Contents

Vehicle identification

• Body code plate
• Vehicle identification number
• Check digit of vehicle identification code (VIN)
• Vehicle certification plate
• Factory e - car brand label
• Combustion emission label (VECI)
• Manufacturer's plate

Lubrication and maintenance

• Grease
• Chassis
• Body
• Engine oil
• Coolant
• Transmission fluid
• Brake fluid
• Power steering fluid
• Refueling tanks
• Maintenance
• Chart B
• Graph A

Engine 2.0 l

• Description
• Specifications
• Oil pump
• Tightening torques for screw connections (nm)
• Cylinder head
• Camshaft oil seals
• Camshafts
• Valve cover
• Valve clearance compensators
• Valves and seats
• Valve rocker arms
• Valve springs and seals
• Engine block
• Crankshaft
• Crankshaft front oil seal
• Crankshaft rear oil seal
• Connecting rods and pistons
• Installing piston rings
• Clamp
• Torsional vibration damper
• Flywheel
• Engine Mount
• Engine lubrication system
• How it works
• Checking engine oil pressure
• Oil pump
• Intake manifold
• Exhaust manifold
• Checking the valve timing
• Timing belt and sprockets
• Installing the timing belt

Engine 2.4 l

• Description
• Specifications
• Oil pump
• Tightening torques for threaded connections (nm)
• Cylinder head
• Removing the cylinder head
• Installing the block head
• Camshaft oil seals
• Camshafts
• Valve cover
• Engine block
• Crankshaft
• Front crankshaft oil seal
• Crankshaft rear oil seal
• Flywheel
• Connecting rods and pistons
• Clamp
• Engine lubrication system
• Checking engine oil pressure
• Oil pump
• Intake manifold
• Exhaust manifold
• Timing belt covers
• Timing Belt and Sprockets
• Timing belt tensioner roller
• Balance shaft and holder assembly

Engine 2.7 l

• Description
• Specifications
• Tightening torques for threaded connections (NM)
• Air filter element
• Cylinder heads
• Camshaft (s)
• Front cylinder head cover
• Rear cylinder head cover
• Valve springs
• Valve stem seals
• Hydraulic slack adjusters
• Rocker arms
• Engine block
• Connecting rod bearings
• Connecting rod bolts
• Connecting rod side clearance
• Crankshaft
• Crankshaft main bearings
• Front crankshaft oil seal
• Crankshaft rear oil seal
• Piston and connecting rod
• Piston rings
• Flywheel
• Engine Mount
• Engine lubrication system
• Checking oil pressure
• Oil change
• Oil pan
• Oil pressure relief valve
• Oil pressure sensor
• Oil pump
• Intake manifold
• Exhaust manifold
• Timing drive system
• Check engine timing
• Timing chain cover
• Timing Chain & Sprockets

Fuel system

• Fuel supply system
• Specification
• Fuel flow valve
• Fuel level sensor
• Fuel pressure regulator
• Fuel pump
• Fuel pump unit
• Fuel rail
• Fuel tank
• Quick coupling device

Fuel injection system

• How it works
• Specification
• Throttle pedal
• Crankshaft position sensor
• Vehicle speed sensor
• Fuel Injector
• Fuel pump relay
• Idle air control valve
• Intake air temperature sensor
• Manifold absolute pressure sensor
• Oxygen sensor
• Throttle body
• Throttle control cable
• Throttle position sensor

Cooling system

• Checking for leaks in the cooling system
• Cooling system ventilation check
• Checking the deaeration of the cooling system
• Checking the coolant level
• Adding additional coolant
• Draining the coolant
• Cleaning the cooling system
• Filling the cooling system
• Specification

Clutch

• Specification
• Clutch pedal
• Clutch pedal latch switch
• Bearing and clutch release lever
• Clutch release cable (T350 models with an engine capacity of 2.0 l)
• Modular clutch

Gearbox

• Manual transmission T350
• Reversing light switch
• Differential
• Differential bearing cups
• Oil
• Gear shift cable
• Gear shifting mechanism
• Input shaft bearing and bushing
• Input shaft
• Output shaft bearing and raceway
• Secondary shaft
• Rear bearing oil feed chute
• Shifter shaft
• Gear selector rail bearing
• Shift shaft
• Gear selector shaft bearing
• Automatic transmission 40TE (41TE)
• Description
• Transmission identification
• Diagnostics and checks of 4XTE transmissions
• Removing the transmission
• Disassembly
• Build
• Installation
• Specifications
• Autostick function switch
• Differential
• Oil
• Gear shift cable
• Adjusting the shift linkage
• Input shaft coupling assembly
• Oil pump
• Planetary gear
• Locking cable for gear shifting
• Gearbox plugs
• Solenoid valves complete with pressure switches
• Input shaft speed sensor
• Output shaft speed sensor
• Torque converter
• Transmission control relay
• Transmission range sensor
• Valve housing

Half-axles

• General information
• Work
• Axle axis diagnostics
• Removing the axle shafts
• Installation
• Tightening torques for screw connections (nm)
• Special tools used to work with axle shafts
• Cover of the inner joint (CV joint)
• Cover clamp
• Cover clamp with lock
• Outer CV joint cover

Front suspension

• Tightening torques for threaded connections (Nm)
• Hub / bearing
• Rotary fist
• Lower ball joint
• Lower control arm
• Shock absorber assembly
• Anti-roll bar
• Upper ball joint
• Upper independent suspension arm

Rear suspension

• Operation
• Tightening torques for screw connections (Nm)
• Hub / bearing
• Hub and bearing diagnostics
• Rotary fist
• Reactive thrust
• Shock absorber assembly
• Anti-roll bar
• Trailing arm
• Upper ball joint
• Upper independent suspension arm

Wheel alignment

• Collapse
• Cross camber
• King pin cross angle
• Convergence
• Negative toe when cornering
• Dynamic Convergence Model
• Pivot angle (S.A.I.)
• Pitch angle (I. A.)
• Rear axle turning angle
• Suspension and steering diagnostics
• Preview wheel alignment
• Measuring curb height
• Wheel alignment
• Rear camber and toe
• Front camber and caster
• Camber adjustment procedure
• Front toe
• Wheel alignment
• All except DODGE SDD
• DODGE SDD

Steering

• Steering column and steering wheel
• Steering column intermediate shaft
• Steering gear
• Power steering pressure switch
• Outside tie rod
• Pump
• Discharge hose
• Return hose with tube
• Return hose to tank
• Hydraulic fluid hose
• Pulley

Braking system

• Basic braking system
• Warnings
• Removing air from the system
• Specification
• Brake fluid level sensor
• Aspirator valve
• Brake lines
• Front disc brake pads
• Rear disc brake pads
• Rear drum brake pads
• Drum brake shoe adjustment
• Front disc brake caliper
• Rear disc brake caliper
• Drum
• Brake fluid
• Connecting block
• Master brake cylinder
• Vacuum brake booster
• Pressure limiter
• Brake disc
• Base plate
• Working brake cylinder
• Parking brake
• Anti-lock braking system (ABS)
• Description
• Bleeding the ABS system
• Specification
• Front wheel speed sensor
• Rear wheel speed sensor
• RPM sensor
• Traction control switch
• Integrated control unit (ICU)

Body

• Precautions
• Lubrication
• Tightening torques of connections (Nm)
• Trunk
• Trunk lid
• Gas prop and loop
• Trunk lid latch
• Trunk lid striker
• Trunk lid lock cylinder
• Emergency release cable
• Doors
• Tape limiting the amount of door opening
• Door
• Door glass
• Door glass inner belt stabilizer
• Outside handle
• Loop
• Latch
• Latch striker
• Lock button corner lever
• Lock cylinder
• Rear vertical guide bar
• Glass regulator
• Additional overlay
• Door finger assembly
• Moisture protection pad
• Additional trim for the rear door
• Exterior Auxiliary drive belt mudguard
• Battery splash guard
• Front wheel mudguard
• Rear wheel mudguard
• Side body molding
• Bonnet cover
• Front wing
• Filler cap
• Radiator grill
• Radiator support bar
• Side mirror
• Spoiler
• Bonnet
• Hinge
• Hood
• Latch
• Latch Release Cable
• Support rod
• Instrument panel
• CD rim
• Glove compartment latch
• Dashboard node
• Dashboard center rim
• Dashboard block rim
• Dashboard end cap
• Dashboard inner rim
• Dashboard outer rim
• Dashboard top cover
• Left lower dashboard trim
• Bottom left panel of the silent device
• Bottom right panel of the silent device
• Dashboard trim, right
• Right bottom dashboard trim
• Impact protection device
• Control panel
• Upper dashboard trim
• Interior
• A-pillar trim
• B-pillar lower trim
• Headboard center panel
• Cowling panel
• Control panel
• Front dashboard
• Lower trim, rear side body
• Rear side trim panel
• Rear shelf trim panel
• Rearview Mirror
• Sun visor
• B-pillar upper trim
• Top molding
• Upper trim, rear side body
• Windscreen shock absorber
• Fixed glass
• Windscreen
• Rear glass

Bumpers and frame

• Bumpers
• Front fascia
• Rear trim
• Reinforcement of the rear bumper
• Framework
• Overall dimensions of the frame
• Front suspension cross member
• Rear suspension cross member
• Front hitch

Exhaust system

• Warning
• Exhaust Gas System
• Specification
• Catalytic converter (2.0 / 2.4 l engines)
• Front catalytic converter (2.7 l engine)
• Rear catalytic converter (2.7 l engine)
• Bypass pipe (2.7 l engine)
• Exhaust pipe: gap from bypass pipe to resonator pipe (2.7 l engine)
• Heat shields
• Muffler with pipe assembly
• Resonator with tube assembly

Tires and wheels

• Tires
• Description
• Identification of tires
• Radial tires
• Temporary (spare) tires
• Rearrangement of wheels
• Tire wear
• Tire pressures
• Wheels
• Description
• Inspection
• Aluminum wheel care
• Specification
• Front wheel studs
• Rear wheel studs

Electrical equipment

• Battery
• Fuses
• Terminal block
• Headlight relay
• Horn relay
• Heated rear window relay
• Location of connectors / grounds / connectors