

MANUFACTURER PLATE

DESCRIPTION

The Manufacturer Plate (Fig. 11) is located in the

engine compartment on the passenger side rear cor-

ner of the hood. The plate contains five lines of infor-

mation:

1. Vehicle Identification Number (VIN)

2. Gross Vehicle Mass (GVM)

3. Gross Train Mass (GTM)

4. Gross Front Axle Rating (GFAR)

5. Gross Rear Axle Rating (GRAR)

Fig. 11 MANUFACTURER PLATE

LH INTRODUCTION 11

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................1

FLUID TYPES

DESCRIPTION

DESCRIPTION - ENGINE OIL AND

LUBRICANTS .........................1

DESCRIPTION - ENGINE COOLANT ........3

DESCRIPTION - AUTOMATIC

TRANSMISSION FLUID ..................3

DESCRIPTION - DIFFERENTIAL

LUBRICANT...........................4

DESCRIPTION - FUEL REQUIREMENTS .....4

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES .......5

FLUID FILL/CHECK LOCATIONS

DESCRIPTION ..........................6

LUBRICATION POINTS

DESCRIPTION ..........................6

MAINTENANCE SCHEDULES

DESCRIPTION

DESCRIPTION ........................6

DESCRIPTION - EXPORT ...............10

HOISTING

STANDARD PROCEDURE - HOISTING .......14

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING . 14

TOWING

STANDARD PROCEDURE - TOWING ........15

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international

symbols to identify engine compartment lubricant

and fluid inspection and fill locations (Fig. 1).

FLUID TYPES

DESCRIPTION

DESCRIPTION - ENGINE OIL AND LUBRICANTS

WARNING: NEW OR USED ENGINE OIL CAN BE

IRRITATING 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 EXPOSED

SKIN WITH SOAP AND WATER. DO NOT WASH

SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR

SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO

NOT POLLUTE, DISPOSE OF USED ENGINE OIL

PROPERLY. CONTACT YOUR DEALER OR GOVERN-

MENT AGENCY FOR LOCATION OF COLLECTION

CENTER IN YOUR AREA.

When service is required, DaimlerChrysler Corpo-

ration recommends that only Mopart brand parts,

lubricants and chemicals be used. Mopart provides

the best engineered products for servicing

DaimlerChrysler Corporation vehicles.

Only lubricants bearing designations defined by

the following organization should be used.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

Fig. 1 INTERNATIONAL SYMBOLS

LH LUBRICATION & MAINTENANCE 0 - 1

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified (GF-3).

Mopart provides engine oils, meeting Material Stan-

dard MS-6395, that meet or exceed this requirement.

SAE VISCOSITY

An SAE viscosity grade is used to specify the vis-

cosity of engine oil. Use only engine oils with multi-

ple viscosities such as 5W-30 or 10W-30. These are

specified with a dual SAE viscosity grade which indi-

cates the cold-to-hot temperature viscosity range.

Select an engine oil that is best suited to your par-

ticular temperature range and variation (Fig. 2).

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for

gasoline engines. The designation of ENERGY CON-

SERVING is located on the label of an engine oil con-

tainer.

CONTAINER IDENTIFICATION

Standard engine oil identification notations have

been adopted to aid in the proper selection of engine

oil. The identifying notations are located on the front

label of engine oil plastic bottles and the top of

engine oil cans (Fig. 3).

This symbol means that the oil has been certified

by the American Petroleum Institute (API). Diamler-

Chrysler only recommend API Certified (GF-3)

engine oils that meet the requirements of Material

Standard MS-6395. Use Mopart or an equivalent oil

meeting the specification MS-6395.

SYNTHETIC ENGINE OILS

There are a number of engine oils being promoted

as either synthetic or semi-synthetic. If you chose to

use such a product, use only those oils that meet the

American Petroleum Institute (API) and SAE viscos-

ity standard. Follow the service schedule that

describes your driving type.

ENGINE OIL ADDITIVES/SUPPLEMENTS

The manufacturer does not recommend the addi-

tion of any engine oil additives/supplements to the

specified engine oil. Engine oil additives/supplements

should not be used to enhance engine oil perfor-

mance. Engine oil additives/supplements should not

be used to extend engine oil change intervals. No

additive is known to be safe for engine durability and

can degrade emission components. Additives can con-

tain undesirable materials that harm the long term

durability of engines by:

• Doubling the level of Phosphorus in the engine

oil. The ILSAC (International Lubricant Standard

Approval Committee) GF-2 and GF-3 standards

require that engine oil contain no more than 0.10%

Phosphorus to protect the vehicles emissions perfor-

mance. Addition of engine oil additives/supplements

can poison, from the added sulfur and phosphorus,

catalysts and hinder efforts to guarantee emissions

performance to 80,000 miles.

• Altering the viscosity characteristics of the

engine oil so that it no longer meets the require-

ments of the specified viscosity grade.

• Creating potential for an undesirable additive

compatibility interaction in the engine crankcase.

Generally it is not desirable to mix additive packages

from different suppliers in the crankcase; there have

been reports of low temperature engine failures

caused by additive package incompatibility with such

mixtures.

GEAR LUBRICANTS

SAE ratings also apply to multigrade gear lubri-

cants. In addition, API classification defines the

lubricants usage. Such as API GL-5 and SAE 75W-

90.

LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage

by the NLGI. All approved products have the NLGI

symbol (Fig. 4) 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

Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY

Fig. 3 API SYMBOL

0 - 2 LUBRICATION & MAINTENANCE LH

FLUID TYPES (Continued)

quality of the lubricant. The following symbols indi-

cate the highest quality.

SPECIALIZED LUBRICANTS AND OILS

Some maintenance or repair procedures may

require the use of specialized lubricants or oils. Con-

sult the appropriate sections in this manual for the

correct application of these lubricants.

DESCRIPTION - ENGINE COOLANT

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 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 boiling 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. Mopart Antifreeze/Coolant, 5

Year/100,000 Mile Formula (MS-9769), or the equiva-

lent ethylene glycol base coolant with hybrid 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 solu-

tion.

The green coolant MUST NOT BE MIXED with

the orange or magenta coolants. When replacing cool-

ant the complete system flush must be performed

before using the replacement coolant.

CAUTION: MoparT Antifreeze/Coolant, 5

Year/100,000 Mile Formula (MS-9769) may not be

mixed with any other type of antifreeze. Doing so

will reduce the corrosion protection and may result

in premature water pump seal failure. If non-HOAT

coolant is introduced into the cooling system in an

emergency, it should be replaced with the specified

coolant as soon as possible.

DESCRIPTION - AUTOMATIC TRANSMISSION

FLUID

NOTE: Refer to the maintenance schedules for the

recommended maintenance (fluid/filter change)

intervals for this transaxle.

NOTE: For fluid level checking procedures, (Refer

to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -

42LE/FLUID - STANDARD PROCEDURE).

NOTE: The 42LE transaxle has separate transmis-

sion and differential oil sumps, each requiring dif-

ferent fluids.

TRANSMISSION FLUID

Mopart ATF+4 is required in this transaxle. Sub-

stitute fluids can induce torque converter clutch

shudder.

Mopart ATF+4 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 indica-

tor of fluid condition. As the vehicle is driven, the

ATF will begin to look darker in color and may even-

tually become brown. This is normal. ATF+4 also

Fig. 4 NLGI SYMBOL

1 - WHEEL BEARINGS

2 - CHASSIS LUBRICATION

3 - CHASSIS AND WHEEL BEARINGS

LH LUBRICATION & MAINTENANCE 0 - 3

FLUID TYPES (Continued)

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