Dodge ZB 2005 Manuel utilisateur

SERVICE MANUAL

2005

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL

SYSTEM, OR TRANSMITTED, IN ANY FORM OR

BY ANY MEANS, ELECTRONIC, MECHANICAL,

PHOTOCOPYING, RECORDING, OR OTHERWISE,

WITHOUT THE PRIOR WRITTEN PERMISSION

OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or

to make additions to or improvements in its products without imposing any

obligations upon itself to install them on its products previously manufactured.

81-526-05015

FOREWORD

The information contained in this service manual has been prepared for the professional automotive tech-

nician involved in daily repair operations. Information describing the operation and use of standard and

optional equipment is included in the Owner’s Manual provided with the vehicle.

Information in this manual is divided into groups. These groups contain description, operation, diagnosis,

testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-

nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar

after the group title is aligned to a solid tab on the first page of each group. The first page of the group has

a contents section that lists major topics within the group. If you are not sure which Group contains the infor-

mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.

A Service Manual Comment form is included at the rear of this manual. Use the form to provide

DaimlerChrysler Corporation with your comments and suggestions.

Tightening torques are provided as a specific value throughout this manual. This value represents the

midpoint of the acceptable engineering torque range for a given fastener application. These torque values are

intended for use in service assembly and installation procedures using the correct OEM fasteners. When

replacing fasteners, always use the same type (part number) fastener as removed.

DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,

repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR

Introduction

0Lubrication & Maintenance

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio/Video

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8N Power Systems

8O Restraints

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission/Transaxle

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

GROUP TAB LOCATOR

Introduction

0Lubrication & Maintenance

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio/Video

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8N Power Systems

8O Restraints

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission/Transaxle

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

INTRODUCTION

TABLE OF CONTENTS

page page

BODY CODE PLATE

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

E-MARK LABEL

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

FASTENER IDENTIFICATION

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

FASTENER USAGE

DESCRIPTION

FASTENER USAGE .....................4

THREADED HOLE REPAIR ...............4

INTERNATIONAL SYMBOLS

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

MANUFACTURE PLATE

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

METRIC SYSTEM

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

TORQUE REFERENCES

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

VECI LABEL

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

VEHICLE IDENTIFICATION NUMBER

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

VEHICLE CERTIFICATION LABEL

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

BODY CODE PLATE

DESCRIPTION

This vehicle does not require a Body Code Plate

due to limited optional equipment and colors.

E-MARK LABEL

DESCRIPTION

An E-mark Label (Fig. 1) is located on the rear

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

following information:

•Date of Manufacture

•Month-Day-Hour (MDH)

•Vehicle Identification Number (VIN)

•Country Codes

•Regulation Number

•Regulation Amendment Number

•Approval Number

Fig. 1 E-MARK LABEL

1 - COUNTRY CODE

2 - REGULATION NUMBER

3 - APPROVAL NUMBER

4 - AMENDMENT NUMBER

ZB INTRODUCTION 1

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.

BOLT MARKINGS AND TORQUES - METRIC

Bolt Markings 8.8/8.9 10.9 12.9

Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.

6 12 105* 14 120* 16 12

8 25 250* 32 23 38 28

10 54 40 60 45 74 55

12 95 70 108 80 135 100

14 155 115 175 130 216 160

16 243 180 324 210 324 240

* Inch Lbs.

BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY

Bolt Markings Grade 5 Grade 8

Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs

1/4 - 20 10 95* 14 125*

1/4 - 28 10 95* 17 150*

5/16 - 18 22 200* 30 270*

5/16 - 24 26 240* 33 300*

3/8-1640305540

3/8-2447356045

7/16-1468508865

7/16-2074559570

1/2 - 13 101 75 135 100

1/2 -20 115 85 150 110

9/16 - 12 135 105 182 135

9/16 - 18 155 115 202 150

5/8 - 11 202 150 263 195

5/8 - 18 215 160 284 210

3/4 - 10 230 170 297 220

3/4 - 16 236 175 304 225

7/8 - 14 405 300 540 400

* Inch Lbs.

2 INTRODUCTION ZB

FASTENER STRENGTH

ZB INTRODUCTION 3

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

Most stripped threaded holes can be repaired using

a Helicoilt. Follow the vehicle or Helicoiltrecommen-

dations 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.

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer

2 Fog Lamps 14 Fuel

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

4 Turn Warning 16 Battery Charging Condition

5 Hazard Warning 17 Engine Oil

6 Windshield Washer 18 Seat Belt

7 Windshield Wiper 19 Brake Failure

8 Windshield Wiper and Washer 20 Parking Brake

9 Wind screen 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

4 INTRODUCTION ZB

MANUFACTURE PLATE

DESCRIPTION

The Manufacturer Plate (Fig. 2) is located in the

engine compartment on the passenger side rear cor-

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

mation:

1. Vehicle Identification Number (VIN)

2. Gross Vehicle Mass (GVM)

3. Gross Train Mass (GTM)

4. Gross Front Axle Rating (GFAR)

5. Gross Rear Axle Rating (GRAR)

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)

Fig. 2 MANUFACTURER PLATE

ZB INTRODUCTION 5

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