Dodge Magnum 2005 Workshop Manual

Download

Page 1

8A 8B 8C

8F 8G 8H

8I 8J 8L

8N 8O

8Q 8R

11 13 14 19 21 22 23 24 25

GROUP TAB LOCATOR

Introduction Lubrication & Maintenance

Suspension

Differential & Driveline

Brakes

Cooling

Audio/Video Chime/Buzzer Clock 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 Navigation/Telecommunication Wiring Engine

Exhaust System Frame & Bumpers Fuel System Steering Automatic Transmission Tires/Wheels Body Heating & Air Conditioning Emissions Control Component and System Index DTC Index

Service Manual Comment Forms (Rear of Manual)

Page 2

Page 3

LX INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

page page

BODY CODE PLATE

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

FASTENER IDENTIFICATION

DESCRIPTION ..........................5

FASTENER USAGE

DESCRIPTION

FASTENER USAGE .....................8

THREADED HOLE REPAIR ...............8

INTERNATIONAL SYMBOLS

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

MANUFACTURE PLATE

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

METRIC SYSTEM

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

TORQUE REFERENCES

DESCRIPTION .........................12

VECI LABEL

DESCRIPTION .........................13

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION .........................13

VEHICLE CERTIFICATION LABEL

DESCRIPTION .........................15

BODY CODE PLATE

DESCRIPTION

LOCATION AND DECODING

The Body Code Plate is located in the engine compartment on the front right side shock tower mounting front panel.

Page 4

2 INTRODUCTION LX

BODY CODE PLATE LINE 3

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.

DIGITS 1, 2, AND 3

Paint procedure

DIGIT 4

Open Space

DIGITS 5 THROUGH 7

Primary Paint

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)

• EZB = 5.7 L, V-8 Cylinder, HEMI, Multi-Displacement, Gasoline,

DIGIT 23

Open Space

Page 5

LX INTRODUCTION 3

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

• LX

DIGITS 20

Carline

• C = Chrysler

• D = Dodge

DIGIT 21

Price Class

• E = Economy

• H = High Line

• L = Low Line

• M = Medium

• P = Premium

• S = Sport

• X = Special

DIGITS 22 AND 23

Body Type

• 48 = Four Door Sedan Tall

• 49 =Hatchback Tall

Page 6

4 INTRODUCTION LX

BODY CODE PLATE LINE 1

DIGITS 1, 2, AND 3

Transaxle Codes

• DG6 = 4-Speed Electronic Automatic Transaxle

• DGJ = 5-Speed 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 INFORMATION/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 followed 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.

Page 7

LX INTRODUCTION 5

FASTENER IDENTIFICATION

DESCRIPTION

Page 8

6 INTRODUCTION LX

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.

Page 9

LX INTRODUCTION 7

Page 10

8 INTRODUCTION LX

FASTENER USAGE

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 reassem-

bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for application and repair procedures.

INTERNATIONAL SYMBOLS

DESCRIPTION

The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

Page 11

LX INTRODUCTION 9

MANUFACTURE PLATE

DESCRIPTION

The Manufacturer Plate is located in the engine compartment on the passenger side rear corner of the hood. The plate contains five lines of information:

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)

Page 12

10 INTRODUCTION LX

METRIC SYSTEM

DESCRIPTION

Page 13

LX INTRODUCTION 11

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

ft-lbs x

1.3558

Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x

Feet x

0.3048

Yards x

0.9144

mph x

1.6093

Feet/Sec x

0.3048

mph x

0.4470

Kilometers/Hr. (Km/h) x

0.27778

= Newton Meters (N·m)

= Meters (M) M x 3.281 = Feet

= Meters M x

= Kilometers/Hr. (Km/h)

= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

= Meters/Sec (M/S) M/S x 2.237 = mph

= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

N·m x 8.851 = in-lbs

N·m x

0.7376

0.2961

0.03937

1.0936

Km/h x

0.6214

= ft-lbs

= Inches Hg

= Inches

= Yards

= mph

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.).

Page 14

12 INTRODUCTION LX

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.

Page 15

LX INTRODUCTION 13

VECI LABEL

DESCRIPTION

All vehicles are equipped with a combined VECI label. This label is located in the engine compartment. 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

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. These labels are permanently attached and cannot be removed without defacing information and destroying label.

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION

The Vehicle Identification Number (VIN) plate is attached to the top left side of the instrument panel. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the decoding chart to determine the identification of a vehicle.

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.

Page 16

14 INTRODUCTION LX

VIN DECODING INFORMATION

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin

2 Make

3 Vehicle Type

5 Vehicle Line

6 Series

7 Body Style

8 Engine

9 Check Digit 0 through 9 or X 10 Model Year 5 = 2005 11 Assembly Plant H = Brampton Assembly

12 Through 17 Vehicle Build Sequence

Restraint System

Gross Vehicle Weight Rating H = 6001-7000 lbs.

1 = Manufactured by DaimlerChrysler Canada Inc.

C = Chrysler D = Dodge 3 = Passenger Car 4 = Multipurpose Passenger Vehicle

With Side Airbags 8 = Multipurpose Passenger Vehicle

with Side Airbags J = Restraint System Air bags Front

Next Generation Multi-Stage Sales Code (CG1) Without Side Air Bags Sales Code (CGS)

A = 300 / 300C / SRT-8 (RWD) K = 300 (AWD)

V = TBD (RWD) Z = TBD (AWD)

2 = L Low Line 3 = M Medium

4 - H High Line 5 = P Premium 6 = S Sport 7 = S Special 3=LX-48

8=LX-49 R = 2.7L V-6 cyl. DOHC 24 Valve

MPI Gasoline G = 3.5L V-6 cyl. High Output 24

Valve MPI Gasoline H = 5.7L V-8 cyl. Gasoline T = 2.7L V-6 cyl. DOHC 24 Valve

MPI Gasoline V = 3.5L V-6 cyl. High Output 24

Valve MPI Gasoline 2 = 5.7L V-8 cyl. HEMI Multiple

Displacement Gasoline

Six Digit Number Assigned By Assembly Plant

Page 17

LX INTRODUCTION 15

VEHICLE CERTIFICATION LABEL

DESCRIPTION

A vehicle certification label is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle 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.

The label is located on the driver-side door shut-face.

Page 18

Page 19

LX LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

FLUID TYPES

DESCRIPTION

ENGINE OIL AND LUBRICANTS ...........1

DESCRIPTION - AXLE ...................3

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

OPERATION

AUTOMATIC TRANSMISSION FLUID ........4

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES .......4

FLUID FILL/CHECK LOCATIONS

DESCRIPTION ..........................5

HOISTING

STANDARD PROCEDURE - HOISTING ........5

INTERNATIONAL SYMBOLS

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

JUMP STARTING

STANDARD PROCEDURE

JUMP STARTING .......................6

FLUID TYPES

DESCRIPTION ENGINE OIL AND LUBRICANTS

LUBRICATION POINTS

DESCRIPTION ..........................7

MAINTENANCE SCHEDULES

DESCRIPTION

DESCRIPTION - SEDAN .................7

DESCRIPTION - WAGON ................13

DESCRIPTION - EXPORT ...............19

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION

DESCRIPTION - FLUID TYPES ...........24

LUBRICANT RECOMMENDATIONS ........25

TOWING

STANDARD PROCEDURE - TOWING ........26

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 GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

When service is required, DaimlerChrysler Corporation 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)

Page 20

0 - 2 LUBRICATION & MAINTENANCE LX

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified. MoparT provides engine oils, meeting Material Standard MS-6395, that meet or exceed this requirement.

SAE VISCOSITY

SAE 5W-20 and SAE 5W-30 enigne oils are recomendedfor all operating temperatures. These engine oils improve low temperature starting and vehicle fuel economy. Refer to the engine oil filler cap for the recommened engine oil viscosity for each vehicle. An SAE viscosity grade is used to

specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-20 or 5W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

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.

This symbol means that the oil has been certified by the American Petroleum Institute (API). DiamlerChrysler only recommend API Certified 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 viscosity standard. Follow the service schedule that describes your driving type.

Page 21

LX LUBRICATION & MAINTENANCE 0 - 3

ENGINE OIL ADDITIVES/SUPPLEMENTS

The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. 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 contain 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 performance. 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 requirements 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 lubricants. 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 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.

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 - AXLE

Note: DaimlerChrysler recommends the use of MoparT lubricants. Fluid additives are not required for these axles.

REAR AXLE

• 198 RII - MoparT Synthetic Gear & Axle Lubricant 75W-140

• 210 RII - MoparT Synthetic Gear & Axle Lubricant 75W-140

AUTOMATIC TRANSMISSION FLUID

Note: Refer to Service Procedures in this group for fluid level checking procedures.

MoparT 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.

Page 22

0 - 4 LUBRICATION & MAINTENANCE LX

MoparT 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.

OPERATION AUTOMATIC TRANSMISSION FLUID

The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES

DESCRIPTION SPECIFICATION

Fuel Tank - V6 Engine 68 L (18 gal.) Fuel Tank - V8 Engine 72 L (19 gal.)

Engine Oil* 5.7 L (6.0 qts.)

Engine Oil* - 5.7L 6.6 L (7.0 qts.) Cooling System - 2.7L** 10.0 L (10.5 qts.) Cooling System - 3.5L** 10.5 L (11.0 qts.)

*(includes filter) **(includes heater and coolant recovery bottle filled to MAX level)

AUTOMATIC TRANSMISSION

Service Fill - NAG1 5.0 L (10.6 pts.)

O-haul Fill - NAG1 7.7 L (16.3 pts.)

Service Fill - 42RLE 3.8L (4.0 qts)

O-haul Fill - 42RLE 8.3L (17.6 pts)

Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of

an auxiliary cooler, these figures may vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/FLUID - STANDARD

PROCEDURE)

AXLE - REAR 198 MM RII Axle 1.4L (1.5 qts.) 210 MM RII Axle 1.6L (1.7 qts.)

Page 23

LX LUBRICATION & MAINTENANCE 0 - 5

FLUID FILL/CHECK LOCATIONS

DESCRIPTION

The fluid check/fill points and lubrication locations are located in each applicable Sections.

HOISTING

STANDARD PROCEDURE - HOISTING

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 VEHICLE. 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 any suspension component, including the front or rear suspension crossmembers. Do not hoist on the front and rear bumpers, the lower liftgate crossmember, the lower radiator crossmember, or the front engine mount.

1 - DRIVE ON LIFT 2 - SAE HOISTING SYMBOLS 2 - FRAME CONTACT LIFT (SINGLE POST) 2 - CHASSIS LIFT (DUAL LIFT) 2 - OUTBOARD LIFT (DUEL LIFT) 2 - FLOOR JACK 3 - HOISTING PADS 3 - FRAME CONTACT LIFT (SINGLE POST) 3 - CHASSIS LIFT (DUAL LIFT) 3 - OUTBOARD LIFT (DUEL LIFT) 3 - FLOOR JACK

Page 24

0 - 6 LUBRICATION & MAINTENANCE LX

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations.

JUMP STARTING

STANDARD PROCEDURE JUMP STARTING

WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN THE BATTERY SYSTEM SECTION OF THE SERVICE MANUAL. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE) Take care to avoid the radiator cooling fan whenever the hood is raised. It can start anytime the ignition switch is on. You can be hurt by the fan.

• DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.

• IF EQUIPPED, 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 BATTERY.

• REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARC-

ING 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.

• Do not attempt to push or tow your vehicle to get it started. Vehicles equipped with an automatic transmission cannot be started this way. Unburned fuel could enter the catalytic converter and once the engine has started, ignite and damage the converter and vehicle. If the vehicle has a discharged battery, booster cables may be used to obtain a start from another vehicle. This type of start can be dangerous if done improperly, so follow this procedure carefully.

• Battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or clothing. Don’t lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush contaminated area immediately with large quantities of water.

• A battery generates hydrogen gas which is flammable and explosive. Keep flame or spark away from the vent holes. Do not use a booster battery or any other booster source with an output that exceeds 12 volts. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

Page 25

LX LUBRICATION & MAINTENANCE 0 - 7

Note: The battery is stored under an access cover in the trunk. Remote battery terminals are located in the engine compartment for jump starting.

Note: The battery in this vehicle has a vent hose that should not be disconnected and should only be replaced with a battery of the same type (vented).

TO JUMP START A DISABLED VEHICLE:

• Wear eye protection and remove any metal jew-

elry such as watch bands or bracelets that might make an inadvertent electrical contact.

• When boost is provided by a battery in another

vehicle, park that vehicle within booster cable reach and without letting the vehicles touch. Set the parking brake, place the automatic transmission in PARK and turn the ignition switch to the OFF (or LOCK) position for both vehicles.

• Turn off the heater, radio and all unnecessary

electrical loads.

• Connect one end of the jumper cable RED clamp

to the remote jump start positive battery post in the engine compartment of the disabled vehicle. Connect the other end of the jumper cable RED clamp to the positive terminal of the booster battery.

• Connect the jumper cable BLACK clamp, first to

the negative terminal of the booster battery and then connect the other end of the jumper cable BLACK clamp to a suitable engine ground on the disabled vehicle battery. Make sure you have a good contact on the engine ground.

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 positive terminal on disabled vehicle.

LUBRICATION POINTS

DESCRIPTION

Lubrication point locations are located in each applicable Sections.

MAINTENANCE SCHEDULES

DESCRIPTION DESCRIPTION - SEDAN

There are two maintenance schedules that show the required service for your vehicle. First is Schedule B. It is for vehicles that are operated under the conditions that are listed below and at the begin-

ning of the schedule. Change the automatic transmission fluid and filter every 60,000 miles (96 000 km) if the vehicle is usually operated under one or more of the conditions marked with an L.

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

Page 26

0 - 8 LUBRICATION & MAINTENANCE LX

• Driving in dusty conditions.

• Short trips of less than 10 miles (16 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).

• Trailer towing.L

• Taxi, police, or delivery service (commercial service).L

• Off-road or desert operation.

Note: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule B of the (Maintenance Schedules( section of this manual.

Note: Most vehicles are operated under the conditions listed for Schedule B.

Second is Schedule A. It is for vehicles that are not operated under any of the conditions listed under Schedule B. Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval

that occurs first.

Note: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while

the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if required.

Once a Month

• Check tire pressure and look for unusual wear or damage.

• Inspect the battery and clean and tighten the terminals as required.

• Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and add as needed.

• Check all lights and all other electrical items for correct operation.

• Check rubber seals on each side of the radiator for proper fit.

At Each Oil Change

• Change the engine oil filter.

• Inspect the exhaust system.

• Inspect the brake hoses.

• Inspect the CV joints and front and rear suspension components.

• Check the automatic transmission fluid level.

• Check the coolant level, hoses, and clamps.

SCHEDULE B

Follow schedule B if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 60,000 miles (96 000 km) if the vehicle is usually operated under one or more of the conditions marked with an L.

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 10 miles (16.2 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).

• Trailer towing.L

Page 27

LX LUBRICATION & MAINTENANCE 0 - 9

• Taxi, police or delivery service (commercial services).L

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

Note: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.

Miles 3,000 6,000 9,000 12,000 15,000 18,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Inspect the front and rear brake linings and rotors.

Replace the air conditioning filter.

Rotate the tires. X X X

XXXXXX

XXXX X

Miles 21,000 24,000 27,000 30,000 33,000 36,000 (Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.* Replace the air conditioning

filter. Rotate the tires. X X X

Miles 39,000 42,000 45,000 48,000 51,000 54,000 (Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Inspect the front and rear brake linings and rotors.

Replace the rear axle fluid. X

XXXXXX

XXX XX

XXXXXX

XX XXX

Page 28

0 - 10 LUBRICATION & MAINTENANCE LX

Miles 39,000 42,000 45,000 48,000 51,000 54,000 (Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)

Replace the air conditioning filter.

Rotate the tires. X X X

Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Check and replace, if necessary, the PCV valve.*‡

Replace the power steering fluid.

Change the automatic transmission fluid and filter.

Replace the air conditioning filter.

Rotate the tires. X X X

XXXXXX

X XXXX

Miles 75,000 78,000 81,000 84,000 87,000 90,000 (Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Replace the spark plugs.

5.7L Engine. Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.*‡ Replace the air conditioning

filter. Rotate the tires. X X X

XXXXXX

XXXX

Page 29

LX LUBRICATION & MAINTENANCE 0 - 11

Miles 93,000 96,000 99,000 100,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Inspect the air cleaner filter and replace if required.

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Flush and replace the engine

coolant. Replace the engine timing

belt (Federal Emissions). 3.5L Engine

Replace the engine timing belt (California Emissions).

3.5L Engine Replace the spark plugs.

2.7L, 3.5L Engines. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Change the rear axle fluid. X Replace the air conditioning

filter. Rotate the tires. X X

XXX XX

XXX

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

SCHEDULE A

Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [6] [12] [18] [24] [30] [36]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors. Replace the air conditioning

filter.

XXXXXX

XXXX X

XXX

Page 30

0 - 12 LUBRICATION & MAINTENANCE LX

Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [6] [12] [18] [24] [30] [36]

Rotate the tires. XXXXXX

Miles 42,000 48,000 54,000 60,000 66,000 72,000 (Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000) [Months] [42] [48] [54] [60] [66] [72]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Replace the spark plugs.

5.7L Engine. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Flush and replace engine coolant at 60 months or 102,000 miles.

Check and replace, if necessary, the PCV valve. *

Replace the air conditioning filter.

Rotate the tires. XXXXXX

XXXXXX

XXX XX

XXX

Miles 78,000 84,000 90,000 96,000 100,000 102,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000) (163 000) [Months] [78] [84] [90] [96] [102]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Replace the spark plugs.

2.7L, 3.5L Engines. Replace the spark plugs.

5.7L Engine. Check and replace, if

necessary, the PCV valve.*‡

XXXX X

XX X X

Page 31

LX LUBRICATION & MAINTENANCE 0 - 13

Miles 78,000 84,000 90,000 96,000 100,000 102,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000) (163 000) [Months] [78] [84] [90] [96] [102]

Replace the engine timing belt (Federal Emissions

equipped vehicles only). 3.5L Engine

Replace the engine timing belt (California Emissions equipped vehicles only). 3.5L Engine

Flush and replace the engine coolant at 60 months or 102,000 miles.

Replace the air conditioning filter.

Rotate the tires. XXXX X

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.

DESCRIPTION - WAGON

ning of the schedule. Change the automatic transmission fluid and filter every 60,000 miles (96 000 km) if the vehicle is usually operated under one or more of the conditions marked with an L.

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 10 miles (16 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).

• Trailer towing.L

• Taxi, police, or delivery service (commercial service).L

• Off-road or desert operation.

Note: Most vehicles are operated under the conditions listed for Schedule B.

that occurs first.

Page 32

0 - 14 LUBRICATION & MAINTENANCE LX

Note: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while

the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if required.

Once a Month

• Check tire pressure and look for unusual wear or damage.

• Inspect the battery and clean and tighten the terminals as required.

• Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and add as needed.

• Check all lights and all other electrical items for correct operation.

• Check rubber seals on each side of the radiator for proper fit.

At Each Oil Change

• Change the engine oil filter.

• Inspect the exhaust system.

• Inspect the brake hoses.

• Inspect the CV joints and front and rear suspension components.

• Check the automatic transmission fluid level.

• Check the coolant level, hoses, and clamps.

SCHEDULE B

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 10 miles (16.2 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F (32° C).

• Trailer towing.L

• Taxi, police or delivery service (commercial services).L

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

Miles 3,000 6,000 9,000 12,000 15,000 18,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

XXXXXX

XXXX X

Page 33

LX LUBRICATION & MAINTENANCE 0 - 15

Miles 3,000 6,000 9,000 12,000 15,000 18,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000)

Inspect the front and rear brake linings and rotors.

Replace the air conditioning filter.

Rotate the tires. X X X

Miles 21,000 24,000 27,000 30,000 33,000 36,000 (Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.* Replace the air conditioning

filter. Rotate the tires. X X X

XXXXXX

XXX XX

Miles 39,000 42,000 45,000 48,000 51,000 54,000 (Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Inspect the front and rear brake linings and rotors.

Replace the rear axle fluid. X Replace the air conditioning

filter. Rotate the tires. X X X Change the Front Differential

Fluid - All Wheel Drive (AWD) only

Change the Transfer Case Fluid - All Wheel Drive (AWD) only

XXXXXX

XX XXX

Page 34

0 - 16 LUBRICATION & MAINTENANCE LX

Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Check and replace, if necessary, the PCV valve.*‡

Replace the power steering fluid.

Change the automatic transmission fluid and filter.

Replace the air conditioning filter.

Rotate the tires. X X X

XXXXXX

X XXXX

Miles 75,000 78,000 81,000 84,000 87,000 90,000 (Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Replace the spark plugs.

5.7L Engine. Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.*‡ Replace the air conditioning

filter. Rotate the tires. X X X

Miles 93,000 96,000 99,000 100,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

XXXXXX

XXXX

XXX XX

XXX

Page 35

LX LUBRICATION & MAINTENANCE 0 - 17

Miles 93,000 96,000 99,000 100,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)

Inspect the air cleaner filter and replace if required.

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Flush and replace the engine

coolant. Replace the engine timing

belt (Federal Emissions). 3.5L Engine

Replace the engine timing belt (California Emissions).

3.5L Engine Replace the spark plugs.

2.7L, 3.5L Engines. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Change the rear axle fluid. X Replace the air conditioning

filter. Rotate the tires. X X Change the Front Differential

Fluid - All Wheel Drive (AWD) only

Change the Transfer Case Fluid - All Wheel Drive (AWD) only

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

SCHEDULE A

Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [6] [12] [18] [24] [30] [36]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engine. Inspect the front and rear

brake linings and rotors.

XXXXXX

XXXX X

Page 36

0 - 18 LUBRICATION & MAINTENANCE LX

Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [6] [12] [18] [24] [30] [36]

Replace the air conditioning filter.

Rotate the tires. XXXXXX

Miles 42,000 48,000 54,000 60,000 66,000 72,000 (Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000) [Months] [42] [48] [54] [60] [66] [72]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Replace the spark plugs.

5.7L Engine. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Flush and replace engine coolant at 60 months or 102,000 miles.

Check and replace, if necessary, the PCV valve. *

Replace the air conditioning filter.

Rotate the tires. XXXXXX

XXXXXX

XXX XX

XXX

Miles 78,000 84,000 90,000 96,000 100,000 102,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000) (163 000) [Months] [78] [84] [90] [96] [102]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Replace the spark plugs.

2.7L, 3.5L Engines. Replace the spark plugs.

5.7L Engine.

XXXX X

XX X X

Page 37

LX LUBRICATION & MAINTENANCE 0 - 19

Miles 78,000 84,000 90,000 96,000 100,000 102,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000) (163 000) [Months] [78] [84] [90] [96] [102]

Check and replace, if necessary, the PCV valve.*‡

Replace the engine timing belt (Federal Emissions equipped vehicles only). 3.5L Engine

Replace the engine timing belt (California Emissions equipped vehicles only). 3.5L Engine

Flush and replace the engine coolant at 60 months or 102,000 miles.

Replace the air conditioning filter.

Rotate the tires. XXXX X

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

DESCRIPTION - EXPORT

There are two maintenance schedules that show the required service for your vehicle. First is Schedule A. It is for vehicles that are not operated under any of the conditions listed under Schedule B.

Note: Most vehicles are operated under the conditions listed for Schedule B.

Second is Schedule B. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. Change the automatic transmission fluid and filter every 96 000 km (60,000 miles) if the vehicle is usually operated under one or more of the conditions marked with an L.

• Day or night temperatures are below 0° C (32° F).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 16 km (10 miles).

• More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F ).

• Trailer towing.L

• Taxi, police, or delivery service (commercial service).L

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

Note: If ANY of these apply to you then change your engine oil every 5 000 km (3,000 miles) or 3 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.

Page 38

0 - 20 LUBRICATION & MAINTENANCE LX

Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while

the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if required.

Once a Month

• Check tire pressure and look for unusual wear or damage.

• Inspect the battery and clean and tighten the terminals as required.

• Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and add as needed.

• Check all lights and all other electrical items for correct operation.

• Check rubber seals on each side of the radiator for proper fit.

At Each Oil Change

• Change the engine oil filter.

• Inspect the exhaust system.

• Inspect the brake hoses.

• Inspect the CV joints and front and rear suspension components.

• Check the automatic transmission fluid level.

• Check the coolant level, hoses, and clamps.

Note: If ANY of these apply to you then change your engine oil every 5 000 km (3,000 miles) or 3 months, whichever comes first and follow schedule B of the (Maintenance Schedules( section of this manual.

If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Maintenance Schedules9 section of this manual.

Note: Under no circumstances should oil change intervals exceed 10 000 km (6000 miles) or 6 months whichever comes first.

SCHEDULE A

Kilometers 12 000 24 000 36 000 48 000 60 000 72 000 (Miles) (7,500) (15,000) (22,500) (30,000) (37,500) (45,000) [Months] [6] [12] [18] [24] [30] [36]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.5.7L

Engines Inspect the front and rear

brake linings and rotors. Replace the air conditioning

filter. Rotate the tires. XXXXXX

XXXXXX

XXXX X

XXX

Page 39

LX LUBRICATION & MAINTENANCE 0 - 21

Kilometers 84 000 96 000 108 000 120 000 132 000 140 000 (Miles) (52,500) (60, 000) (67,500) (75,000) (82,500) (90,000) [Months] [42] [48] [54] [60] [66] [72]

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Replace the spark plugs. 5.7L

Engines Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Flush and replace engine coolant at 60 months or 160,000 km.

Check and replace, if necessary, the PCV valve. *

Replace the air conditioning filter.

Rotate the tires. XXXXXX

XXXXXX

X XXXX

XXX

Kilometers 156 000 160 000 168 000 (Miles) (97,500) (100,000) (105,000) [Months] [78] [84]

Change engine oil and engine oil filter. X X Inspect the air cleaner filter and replace if required.* X X Replace the spark plugs. 2.7L, 3.5L Engines. X Check and Inspect the accessory drive belt and tensioner. Replace if

required. Flush and replace the engine coolant at 60 months or 160,000 km. X Replace the air conditioning filter. X Rotate the tires. X X

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

SCHEDULE B

Follow schedule B if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 96 000 km (60,000 miles) if the vehicle is usually operated

under one or more of the conditions marked with an L.

• Day or night temperatures are below 0° C (32° F).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

Page 40

0 - 22 LUBRICATION & MAINTENANCE LX

• Short trips of less than 16.2 km (10 miles).

• More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F).

• Trailer towing.L

• Taxi, police or delivery service (commercial services).L

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

Kilometers 5 000 10 000 14 000 19 000 24 000 29 000 (Miles) (3,000) (6,000) (9,000) (12,000) (15,000) (18,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. *

Inspect the front and rear brake linings and rotors.

Replace the air conditioning filter.

Rotate the tires. X X X

XXXXXX

XXXX X

Kilometers 34 000 38 000 43 000 48 000 53 000 58 000 (Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner

filter.

Replace the spark plugs.

5.7L Engines Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.* Replace the air conditioning

filter. Rotate the tires. X X X

Kilometers 62 000 67 000 72 000 77 000 82 000 86 000 (Miles) (39,000) (42,000) (45,000) (48,000) (51,000) (54,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Inspect the front and rear brake linings and rotors.

Replace the rear axle fluid. X

X X XXXX

XXX XX

XXXXXX

XX XXX

Page 41

LX LUBRICATION & MAINTENANCE 0 - 23

Kilometers 62 000 67 000 72 000 77 000 82 000 86 000 (Miles) (39,000) (42,000) (45,000) (48,000) (51,000) (54,000)

Replace the air conditioning filter.

Rotate the tires. X X X

Kilometers 91 000 96 000 101 000 106 000 110 000 115 000 (Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter. X Replace the spark plugs.

5.7L Engines Inspect the front and rear

brake linings and rotors. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Check and replace, if necessary, the PCV valve.*‡

Replace the power steering fluid.

Change the automatic transmission fluid and filter.

Replace the air conditioning filter.

Rotate the tires. X X X

XXXXXX

X XXXX

Kilometers 120 000 125 000 130 000 134 000 139 000 144 000 (Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Replace the air cleaner filter.*

Replace the spark plugs.

5.7L Engines Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Check and replace, if

necessary, the PCV valve.*‡ Replace the air conditioning

filter. Rotate the tires. X X X

XXXXXX

XXXX

Page 42

0 - 24 LUBRICATION & MAINTENANCE LX

Kilometers 149 000 154 000 158 000 160 000 163 000 168 000 (Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)

Change engine oil and engine oil filter.

Inspect the air cleaner filter and replace if required.*

Inspect the air cleaner filter and replace if required.

Replace the air cleaner filter. X Inspect the front and rear

brake linings and rotors. Replace the spark plugs.

2.7L, 3.5L Engines. Flush and replace the engine

coolant. Check and Inspect the

accessory drive belt and tensioner. Replace if required.

Change the rear axle fluid. X Replace the air conditioning

filter. Rotate the tires. X X

XXX XX

XXX

* This maintenance is recommended by the manufacture to the owner but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION DESCRIPTION - FLUID TYPES

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)

• National Lubricating Grease Institute (NLGI)

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.

Page 43

LX LUBRICATION & MAINTENANCE 0 - 25

API QUALITY CLASSIFICATION

This symbol 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.

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 75W-90.

LUBRICANTS AND GREASES

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.

LUBRICANT RECOMMENDATIONS

LUBRICANTS AND GREASES

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.

Page 44

0 - 26 LUBRICATION & MAINTENANCE LX

Chassis

Component Fluid, Lubricant, or Genuine Part

Steering Gear & Linkage, Ball Joints, Prop Shafts & Yokes, Wheel Bearings

MoparT Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB

Body

Component Fluid, Lubricant, and Genuine Part

Hinges:

Door & Hood MoparT Engine Oil

Swing Gate MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

Latches: Door, Hood/Safety Catch, Swing Gate

Seat Regulator & Track MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Lock Cylinders MoparT Lock Cylinder Lube

MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

TOWING

STANDARD PROCEDURE - TOWING

WARNINGS AND CAUTIONS

WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR REAR BUMPER. DO NOT GO UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. 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 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

• FWD vehicles, use of a flat bed towing device or

a wheel lift is recommended.

• AWD vehicles, a flat bed towing device is recom-

mended.

When using a wheel lift towing device, be sure the 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.

Page 45

LX LUBRICATION & MAINTENANCE 0 - 27

CAUTION:

• Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia and air dams will result.

• The only approved method of towing is with a flat bed truck.

• Do not tow the vehicle from the rear. Damage to the rear sheet metal, liftgate and fascia will occur.

• Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transmission

may result.

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 the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels from the front end of the vehicle and lower the front end closer to the ground, to increase the ground clearance at the rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake 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 BED TOWING TIE DOWNS

CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result.

The vehicle can be tied to a flat bed device using the pair of front transportation slots on the bottom surface of the rails, behind the front wheels. The rear transportation slots are on the bottom of the left bumper extension and in the bracket extending inboard of the right bumper extension.

TOWING – FRONT WHEEL DRIVE

Your vehicle may be towed under the following conditions: The gear selector must be in NEUTRAL, the distance to be traveled must not exceed 100 miles (160 km), and the towing speed must not exceed 44 mph (72 km/h). Exceeding these towing limits may cause a transmission gear train failure. If the transmission is not operative, or if the vehicle is to be towed more than 100 miles (160 km), the vehicle must be towed with the front wheels off the ground.

TOWING – ALL WHEEL DRIVE

Your vehicle may be towed under the following conditions: The gear selector must be in NEUTRAL, the distance to be traveled must not exceed 100 miles (160 km), the towing speed must not exceed 44 mph (72 km/h), and both front and rear wheels must be on the ground. If your vehicle must be towed farther or at a higher rate of speed, it must be transported on a flat bed truck.

ALL TRANSMISSIONS

• Do not attempt to tow this vehicle from the front with sling type towing equipment. Damage to the front fascia

will result.

• The only approved method of towing is with a flat bed truck.

• Do not tow the vehicle from the rear. Damage to the rear sheet metal, liftgate and fascia will occur.

• Do not push or tow this vehicle with another vehicle as damage to the bumper fascia and transmission may

result.

If it is necessary to use the accessories while being towed (wipers, defrosters, etc.), the key must be in the ON position, not the ACCESSORY position. Make certain the transmission remains in NEUTRAL.

Page 46

0 - 28 LUBRICATION & MAINTENANCE LX

WITHOUT THE IGNITION KEY

Special care must be taken when the vehicle is towed with the ignition in the LOCK position. The only approved method of towing with out the ignition key is with a flat bed truck. Proper towing equipment is necessary to prevent damage to the vehicle.

TOWING THIS VEHICLE BEHIND ANOTHER VEHICLE (Flat towing with all four wheels on the ground)

Flat towing of vehicles equipped with an automatic transmission, is only permitted within the limitations described in this section.

FLAT TOWING WITH TOW BAR

• Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44

mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral.

• AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOWING EQUIP-

MENT in this section.

TOWING THIS VEHICLE BEHIND ANOTHER VEHICLE WITH A TOW DOLLEY

The manufacture does not recommend that you tow an All-Wheel Drive (AWD) or front wheel drive vehicle on a tow dolley. Vehicle damage may occur.

Page 47

LX SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

SUSPENSION

STANDARD PROCEDURE

LUBRICATION .........................1

FRONT .................................2

REAR .................................50

WHEEL ALIGNMENT .....................135

SUSPENSION

STANDARD PROCEDURE LUBRICATION

There are no serviceable lubrication points on the front or rear suspension. The ball joints are sealed-for-life and require no maintenance.

Page 48

2 - 2 FRONT LX

FRONT

TABLE OF CONTENTS

page page

FRONT

DESCRIPTION ..........................2

SPECIFICATIONS

FRONT SUSPENSION FASTENER TORQUE . . 3

HUB / BEARING

DESCRIPTION ..........................3

DIAGNOSIS AND TESTING

HUB AND BEARING ....................4

REMOVAL ..............................4

INSTALLATION ..........................5

KNUCKLE

REMOVAL ..............................5

DISASSEMBLY - BALL JOINT ..............10

ASSEMBLY - BALL JOINT .................13

INSTALLATION .........................14

BALL JOINT - LOWER

DESCRIPTION .........................17

DIAGNOSIS AND TESTING

LOWER BALL JOINT ...................17

ARM - LOWER CONTROL

REMOVAL .............................17

FRONT

INSTALLATION .........................22

SHOCK ASSEMBLY

REMOVAL .............................26

DISASSEMBLY .........................29

ASSEMBLY ............................31

INSTALLATION .........................33

BAR - STABILIZER

REMOVAL .............................35

INSTALLATION .........................37

STRUT - TENSION

REMOVAL .............................39

INSTALLATION .........................41

BALL JOINT - UPPER

DESCRIPTION .........................43

DIAGNOSIS AND TESTING

UPPER BALL JOINT ...................43

ARM - UPPER CONTROL

REMOVAL .............................44

INSTALLATION .........................47

DESCRIPTION

The front suspension is a long and short arm design. Each side of the front suspension includes the following components:

• Hub And Bearing (not shown)

• Knuckle (3)

• Lower Control Arm (5)

• Shock Assembly (1)

• Stabilizer Bar (6) and Link (7)

• Tension Strut (4)

• Upper Control Arm (2)

Page 49

LX FRONT 2 - 3

SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

ENGINE CRADLE MOUNTING BOLTS 185 136 — SPINDLE HUB NUT 250 184 — KNUCKLE DUST SHIELD SCREWS 10 7 89 LOWER CONTROL ARM CRADLE NUT 176 130 — LOWER CONTROL ARM BALL JOINT

NUT TENSION STRUT CRADLE NUT 176 130 — TENSION STRUT BALL JOINT NUT 68 + 90° TURN 50 + 90° TURN — SHOCK ABSORBER LOWER

MOUNTING BOLT SHOCK ABSORBER UPPER

MOUNTING NUTS SHOCK ABSORBER SHAFT NUT 95 70 — STABILIZER BAR LINK SHOCK NUT 146 108 — STABILIZER BAR LINK NUT 146 108 — STABILIZER BAR ISOLATOR RETAINER

BOLTS STABILIZER BAR HEAT SHIELD

SCREWS UPPER CONTROL ARM BALL JOINT

NUT UPPER CONTROL ARM BODY NUTS 75 55 — OUTER TIE ROD BALL JOINT NUT 85 63 — TIE ROD JAM NUT 75 55 —

68 + 90° TURN 50 + 90° TURN —

174 128 —

27 20 239

60 44 —

7562

47 + 90° TURN 35 + 90° TURN —

HUB / BEARING

DESCRIPTION

The front wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the center of the spindle using a retaining nut. It has five wheel mounting studs (3) on the hub flange.

The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing. Otherwise, the hub and bearing is serviced only as a complete assembly.

If a vehicle is equipped with antilock brakes, the tone wheel (2) for the wheel speed sensor is pressed onto the hub and bearing.

Page 50

2 - 4 FRONT LX

DIAGNOSIS AND TESTING HUB AND BEARING

Note: The hub and bearing is designed for the life of the vehicle and should require no maintenance.

With wheel and brake rotor removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced.

Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly.

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

3. Access and remove front brake rotor. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL)

4. Remove dust cap (2).

5. Remove hub nut (1).

6. Slide hub and bearing off knuckle spindle.

Page 51

LX FRONT 2 - 5

INSTALLATION

1. Slide hub and bearing onto knuckle spindle.

2. Install hub nut (1) on end of spindle. Tighten hub nut to 250 N·m (184 ft. lbs.) torque.

3. Install brake rotor, then disc brake caliper and adapter assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - INSTALLATION)

4. Install dust cap (2) on hub and bearing.

5. Install tire and wheel assembly (1) (Refer to 22 TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

6. Lower vehicle.

7. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.

8. Check and adjust brake fluid level as necessary.

KNUCKLE

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

Page 52

2 - 6 FRONT LX

2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

3. Remove screw (3) fastening wheel speed sensor to knuckle (1). Pull sensor head (4) out of knuckle.

4. Remove wheel speed sensor cable routing clip (2) from brake flex hose routing bracket (5).

5. Remove screw (3) fastening brake flex hose routing bracket (2) to knuckle (4).

6. Access and remove front brake rotor. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL)

Page 53

LX FRONT 2 - 7

7. Remove nut (1) from outer tie rod end stud.

8. Using Puller (2), Special Tool 9360, separate tie rod stud (1) from knuckle.

9. Loosen nut (4) attaching upper ball joint stud (1) to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help

keep end of stud from distorting while using Puller in next step.

Page 54

2 - 8 FRONT LX

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

10. Using Puller (2), Special Tool 9360, separate

upper ball joint stud (1) from knuckle.

11. Remove nut (4) from end of upper ball joint stud

(1).

12. Loosen nut (3) attaching tension strut (2) ball joint

stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will

help keep end of stud from distorting while using Puller in next step.

Page 55

LX FRONT 2 - 9

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

13. Using Puller (1), Special Tool 9360, separate ten-

sion strut ball joint stud (2) from knuckle.

14. Remove nut (3) from end of tension strut (2) ball

joint stud.

15. Loosen nut (5) attaching ball joint stud to lower

control arm (4). Back nut off until nut is even with end of stud. Keeping nut on at this location will

help keep end of stud from distorting while using Puller in next step.

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

16. Using Puller (1), Special Tool 9360, separate ball

joint stud (2) from lower control arm.

Page 56

2 - 10 FRONT LX

17. Remove nut (5) from end of ball joint stud attach-

ing lower control arm to knuckle.

18. Remove knuckle from vehicle.

19. If hub and bearing needs to be removed, perform

the following: a. Remove dust cap (2). b. Remove hub nut (1). c. Slide hub and bearing off knuckle spindle.

20. If shield needs to be removed from knuckle,

remove 3 mounting screws, then shield.

DISASSEMBLY - BALL JOINT

Note: To perform this procedure it works best to mount Press (3), Special Tool C-4212F, in a vise and hold the component in your hands.

1. Place Receiver (1), Special Tool 9320-5, into cup area of Press (3), Special Tool C-4212F, as shown and tighten set screw.

2. Place Remover (2), Special Tool 9320-3, onto end of screw-drive of Press (3), Special Tool C-4212F, as shown.

Page 57

LX FRONT 2 - 11

3. Using a pair of snap-ring pliers (2), remove snapring (3) from bottom of ball joint (1).

4. Install halves of Support Clamp (1), Special Tool 9320-1, over ball joint (2) and around knuckle surface (3) as shown. Install and snug Support Clamp (1) screws from underside.

5. Position knuckle (1) over tools guiding top of ball joint inside of Receiver (6), then hand tighten Press screw-drive (4) until Remover (3) comes into contact with bottom of ball joint (2).

Page 58

2 - 12 FRONT LX

Note: When positioning knuckle over tools, make sure Receiver, Special Tool 9320-5, sets into recessed area (4) of Support Clamp, Special Tool 9320-1.

6. Tighten Press screw-drive (4) forcing ball joint out of knuckle (1) and into Receiver (6).

7. Loosen screw-drive (4) and remove knuckle (1) from Press. Remove ball joint from Receiver (6).

8. Remove Support Clamp (1) from knuckle (3).

Page 59

LX FRONT 2 - 13

ASSEMBLY - BALL JOINT

Note: To perform this procedure it works best to mount Press (3), Special Tool C-4212F, in a vise and hold the component in your hands.

1. Place Installer (1), Special Tool 9320-4, into cup area of Press (3), Special Tool C-4212F, as shown and tighten set screw.

2. Place Remover (2), Special Tool 9320-3, onto end of screw-drive of Press (3), Special Tool C-4212F, as shown.Note: This is the reverse of how

Remover is installed on screw-drive for removal.

3. Start NEW ball joint (1) into bore of knuckle (2).

4. Position knuckle (1) over tools guiding top of ball joint inside of Installer (5) until outside flange of ball joint (4) comes into contact with Installer, then hand tighten Press screw-drive (3) until Remover (2) comes into contact with bottom of knuckle (1).

5. Using hand tools, tighten screw-drive (3), pressing ball joint into knuckle until flange (4) comes to a stop against the knuckle.

6. Loosen screw-drive and remove knuckle from Press.

Page 60

2 - 14 FRONT LX

7. Install snap-ring (3) into groove on bottom of ball joint.

8. Inspect ball joint for proper fit. Make sure seal boot is uniform and wire rings are in place.

INSTALLATION

1. If shield needs to be installed on knuckle, place shield in place and attach to knuckle using 3 screws. Tighten screws to 10 N·m (89 in. lbs.) torque.

2. If hub and bearing needs to be installed on knuckle, perform the following:

a. Slide hub and bearing onto knuckle spindle. b. Install hub nut (1) on end of spindle. Tighten

hub nut to 250 N·m (184 ft. lbs.) torque.

c. Install dust cap (2).

Page 61

LX FRONT 2 - 15

3. Place knuckle (1) over lower ball joint studs on vehicle and loosely install NEW nuts by hand.

CAUTION: It is important to tighten nuts as described in following steps to avoid damaging ball stud joints.

4. Completely install NEW nut (5) on ball joint stud attaching lower control arm (4) to knuckle (1). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 68 N·m + 90° turn (50 ft. lbs. + 90° turn) torque.

5. Completely install NEW nut (3) on ball joint stud attaching tension strut (2) to knuckle (1). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 68 N·m + 90° turn (50 ft. lbs. + 90° turn) torque.

CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.

6. Place upper ball joint stud (1) through hole in top of knuckle and install nut (4). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 N·m + 90° turn (35 ft. lbs. + 90° turn) torque.

CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.

7. Place outer tie rod stud through hole in knuckle (2) and install nut (1). Tighten nut by holding stud with a wrench while turning nut with another wrench. Tighten nut using crow foot wrench on torque wrench to 85 N·m (63 ft. lbs.) torque.

8. Install brake rotor, then disc brake caliper and adapter assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - INSTALLATION)

Page 62

2 - 16 FRONT LX

9. Install screw (3) fastening brake flex hose routing bracket (2) to knuckle (4). Tighten screw to 12 N·m (106 in. lbs.) torque.

10. Install wheel speed sensor head (4) into knuckle

and install mounting screw (3). Tighten screw to 11 N·m (95 in. lbs.) torque.

11. Attach wheel speed sensor cable and routing clip

(2) to brake flex hose routing bracket (5).

12. Install tire and wheel assembly (1) (Refer to 22 -

TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

13. Lower vehicle.

14. Pump brake pedal several times to ensure vehicle

has a firm brake pedal before moving vehicle.

15. Check and adjust brake fluid level as necessary.

16. Perform wheel alignment. (Refer to 2 - SUSPEN-

SION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

Page 63

LX FRONT 2 - 17

BALL JOINT - LOWER

DESCRIPTION

There are two lower ball joints on the RWD version of this vehicle. One in for the lower control arm and the other for the tension strut. The ball joint for the lower control arm is pressed into the knuckle and the ball joint for the tension strut is part of the tension strut. The ball joints are both “sealed for life” components and cannot be maintenance lubricated. These ball joints are lubricated for life at the time of assembly. No attempt should be made to

ever add any lubrication to these ball joints.

The ball joint for the lower control arm is a ball joint and seal boot cartridge type and can be replaced as a separate component of the knuckle. The boot cannot be serviced separately. To service this ball joint, (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - DISASSEMBLY).

Neither the ball joint, not the seal boot for the tension strut can be serviced as a separate component. They entire tension strut must be replaced if either are damaged.

The ball joint connection to the lower control arm and the ball joint connection at the knuckle is achieved by an interference fit created by the tapered stud of the ball joint and a tapered hole in the steering knuckle. The ball joint stud is retained in the steering knuckle using a locking nut.

DIAGNOSIS AND TESTING LOWER BALL JOINT

1. Raise vehicle on a drive-on hoist.

Note: If a drive-on hoist is not available, use wooden blocks with jack stands to support the lower control arm in the ball joint area. Place the jack stands appropriately and lower the hoist placing weight on the lower control arm. The lower control arms should now be supporting the vehicle weight.

2. Using a jack, lift the front end off the hoist and position a wooden block underneath lower control arm supporting that corner of the vehicles weight.

3. Remove tire and wheel assembly. (Refer to 22 - TIRES/WHEELS - REMOVAL)

4. If checking ball joint for lower control arm – Attach a dial indicator to base of lower control arm, then align dial indicator’s contact pointer with direction of stud axis and touch machined flat on knuckle near ball joint. Zero dial indicator.

5. If checking ball joint for tension strut – Attach a dial indicator to base of tension strut, then align dial indicator’s contact pointer with direction of stud axis and touch machined flat on knuckle near ball joint. Zero dial indicator.

Note: Use care when applying the load to the knuckle so as to not damage components of suspension.

6. Insert a pry bar and rest it against bottom of lower control arm or tension strut (depending on which is being tested) and use lever principle to push knuckle downward until dial indicator no longer moves.

7. Record any ball joint movement. If movement in the lower control arm exceeds 1.5 mm (.059 in.), the ball joint is faulty.

8. If the ball joint for the lower control arm needs replaced, it can be serviced separately. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - DISASSEMBLY)

9. If the tension strut ball joint needs replaced, the entire tension strut needs to be replaced. (Refer to 2 - SUSPENSION/FRONT/TENSION STRUT - REMOVAL)

ARM - LOWER CONTROL

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

Page 64

2 - 18 FRONT LX

2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

3. Remove belly pan. (Refer to 23 - BODY/EXTERIOR/BELLY PAN - REMOVAL)

4. Remove screws (1) fastening stabilizer bar heat shield (3) on side of control arm repair.

5. Remove bolts (2) fastening stabilizer bar bushing retainer (1) in place on side of control arm repair.

Page 65

LX FRONT 2 - 19

6. Remove retainer halves (1)(2) from around stabilizer bar bushing (3).

7. Utilizing slit, remove bushing (1) from stabilizer bar (2).

Note: In the following step, the lower control arm cradle bolt (3) is accessed through the opening (2) created by removal of the bushing from the stabilizer bar (4).

CAUTION: If the lower control arm bolt at the engine cradle has a torx head, it is a special wheel alignment adjustment bolt and the bolt head must not be rotated in the vehicle or damage to the bolt and control arm bushing will result. While holding the bolt in place with a wrench, remove the nut, then slide the bolt out of the bushing and cradle taking note of bolt positioning in lower control arm bushing for reassembly purposes. The bolt needs to be installed in the same position as removed to make sure wheel camber and caster return to adjusted position.

Page 66

2 - 20 FRONT LX

8. Remove bolt and nut (1) securing lower control arm (2) to engine cradle. If the bolt has a torx head (see above note), remove the bolt and nut by holding the bolt in place with a wrench, removing the nut, then sliding the bolt out of the bushing and cradle while taking note of bolt positioning in lower control arm bushing for reassembly purposes.

9. Remove bolt (3) securing shock assembly (1) to lower control arm (4).

10. Remove screw (3) fastening wheel speed sensor

to knuckle (1). Pull sensor head (4) out of knuckle.

11. Remove wheel speed sensor cable routing clip (2)

from brake flex hose routing bracket (5).

Page 67

LX FRONT 2 - 21

12. Loosen nut (5) attaching ball joint stud to lower

control arm (4). Back nut off until nut is even with end of stud. Keeping nut on at this location will

help keep end of stud from distorting while using Puller in next step.

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

13. Using Puller (1), Special Tool 9360, separate ball

joint stud (2) from lower control arm.

14. Remove nut (5) from end of ball joint stud attach-

ing lower control arm to knuckle.

15. Pry knuckle downward and slide ball joint stud out

of lower control arm. Position knuckle outward, away from lower control arm.

16. Slide lower control arm out of engine cradle and

remove from vehicle.

Page 68

2 - 22 FRONT LX

INSTALLATION

Note: If installing a lower control arm engine cradle bolt that is a wheel alignment adjustment bolt (lengthwise grooved shaft), make sure to install it in the same position which it was in upon removal. For more details on installation of this special bolt, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

1. Slide lower control arm (4) into position in engine cradle and install mounting bolt from rear.

2. Install nut (1) on lower control arm cradle bolt, but do not tighten at this time.

Page 69

LX FRONT 2 - 23

3. Pull knuckle (1) downward and position lower control arm (4) over ball joint stud. Release knuckle, guiding stud into lower control arm. Install NEW nut (5) on ball joint stud attaching lower control arm (4) to knuckle (1). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 68 N·m + 90° turn (50 ft. lbs. + 90° turn) torque.

4. Install wheel speed sensor head (4) into knuckle and install mounting screw (3). Tighten screw to 11 N·m (95 in. lbs.) torque.

5. Attach wheel speed sensor cable and routing clip (2) to brake flex hose routing bracket (5).

6. Install lower shock mounting bolt (3) attaching shock assembly (1) to lower control arm (4). Do

not tighten bolt at this time.

Page 70

2 - 24 FRONT LX

7. Install tire and wheel assembly (1) (Refer to 22 TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

8. Lower vehicle.

CAUTION: Because stabilizer bar is disconnected at cradle it is important to use extra care while moving vehicle to alignment rack/drive-on lift.

9. Position vehicle on an alignment rack/drive-on lift.

10. Tighten lower shock mounting bolt (3) to 174 N·m

(128 ft. lbs.) torque.

11. Perform wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

CAUTION: If the control arm engine cradle bolt is a wheel alignment adjustment bolt (lengthwise grooved shaft), be sure to only tighten the nut. Do not rotate the bolt or damage to the bushing will occur.

12. Once camber is found to be within specifications,

using a crowfoot wrench, tighten lower control arm cradle bolt nut (1) to 176 N·m (130 ft. lbs.) torque while holding the bolt stationary.

CAUTION: Because of stabilizer bushing outer shape, it is very important to install bushings in position discussed in following step.

13. Utilizing slit in bushing, install stabilizer bar bush-

ing (1) against locating collar on stabilizer bar (2) as shown. Make sure slit in bushing is positioned toward rear of vehicle.

Page 71

LX FRONT 2 - 25

14. Install stabilizer bar bushing retainer halves (1)(2)

around bushing (3).

15. Install bolts (2) securing stabilizer bar bushing

retainer halves (2) to cradle. Tighten bolts (2) to 60 N·m (44 ft. lbs.) torque.

16. Install stabilizer bar heat shield (3) over stabilizer

bar bushing retainer. Install mounting screws (1).

17. Install belly pan. (Refer to 23 - BODY/EXTERIOR/

BELLY PAN - REMOVAL)

Page 72

2 - 26 FRONT LX

SHOCK ASSEMBLY

REMOVAL

1. Remove front shock tower cap (1) from top of shock assembly (4).

2. Remove three nuts (2) fastening shock assembly (4) to shock tower (3).

3. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

4. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

Page 73

LX FRONT 2 - 27

5. Remove nut (2) fastening stabilizer link (3) to shock assembly (1). Slide link ball joint stem from shock assembly.

6. Remove bolt (3) securing shock assembly (1) to lower control arm (4).

7. Disconnect wheel speed sensor cable routing clip (2) at brake tube bracket (3).

Page 74

2 - 28 FRONT LX

8. Loosen nut (4) attaching upper ball joint stud (1) to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help

keep end of stud from distorting while using Puller in next step.

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

9. Using Puller (2), Special Tool 9360, separate upper ball joint stud (1) from knuckle.

10. Remove nut (4) from end of upper ball joint stud

(1).

11. Tip top of knuckle outward using care not to over-

extend bake flex hose.

12. Remove shock assembly from vehicle.

Page 75

LX FRONT 2 - 29

DISASSEMBLY

The shock assembly must be removed from vehicle for it to be disassembled and assembled. For shock assembly disassembly and assembly, use of shock Spring Compressor, Pentastar Service Equipment

(PSE) tool W-7200, or equivalent, is recommended to compress coil spring. Follow manufacturer’s instructions closely.

WARNING: Do not remove shock shaft nut before coil spring is compressed. Coil spring is held under pressure and must be compressed, removing spring tension from upper and lower mounts, before shock removal.

1. Position shock assembly coil spring (1) on hooks (2) of Compressor following manufacturers instructions. Install clamp securing shock to lower spring coil.

2. Position Compressor upper hooks (1) on upper coil spring (2) following manufacturers instructions. To ease installation, rotate shock as necessary positioning shock in compressor so that upper spring coil ends (step in upper mount) at straight outward position from Compressor.

3. Compress coil spring until all spring tension is removed from upper mount.

Page 76

2 - 30 FRONT LX

4. Position Wrench (2), Special Tool 9362, on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, remove nut from shock shaft using Wrench.

5. Remove clamp from bottom of coil spring and remove shock and lower isolator out through bottom of coil spring.

Note: If upper mount or coil spring needs to be serviced, proceed with next step, otherwise, proceed with step 8.

6. Remove upper mount (1) from shock shaft and coil spring.

Note: Prior to removing spring from compressor, note location of lower spring coil end in relationship to compressor to ease assembly of components later.

7. Back off Compressor drive, releasing tension from coil spring. Push back compressor upper hooks and remove coil spring from Compressor.

Page 77

LX FRONT 2 - 31

8. Remove jounce bumper (4) from shock shaft by pulling straight up and off.

9. Remove lower isolator (2) from shock body by pulling straight up and off shock shaft.

10. Inspect shock assembly components for following

and replace as necessary:

• Inspect shock (3) for any condition of shaft binding over full stroke of shaft.

• Inspect upper mount (5) for cracks and distortion and its retaining studs for any sign of damage.

• Inspect upper spring isolator (5) for severe deterioration.

• Inspect lower spring isolator (2) for severe deterioration.

• Inspect dust shield for tears and deterioration.

• Inspect coil spring (1) for cracks in the coating

and corrosion.

• Inspect jounce bumper (4) for cracks and signs of deterioration.

ASSEMBLY

CAUTION: Use care not to damage coil spring coating during spring assembly. Damage to coating will jeopardize its corrosion protection.

Note: Left and right springs must not be interchanged.

Note: If coil spring has been removed from spring compressor, proceed with next step, otherwise, proceed with step 4.

1. Place coil spring (part number tag end upward) in compressor lower hooks following manufacturers instructions. To ease shock reassembly, rotate coil spring around until upper coil (1) ends at straight outward position from Compressor. Proper orientation of spring to upper mount (once installed) is necessary.

2. Position compressor upper hooks over coil spring following manufacturers instructions.

3. Compress coil spring far enough to allow shock installation.

Page 78

2 - 32 FRONT LX

4. If separated, install upper mount (1) onto coil spring (2). Match step in upper isolator to end of spring coil.

5. Install lower spring isolator (2) on shock body (3).

6. Install jounce bumper (4) on shock shaft, small end first.

7. Install shock through bottom of coil spring until lower spring isolator (on shock) contacts lower end of coil spring. Match step built into isolator (1) to lower coil end (2). Once in this position, stabilizer bar bracket, or clevis key on AWD models, should point straight inward toward Compressor body. If not, rotate isolator on shock body until alignment is achieved when isolator is correctly positioned with lower spring coil.

8. Install clamp to hold shock and coil spring together.

Page 79

LX FRONT 2 - 33

9. Install retaining nut (1) on shock shaft (2) as far as possible by hand. Make sure nut is installed far enough for 8 mm socket to grasp hex (2) on end of shaft for tightening.

10. Install Wrench (on end of a torque wrench), Spe-

cial Tool 9362, on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, tighten nut using Wrench to 90 N·m (66 ft. lbs.) torque.

11. Slowly release tension from coil spring by backing

off Compressor drive fully. As tension is relieved, make sure shock components are properly in place.

12. Remove clamp from lower end of coil spring and

shock. Push back spring compressor upper and lower hooks, then remove shock assembly from spring compressor.

13. Install shock assembly on vehicle. (Refer to 2 -

SUSPENSION/FRONT/SHOCK - INSTALLATION)

INSTALLATION

1. Place shock assembly into front suspension using reverse direction in which it was removed.

CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.

2. Place upper ball joint stud (1) through hole in top of knuckle and install nut (4). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 N·m + 90° turn (35 ft. lbs. + 90° turn) torque.

Page 80

2 - 34 FRONT LX

3. Connect wheel speed sensor cable routing clip (2) at brake tube bracket (3).

4. Install lower shock mounting bolt (3) attaching shock assembly (1) to lower control arm (4). Do

not tighten bolt at this time.

5. Slide stabilizer link (3) ball joint stem into shock assembly from front. Install nut fastening link (3) to shock assembly (1). Tighten nut by holding ball joint stud while turning nut. Tighten nut using crow foot wrench on torque wrench to 146 N·m (108 ft. lbs.) torque.

Page 81

LX FRONT 2 - 35

6. Install tire and wheel assembly (1) (Refer to 22 TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

7. Lower vehicle.

8. Install three nuts (2) fastening shock assembly (4) to shock tower (3). Tighten nuts to 27 N·m (20 ft. lbs.) torque.

9. Align shock tower cap (1) with shock mounting nuts (2) and snap into place.

BAR - STABILIZER

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

2. Remove belly pan. (Refer to 23 - BODY/EXTERIOR/BELLY PAN - REMOVAL)

Page 82

2 - 36 FRONT LX

3. On each side of vehicle, remove screws (1) fastening stabilizer bar heat shield (3). Remove heat shield.

4. On each side of vehicle, remove bolts (2) fastening stabilizer bar isolator retainer (1) in place.

5. On each side of vehicle, remove retainer halves (1)(2) from around stabilizer bar isolator (3).

Page 83

LX FRONT 2 - 37

6. Utilizing slit, remove each isolator (1) from stabilizer bar (2).

7. On each side of vehicle, remove nut (5) fastening stabilizer link (3) to stabilizer bar (4). Slide link ball joint stem (1) from bar, then remove bar from vehicle.

INSTALLATION

Note: When attaching stabilizer link to stabilizer bar, make sure link ball joint stem is pointed inboard toward engine cradle.

1. On each side of vehicle, raise stabilizer bar (4) to stabilizer link (3) and slide link ball joint stem (1) through mounting hole in bar. Loosely install nut (5) at this time.

Page 84

2 - 38 FRONT LX

CAUTION: Because of stabilizer isolator outer shape, it is very important to install isolators in position discussed in following step.

2. Utilizing slit in isolator, install each stabilizer bar isolator (1) on bar resting against locating collar (2) as shown. Make sure slit in isolator is positioned toward rear of vehicle.

3. On each side of vehicle, install stabilizer bar isolator retainer halves (1)(2) around isolator (3).

4. On each side of vehicle, install bolts (2) securing stabilizer bar isolator retainer halves (2) to cradle. Tighten bolts (2) to 60 N·m (44 ft. lbs.) torque.

Page 85

LX FRONT 2 - 39

5. On each side of vehicle, install stabilizer bar heat shield (3) over stabilizer bar isolator retainer. Install mounting screws (1).

6. While holding stem from rotating at hex (1) or flat (2) tighten stabilizer link nuts at each end of stabilizer bar (4) to 146 N·m (108 ft. lbs.) torque.

7. Install belly pan. (Refer to 23 - BODY/EXTERIOR/BELLY PAN - REMOVAL)

8. Lower vehicle.

STRUT - TENSION

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

Page 86

2 - 40 FRONT LX

2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

3. Remove belly pan. (Refer to 23 - BODY/EXTERIOR/BELLY PAN - REMOVAL)

4. Loosen nut (3) attaching tension strut (2) ball joint stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will

help keep end of stud from distorting while using Puller in next step.

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

5. Using Puller (1), Special Tool 9360, separate tension strut ball joint stud (2) from knuckle.

Page 87

LX FRONT 2 - 41

6. Remove nut (3) from end of tension strut (2) ball joint stud.

7. Rotate knuckle outward and push ball joint upward, out of knuckle.

8. Remove nut and bolt (2) securing tension strut (1) to engine cradle (3).

9. Slide tension strut out of cradle bracket and remove from vehicle.

INSTALLATION

Note: If installing a tension strut engine cradle bolt that is a wheel alignment adjustment bolt (lengthwise grooved shaft), make sure to install it in the same position which it was in upon removal. For more details on installation of this special bolt, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

Page 88

2 - 42 FRONT LX

1. Slide bushing end of tension strut (1) into cradle bracket (3).

2. Install mounting bolt (2) from front through cradle and bushing.

3. Install nut (2), but do not tighten at this time.

4. Insert tension strut (2) ball joint stud downward, into knuckle hole.

6. Install tire and wheel assembly (1) (Refer to 22 - TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

7. Lower vehicle.

8. Position vehicle on an alignment rack/drive-on lift.

Page 89

LX FRONT 2 - 43

9. Perform wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)

CAUTION: If the tension strut engine cradle bolt is a wheel alignment adjustment bolt (lengthwise grooved shaft), be sure to only tighten the nut. Do not rotate the bolt or damage to the bushing will occur.

10. Once alignment is found to be within specifica-

tions, using a crowfoot wrench, tighten tension strut cradle bolt nut (2) to 176 N·m (130 ft. lbs.) torque while holding the bolt stationary.

11. Install belly pan. (Refer to 23 - BODY/EXTERIOR/BELLY PAN - REMOVAL)

BALL JOINT - UPPER

DESCRIPTION

The upper ball joint is pressed into the upper control arm. The ball joint is a “sealed for life” component and cannot be maintenance lubricated. This ball joint is lubricated for life at the time of assembly. No attempt should be made

to ever add any lubrication to this ball joint.

Neither the upper ball joint, nor the seal boot can be serviced as a separate component. The entire upper control arm must be replaced if either are damaged.

The ball joint connection at the knuckle is achieved by an interference fit created by the tapered stud of the ball joint and a tapered hole in the steering knuckle. The ball joint stud is retained in the steering knuckle using a locking nut.

DIAGNOSIS AND TESTING UPPER BALL JOINT

1. Raise vehicle on a drive-on hoist.

2. Using a jack, lift the front end off the hoist and position a wooden block underneath lower control arm supporting that corner of the vehicles weight.

3. Remove tire and wheel assembly. (Refer to 22 - TIRES/WHEELS - REMOVAL)

4. Attach a dial indicator to body of upper control arm, then align dial indicator’s contact pointer with direction of stud axis and touch machined flat on end of knuckle near ball joint. Zero dial indicator.

Note: Use care when applying the load to the knuckle so as to not damage components of suspension.

5. Insert a pry bar and rest it against top of upper control arm and use lever principle to push arm downward until dial indicator no longer moves.

6. Record any ball joint movement. If movement in the control arm exceeds 1.5 mm (.059 in.), the ball joint is faulty.

7. If the ball joint needs replaced, the entire upper control arm needs to be replaced. (Refer to 2 - SUSPENSION/ FRONT/UPPER CONTROL ARM - REMOVAL)

Page 90

2 - 44 FRONT LX

ARM - UPPER CONTROL

REMOVAL

1. If removing left upper control arm, remove and reposition coolant recovery container. (Refer to 7 - COOLING/ ENGINE/COOLANT RECOVERY CONTAINER - REMOVAL)

2. If removing right upper control arm, remove IPM from mount and reposition. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL)

3. Remove front shock tower cap (1) from top of shock assembly (4).

4. Remove three nuts (2) fastening shock assembly (4) to shock tower (3).

5. remove nuts (2) from upper control arm mounting bolts (1).

6. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

Page 91

LX FRONT 2 - 45

7. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

8. Disconnect wheel speed sensor cable routing clip (2) at brake tube bracket (3).

9. Loosen nut (4) attaching upper ball joint stud (1) to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help

keep end of stud from distorting while using Puller in next step.

Page 92

2 - 46 FRONT LX

CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

10. Using Puller (2), Special Tool 9360, separate

upper ball joint stud (1) from knuckle.

11. Remove nut (4) from end of upper ball joint stud

(1).

12. Pull shock assembly (3) downward until studs

clear shock tower (2), then pull it outward allowing access to upper control arm mounting bolts.

13. Remove upper control arm mounting (flag) bolts

(1).

14. Remove upper control arm (2) from bracket (3) in

shock tower (4).

Page 93

LX FRONT 2 - 47

INSTALLATION

1. Slide upper control arm (2) into bracket (3) located in shock tower (4).

2. Install upper control arm mounting (flag) bolts (1) through bracket, arm and tower. Position flags on bolt heads outward, toward wheel opening.

3. Move shock assembly (3) allowing studs to be inserted through shock tower (2) mounting holes.

4. Place upper ball joint stud (1) through hole in top of knuckle and install nut (4). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 N·m + 90° turn (35 ft. lbs. + 90° turn) torque.

5. Connect wheel speed sensor cable routing clip (2) at brake tube bracket (3).

Page 94

2 - 48 FRONT LX

6. Install tire and wheel assembly (1) (Refer to 22 TIRES/WHEELS - INSTALLATION). Tighten wheel mounting nuts (3) to 150 N·m (110 ft. lbs.) torque.

7. Lower vehicle to curb position.

8. Install nuts (2) on upper control arm body mounting bolts (1). Tighten nuts to 75 N·m (55 ft. lbs.) torque.

9. Install three nuts (2) fastening shock assembly (4) to shock tower (3). Tighten nuts to 27 N·m (20 ft. lbs.) torque.

10. Align shock tower cap (1) with shock mounting

nuts (2) and snap into place.

Page 95

LX FRONT 2 - 49

11. If installing left upper control arm, install coolant recovery container. (Refer to 7 - COOLING/ENGINE/COOLANT

RECOVERY CONTAINER - INSTALLATION)

12. If installing right upper control arm, install IPM. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTE-

GRATED POWER MODULE - INSTALLATION)

Page 96

2 - 50 REAR LX

REAR

TABLE OF CONTENTS

page page

REAR

DESCRIPTION .........................50

SPECIFICATIONS

REAR SUSPENSION FASTENER TORQUE . . 51

SPECIAL TOOLS

REAR SUSPENSION ...................52

HUB / BEARING

DESCRIPTION .........................53

DIAGNOSIS AND TESTING

HUB AND BEARING ...................53

REMOVAL .............................53

INSTALLATION .........................55

KNUCKLE

REMOVAL .............................58

INSTALLATION .........................61

CAMBER LINK

REMOVAL .............................64

INSTALLATION .........................67

COMPRESSION LINK

REMOVAL .............................73

INSTALLATION .........................73

SPRING LINK

REMOVAL .............................74

INSTALLATION .........................77

TENSION LINK

REMOVAL .............................79

INSTALLATION .........................82

TOE LINK

REMOVAL

LEFT LINK ...........................88

RIGHT LINK ..........................91

INSTALLATION

LEFT LINK ...........................93

RIGHT LINK ..........................97

SHOCK ABSORBER

DESCRIPTION .........................99

REMOVAL

STANDARD ..........................99

LOAD-LEVELING .....................101

INSTALLATION

STANDARD .........................104

LOAD-LEVELING .....................106

SPRING

REMOVAL ............................109

INSTALLATION ........................113

BAR - STABILIZER

REMOVAL ............................117

INSTALLATION ........................124

REAR

DESCRIPTION

This vehicle utilizes a five-link rear suspension including the following major components:

• Camber Link (1)

• Compression Link (5)

• Spring Link (2)

• Tension Link (6)

• Toe Link (3)

• Coil Spring

• Crossmember

• Hub And Bearing

• Knuckle (4)

• Shock Absorber

• Stabilizer Bar

The knuckle, camber link, compression link and tension link are aluminum castings. Extra care needs to be taken when servicing these components.

Service Procedures for the crossmember can be found in Frame And Bumpers. (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER - REMOVAL)

Page 97

LX REAR 2 - 51

SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Brake Caliper Adapter Knuckle Bolts 119 88 — Camber Link Crossmember Bolt 85 63 — Camber Link Knuckle Bolt 98 72 — Compression Link Crossmember Bolt 85 63 — Compression Link Knuckle Bolt 81 60 — Crossmember Mounting Bolts 180 133 — Hub And Bearing Mounting Bolts 68 50 — Hub Nut 213 157 — Parking Brake Cable Knuckle Bolt 8 — 71 Shock Absorber Mounting Bolts - Upper 52 38 — Shock Absorber Mounting Bolt Nut - Lower 72 53 — Spring Link Crossmember Bolt 108 80 — Spring Link Knuckle Nut 138 102 — Stabilizer Bar Isolator Retainer Bolts 61 45 — Stabilizer Link Nuts 61 45 — Tension Link Crossmember Bolt 85 63 — Tension Link Knuckle Bolt 98 72 — Toe Link Crossmember Nut 108 80 — Toe Link Knuckle Bolt 81 60 —

Page 98

2 - 52 REAR LX

SPECIAL TOOLS REAR SUSPENSION

Remover/Installer, Sleeve 9361

Page 99

LX REAR 2 - 53

HUB / BEARING

DESCRIPTION

The rear wheel bearing and wheel hub of this vehicle are a one piece sealed unit or hub and bearing unit type assembly. The hub and bearing (1) is mounted to the center of the knuckle using 4 bolts. It has five wheel mounting studs (2) on the hub flange.

The center of the hub and bearing is splined to match the axle half shaft.

DIAGNOSIS AND TESTING HUB AND BEARING

Note: The hub and bearing is designed for the life of the vehicle and should require no maintenance.

REMOVAL

1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

Page 100

2 - 54 REAR LX

2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).

3. While a helper applies brakes to keep hub from rotating, remove hub nut (1) from the half shaft (2).

Note: In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before guide pin bolts are removed, by grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. Never push on piston directly as it may get damaged.

4. Remove two bolts (1) securing disc brake caliper adapter (3) to knuckle (2).

5. Remove disc brake caliper and adapter (3) from knuckle as an assembly. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.

Dodge Magnum 2005 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual