Dodge Dakota 2002 Manuel utilisateur

GROUP TAB LOCATOR

Introduction

0Lubrication & Maintenance

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission and Transfer Case

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

INTRODUCTION

TABLE OF CONTENTS

page page

VEHICLE SAFETY CERTIFICATION LABEL

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

VEHICLE IDENTIFICATION NUMBER

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

VEHICLE EMISSION CONTROL INFORMATION

(VECI)

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

BODY CODE PLATE

DESCRIPTION ..........................4

INTERNATIONAL VEHICLE CONTROL &

DISPLAY SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS . . . 6

FASTENER IDENTIFICATION

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

FASTENER USAGE

DESCRIPTION - FASTENER USAGE .........9

THREADED HOLE REPAIR

DESCRIPTION - THREADED HOLE REPAIR ....9

METRIC SYSTEM

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

TORQUE REFERENCES

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

VEHICLE SAFETY

CERTIFICATION LABEL

DESCRIPTION

A vehicle safety certification label (Fig. 1) is

attached to every DaimlerChrysler Corporation vehi-

cle. The label certifies that the vehicle conforms to all

applicable Federal Motor Vehicle Safety Standards.

The label also lists:

•Month and year of vehicle manufacture.

•Gross Vehicle Weight Rating (GVWR). The gross

front and rear axle weight ratings (GAWR’s) are

based on a minimum rim size and maximum cold tire

inflation pressure.

•Vehicle Identification Number (VIN).

•Type of vehicle.

•Type of rear wheels.

•Bar code.

•Month, Day and Hour (MDH) of final assembly.

•Paint and Trim codes.

•Country of origin.

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

face.

Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -

TYPICAL

DR INTRODUCTION 1

VEHICLE IDENTIFICATION

NUMBER

DESCRIPTION

VIN CODING/LOCATIONS

The Vehicle Identification Number (VIN) plate is

located on the lower windshield fence near the left

a-pillar (Fig. 2). The VIN contains 17 characters that

provide data concerning the vehicle. Refer to the VIN

decoding chart to determine the identification of a

vehicle.

The VIN is also imprinted on the:

•Body Code Plate.

•Equipment Identification Plate.

•Vehicle Safety Certification Label.

•Frame rail.

To protect the consumer from theft and possible

fraud the manufacturer is required to include a

Check Digit at the ninth position of the VIN. The

check digit is used by the manufacturer and govern-

ment agencies to verify the authenticity of the vehi-

cle and official documentation. The formula to use

the check digit is not released to the general public.

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation

3 = Manufactured By DaimlerChrysler De Mexico

2 Make D = Dodge

3 Vehicle Type 2 = Incomplete with Side Airbag

3 = Truck with Side Airbag

6 = Incomplete Less Side Airbag

7 = Truck Less Side Airbag

4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.

H = 6,001-7,000 lbs.

J = 7,001-8,000 lbs.

K = 8,001-9,000 lbs.

L = 9,001-10,000 lbs.

M = 10,001-14,000 lbs.

W = Buses/Incomplete Vehicles with Hydraulic Brakes

5 Vehicle Line A = Ram Pickup 4X2

U = Ram Pickup 4X4

6 Series 1 = 1500

2 = 2500

3 = 3500 Less Dual Rear Wheels

4 = 3500 With Dual Rear Wheels

7 Body Style 6 = Conventional Cab

8 = Quad Cab Full Rear Doors

Fig. 2 VIN LOCATION

1 - DASH PANEL

2 - VIN CODE PLATE

2 INTRODUCTION DR

POSITION INTERPRETATION CODE = DESCRIPTION

8 Engine K = 3.7L 6 cyl. MPI Gasoline

N = 4.7L 8 cyl. MPI Gasoline

D = 5.7L 8 cyl. SMPI Gasoline

6 = 5.9L 6 cyl. Turbo Diesel

C = 5.9L 6 cyl. Turbo Diesel High Output

W = 8.0L 10 cyl. MPI Gasoline

Z = 5.9L 8 cyl. SMPI Gasoline Light Duty

9 Check Digit 0 through 9 or X

10 Model Year 3 = 2003

11 Plant Location S = Dodge City

G = Saltillo

J = St. Louis (North)

12 thru 17 Vehicle Build Sequence

VEHICLE EMISSION CONTROL

INFORMATION (VECI)

DESCRIPTION

All models have a Vehicle Emission Control Infor-

mation (VECI) Label. DaimlerChrysler permanently

attaches the label in the engine compartment (Fig.

3). The label cannot be removed without defacing

label information and destroying label.

The label contains the vehicle’s emission specifica-

tions and vacuum hose routings. All hoses must be

connected and routed according to the label.

The label also contains an engine vacuum sche-

matic. There are unique labels for vehicles built for

sale in the state of California and the country of

Canada. Canadian labels are written in both the

English and French languages.

The VECI label contains the following:

•Engine family and displacement

•Evaporative family

•Emission control system schematic

•Certification application

•Engine timing specifications (if adjustable)

•Idle speeds (if adjustable)

•Spark plug and gap

Fig. 3 VEHICLE EMISSIONS CERTIFICATION

INFORMATION LABEL

1 - VECI LABEL LOCATION

2 - RADIATOR SUPPORT

DR INTRODUCTION 3

VEHICLE IDENTIFICATION NUMBER (Continued)

BODY CODE PLATE

DESCRIPTION

The Body Code Plate (Fig. 5) is located on the right

front hydroform fender rail just behind the headlight

assembly (Fig. 4). There are seven lines of informa-

tion on the body code plate. Lines 5, 6, and 7 are not

used to define service information. Information reads

from left to right, starting with line 4 in the center of

the plate to line 1 at the bottom of the plate.

The last code imprinted on a vehicle code plate will

be followed by the imprinted word END. When two

vehicle code plates are required, the last available

spaces on the first plate will be imprinted with the

letters CTD (for continued).

When a second vehicle code plate is necessary, the

first four spaces on each row will not be used because

of the plate overlap.

BODY CODE PLATE—LINE 4

DIGITS 1 THROUGH 12

Vehicle Order Number

DIGITS 13, 14, AND 15

Transmission Codes

•DGT = 4–speed Automatic (46RE)

•DG4 = 4–speed Automatic (45RFE)

•DGP = 4–speed Automatic (47RE)

•DG8 = 4–speed Automatic (48RE)

•DDC = 5–speed Manual (NV3500)

•DDP = 5–speed Manual (NV4500)

•DEE = 6–speed Manual (NV5600)

DIGITS 16, 17, AND 18

Car Line Shell

•DR1=15004X2

•DR6=15004X4

•DR2=25004X2

•DR7=25004X4

•DR3=35004X2

•DR8=35004X4

Fig. 4 BODY CODE PLATE LOCATION

1 - FENDER

2 - RADIATOR CROSSMEMBER

3 - HYDROFORM FENDER RAIL

4 - RIVOT (2)

5 - BODY CODE PLATE

Fig. 5 BODY CODE PLATE

1 - PRIMARY PAINT

2 - SECONDARY PAINT

3 - TRANSMISSION CODE

4 - VEHICLE MODEL NUMBER

5 - ENGINE CODE

6 - INTERIOR TRIM CODE

7 - VEHICLE IDENTIFICATION NUMBER

8 - TAILGATE CODE

9 - CARGO BOX CODE

10 - TAILGATE TRIM CODE

11 - BODY-IN-WHITE SEQUENCE

12 - MARKET CODE

13 - SPECIES CODE

14 - PAINT PROCEDURE

15 - VEHICLE ORDER NUMBER

4 INTRODUCTION DR

DIGIT 19

Price Class

•L = Low

•H = Highline

DIGITS 20 AND 21

Body Type

•41 = Ram Truck Quad Cab, Short Box

•42 = Ram Truck Quad Cab, Long Box

•61 = Ram Truck Standard Cab, Short Box

•62 = Ram Truck Standard Cab, Long Box

BODY CODE PLATE—LINE 3

DIGITS 1,2, AND 3

Paint Procedure

•APA = Monotone

•AP9 = Special

•APD = Two-tone (Lower break)

DIGIT 4

Open Space

DIGITS 5 THROUGH 8

Primary Paint

(Refer to 23 - BODY/PAINT - SPECIFICATIONS)

for color codes.

DIGIT 9

Open Space

DIGITS 10 THROUGH 13

Secondary Paint

DIGIT 14

Open Space

DIGITS 15 THROUGH 18

Interior Trim Code

DIGIT 19

Open Space

DIGITS 20, 21, AND 22

Engine Code

•EKG = 3.7 L 6 cyl. MPI Gasoline

•EVA = 4.7 L 8 cyl. MPI Gasoline

•EZA = 5.7 L 8 cyl. SMPI Gasoline

•EML = 5.9 L 8 cyl. SMPI Gasoline

•ETC = 5.9 L 6 cyl. Cummins Turbo Diesel

•ETH = 5.9 L 6 cyl. Cummins Turbo Diesel High

Output

•EWA = 8.0 L 10 cyl. MPI Gasoline

BODY CODE PLATE—LINE 2

DIGIT 1 Open Space

DIGITS 2 AND 3 Species Code. (Used for Manufacturing)

DIGIT 4

Open Space

DIGIT 5

Market Code

•B = International

•C = Canada

•M = Mexico

•U = United States

DIGIT 6

Open Space

DIGITS 7 THROUGH 23

Vehicle Identification Number (VIN)

(Refer to VEHICLE DATA/VEHICLE INFORMA-

TION/VEHICLE IDENTIFICATION NUMBER -

DESCRIPTION) for proper breakdown of VIN code.

BODY CODE PLATE—LINE 1

DIGITS 1 THROUGH 6 Body-in-white assembly sequence.

DIGIT 7

Open Space

DIGIT 8 Tailgate trim code.

DIGIT 9

Open Space

DIGITS 10 THROUGH 12 Cargo box code

DIGIT 13

Open Space

DIGITS 14 THROUGH 16 Tailgate code

DR INTRODUCTION 5

BODY CODE PLATE (Continued)

INTERNATIONAL VEHICLE

CONTROL & DISPLAY

SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS

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.

FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2

to grade 8. The higher the grade number, the greater

the bolt strength. Identification is determined by the

line marks on the top of each bolt head. The actual

bolt strength grade corresponds to the number of line

marks plus 2. The most commonly used metric bolt

strength classes are 9.8 and 10.9. The metric

strength class identification number is imprinted on

the head of the bolt. The higher the class number,

the greater the bolt strength. Some metric nuts are

imprinted with a single-digit strength class on the

nut face. Refer to the Fastener Identification and

Fastener Strength Charts (Fig. 6) and (Fig. 7).

INTERNATIONAL SYMBOLS

1 High Beam 13 Rear Window Washer

2 Fog Lamps 14 Fuel

3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature

4 Turn Warning 16 Battery Charging Condition

5 Hazard Warning 17 Engine Oil

6 Windshield Washer 18 Seat Belt

7 Windshield Wiper 19 Brake Failure

8 Windshield Wiper and Washer 20 Parking Brake

9 Windscreen Demisting and Defrosting 21 Front Hood

10 Ventilating Fan 22 Rear hood (Decklid)

11 Rear Window Defogger 23 Horn

12 Rear Window Wiper 24 Lighter

6 INTRODUCTION DR

Fig. 6 FASTENER IDENTIFICATION

DR INTRODUCTION 7

FASTENER IDENTIFICATION (Continued)

Fig. 7 FASTENER STRENGTH

8 INTRODUCTION DR

FASTENER IDENTIFICATION (Continued)

FASTENER USAGE

DESCRIPTION - FASTENER USAGE

WARNING: USE OF AN INCORRECT FASTENER

MAY RESULT IN COMPONENT DAMAGE OR PER-

SONAL INJURY.

Fasteners and torque specifications references in

this Service Manual are identified in metric and SAE

format.

During any maintenance or repair procedures, it is

important to salvage all fasteners (nuts, bolts, etc.)

for reassembly. If the fastener is not salvageable, a

fastener of equivalent specification must be used.

THREADED HOLE REPAIR

DESCRIPTION - THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using

a Helicoilt. Follow the vehicle or Helicoiltrecommen-

dations for application and repair procedures.

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one,

ten, one hundred, one thousand and one million.

The following chart will assist in converting metric

units to equivalent English and SAE units, or vise

versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters

(N·m) N·m x 8.851 = in-lbs

ft-lbs x 1.3558 = Newton Meters

(N·m) N·m x 0.7376 = ft-lbs

Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi

Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 = Meters (M) M x 3.281 = Feet

Yards x 0.9144 = Meters M x 1.0936 = Yards

mph x 1.6093 = Kilometers/Hr.

(Km/h) Km/h x 0.6214 = mph

Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph

Kilometers/Hr.

(Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.

(Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).

Also, use the chart to convert between millimeters

(mm) and inches (in.) (Fig. 8).

DR INTRODUCTION 9

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