2002 DODGE INTREPID Service Repair Manual PDF
2002 DODGE INTREPID Service Repair Manual PDF
2002 DODGE INTREPID Service Repair Manual PDF
Introduction
2 Suspension
3 Driveline
5 Brakes
7 Cooling
8A Audio
8B Chime/Buzzer
8C Clock
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
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
21 Transaxle
22 Tires/Wheels
23 Body
25 Emissions Control
INTRODUCTION
TABLE OF CONTENTS
page page
DIGIT 21
Price Class
E = Economy
H = High Line
L = Low Line
M = Mid Line
P = Premium
S = Special/Sport
X = Performance Image
DIGITS 22 AND 23
Fig. 2 BODY CODE PLATE LOCATION Body Type
1 - BODY COPY PLATE 41 = Four Door Sedan
2 - BATTERY TRAY
BODY CODE PLATE LINE 1
DIGITS 20, 21, AND 22
Engine Code DIGITS 1, 2, AND 3
EER = 2.7 L, Six Cylinder, 24 Valve, DOHC, Transaxle Codes
Gasoline, Aluminum Block (MPI) DGX = 42LE 4-Speed Electronic Automatic
EGG = 3.5 L, Six Cylinder, 24 Valve, SOHC, Transaxle
High Output, Gasoline, Aluminum Block (MPI)
EGK = 3.5 L, Six Cylinder, 24 Valve, SOHC, DIGIT 4
High Output, Gasoline, Aluminum Block (MPI) Open Space
EGJ = 3.5 L, Six Cylinder, 24 Valve, SOHC,
DIGIT 5
High Output, Gasoline, Aluminum Block
EGC = 3.5 L, Six Cylinder, 24 Valve, SOHC, Market Code
Magnum, Gasoline, Aluminum Block C = Canada
B = International
DIGIT 23 M = Mexico
Open Space U = United States
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 3) and (Fig. 4).
4 INTRODUCTION LH
FASTENER IDENTIFICATION (Continued)
TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts (Fig. 7).
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) is located
on the upper left corner of the upper plenum, near
the left windshield pillar (Fig. 8). The VIN consists of
17 characters in a combination of letters and num-
bers that provide specific information about the vehi-
cle. Refer to VIN Code Breakdown table for decoding
information.
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL - The label contains the vehicles emission specifica-
TYPICAL tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
12 INTRODUCTION LH
MANUFACTURE PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 11) is located in the
engine compartment on the passenger side rear cor-
ner of the hood. The plate contains five lines of infor-
mation:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
Fig. 11 MANUFACTURER PLATE
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
LH LUBRICATION & MAINTENANCE 0-1
page page
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR label of engine oil plastic bottles and the top of
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO engine oil cans (Fig. 3).
NOT POLLUTE, DISPOSE OF USED ENGINE OIL This symbol means that the oil has been certified
PROPERLY. CONTACT YOUR DEALER OR GOVERN- by the American Petroleum Institute (API). Diamler-
MENT AGENCY FOR LOCATION OF COLLECTION Chrysler only recommend API Certified engine oils
CENTER IN YOUR AREA. that meet the requirements of Material Standard
MS-6395. Use Mopar or an equivalent oil meeting
When service is required, DaimlerChrysler Corpo-
the specification MS-6395.
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
Society of Automotive Engineers (SAE)
American Petroleum Institute (API)
National Lubricating Grease Institute (NLGI)
CAUTION:
Do not attempt to push or tow the vehicle to start it.
The vehicle cannot be started this way. Pushing
with another vehicle may damage the transaxle or
the rear of the 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 the procedure carefully.
NOTE:
The battery is stored in a compartment in front of
the tire in the right front fender and is accessible
through the engine compartment.
Fig. 9 TOWING
Use a flat bed towing device when wheel lift tow-
ing device is not available.
SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION
TABLE OF CONTENTS
page page
CAUTION SPECIFICATIONS
CAUTION: Only frame contact hoisting equipment FRONT SUSPENSION FASTENER TORQUE
can be used on this vehicle. All vehicles have a
fully independent rear suspension. The vehicles
cannot be hoisted using equipment designed to lift Ft. In.
DESCRIPTION Nm
a vehicle by the rear axle. If this type of hoisting Lbs. Lbs.
equipment is used, damage to rear suspension Ball Joint Pinch Bolt Nut 55 40
components will occur. Hub And Bearing Mounting
110 81
Bolts
CAUTION: If the vehicle is equipped with the Tire Hub And Bearing Axle Hub
142 105
Pressure Monitoring (TPM) System, the tire/wheel Nut
assembly needs to be reinstalled in the same loca- Lower Control Arm Pivot
142 105
tion it is removed from or the TPM System (sen- Bolt
sors) will need to be retrained. Mark each tire/wheel Stabilizer Bar Bushing
assembly indicating location, prior to its removal. If 61 45
Retainer Bolts
the tire/wheel assemblies are switched, rotated or
replaced, the TPM System needs to be retrained. Stabilizer Bar Link Lower
88 65
(Refer to 22 - TIRES/WHEELS/TIRE PRESSURE Nut
MONITORING/SENSOR - STANDARD PROCEDURE) Stabilizer Bar Link Upper
95 70
Nut
Strut Body Tower Mounting
CAUTION: At no time when servicing a vehicle, can 37 28
Nuts
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an Strut Clevis-to-Knuckle Nuts 203 150
original plastic clip. Also, NO holes can be drilled Strut Shaft Nut 95 70
into the front shock tower in the area shown (Fig.
Tie Rod Adjuster Pinch Bolt 38 28
2), for the installation of any metal fasteners into
the shock tower. Because of the minimum clear- Tie Rod Steering Arm Nut 37 27
ance in this area, installation of metal fasteners Tension Strut Mounting Nut 130 95
could damage the coil spring coating and lead to a Wheel Mounting (Lug) Nuts 135 100
corrosion failure of the spring.
SPECIAL TOOLS
FRONT SUSPENSION
HUB / BEARING
DESCRIPTION
The front wheel bearing and front wheel hub of
this vehicle are a hub and bearing unit type assem-
bly. This unit combines the front wheel mounting
hub (flange) and the front wheel bearing into a
sealed one piece unit. The hub and bearing is
mounted to the center of the steering knuckle and is
Socket/Wrench Front Strut Nut 6864 retained by three mounting bolts accessible from the
rear of the steering knuckle. The hub flange has five
wheel mounting studs.
The wheel mounting studs used to mount the tire
and wheel to the vehicle are the only replaceable
components of the hub and bearing assembly. Other-
wise, the hub and bearing is serviced only as a com-
plete assembly.
OPERATION
Puller C-3894A The hub and bearing has internal bearings that
allow the hub to rotate with the driveshaft and tire
and wheel. The five wheel mounting studs mount the
tire and wheel, and brake rotor to the vehicle.
Fig. 7 Hub And Bearing Removal And Installation Fig. 9 Hub And Bearing Assembly Seal
1 - SEAL CAN MUST REMAIN TIGHT AGAINST HUB AND
1 - HUB/BEARING ASSEMBLY BEARING ASSEMBLY HERE
2 - STEERING KNUCKLE 2 - SEAL
3 - FLINGER
4 - DO NOT ALLOW FLINGER TO BE BENT OR DAMAGED
DURING REMOVAL OF HUB/BEARING OR C/V JOINT
5 - HUB/BEARING ASSEMBLY
KNUCKLE
DESCRIPTION - STEERING KNUCKLE
The steering knuckle is a single casting with legs
machined for attachment to the front strut assembly
and lower control arm ball joint (Fig. 1). The steering
knuckle also has machined abutments on the casting
to support and align the front brake caliper. The
knuckle also holds the hub and bearing, and supports
the driveshaft. The hub and bearing is positioned
through the center of the knuckle. The driveshaft
outer constant velocity (C/V) stub shaft is splined to
the center of the hub.
Fig. 14 Speed Sensor Head Removal Fig. 16 Hub And Bearing Retaining Bolts
1 - SENSOR EAR 1 - STEERING KNUCKLE
2 - PUNCH 2 - HUB/BEARING ATTACHING BOLTS
3 - SPEED SENSOR HEAD 3 - HALF SHAFT
OPERATION
LOWER BALL JOINT The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
DESCRIPTION movement of the suspension during the jounce and
The ball joint is an integral part of the control arm rebound travel.
and has a non-tapered stud with a notch for clamp
(pinch) bolt installation. The stud is clamped and DIAGNOSIS AND TESTING - LOWER CONTROL
locked into the steering knuckle leg using a clamp ARM
(pinch) bolt. Inspect the lower control arm for signs of damage
The ball joint used in the lower control arm of this from contact with the ground or road debris. If the
vehicle is a sealed-for-life ball joint and requires no lower control arm shows any sign of damage, inspect
maintenance lubrication. The ball joint cannot be ser- the lower control arm to see if it is bent.
viced separately from the lower control arm. If the The only serviceable components of the lower con-
ball joint is determined to be defective it will require trol arm are the pivot bushing and the tension strut
replacement of the complete lower control arm. Refer bushing. The lower control arm is serviced as a com-
to DIAGNOSIS AND TESTING in this section for plete assembly otherwise. Do not attempt to
proper testing of the ball joint. repair or straighten a broken or bent lower
control arm. It must be replaced.
NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
attempt should be made to ever add any lubrication REMOVAL - LOWER CONTROL ARM
to the lower ball joint. (1) Raise vehicle on jackstands or centered on a
frame contact hoist. See Hoisting in Lubrication and
Maintenance.
OPERATION (2) Remove the wheel and tire assembly from the
The ball joint is a pivotal joint on the lower control vehicle.
arm that allows the knuckle to move up and down, (3) Remove the ball joint stud to steering knuckle
and turn with ease. attaching nut and bolt (Fig. 24).
INSTALLATION - LOWER CONTROL ARM CAUTION: Pulling steering knuckle out from vehicle
(1) Position tension strut in lower control arm as after releasing from ball joint can separate inner
shown (Fig. 35). Make sure the word FRONT which C/V joint. See Driveshafts.
is stamped in tension strut, is positioned away from
control arm. CAUTION: When ball joint stud is installed into
steering knuckle, do not let ball joint seal hit up
against steering knuckle. If ball joint seal hits steer-
ing knuckle, seal damage may occur. If ball joint
seal becomes torn, replace seal before assembling
lower control arm to knuckle.
STABILIZER BAR
DESCRIPTION
The stabilizer bar interconnects both front struts of
the vehicle and is attached to the front cradle/cross-
member (Fig. 1) .
Attachment of the stabilizer bar to the front cradle/
crossmember is through 2 rubber-isolator cushion
bushings and retainers. A double ball jointed stabi-
lizer bar link is used to attach each end of the stabi-
lizer bar to the front strut assemblies. All parts of
the stabilizer bar are replaceable as individual com-
ponents.
The stabilizer bar to front cradle cushion bushings
are slit for easy removal and installation. The slit
must be positioned toward the front of the vehicle Fig. 36 Stabilizer
when the stabilizer bar is installed.
1 - STABILIZER BAR
2 - SLIT
OPERATION 3 - FRONT OF CAR
Jounce and rebound movements affecting one 4 - SLIT
wheel are partially transmitted to the opposite wheel 5 - ISOLATOR BUSHINGS
of the vehicle through the stabilizer bar. This helps 6 - RETAINERS
to minimize the body roll of the vehicle during sus-
pension movement.
Fig. 50 Stabilizer
1 - STABILIZER BAR
STRUT
2 - SLIT
3 - FRONT OF CAR DESCRIPTION - STRUT ASSEMBLY (FRONT)
4 - SLIT The front strut and suspension of the vehicle is
5 - ISOLATOR BUSHINGS supported by coil springs positioned around the
6 - RETAINERS struts (Fig. 1). The springs are contained between an
upper seat, located just below the upper strut mount
and a lower spring seat on the strut housing. A steer-
INSTALLATION - STABILIZER BAR BUSHING
ing arm is permanently attached to each strut mak-
(FRONT) ing it side specific.
(1) Install bushings onto stabilizer bar with slits The top of each strut assembly is bolted to the
facing forward and flat side facing downward. The upper fender reinforcement (strut tower) through a
stabilizer bar to cradle assembly bushings must rubber isolated mount.
be positioned on the stabilizer bar so the slit in The bottom of the strut assembly attaches to the
the bushing is positioned toward front of vehi- top of the steering knuckle with two serrated
cle (Fig. 51). through-bolts and prevailing torque nuts.
Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service.
The components of the strut assembly listed below
are serviceable if found to be defective (Fig. 52):
Strut shaft retainer nut
Upper mount
Seat and bearing
Dust shield
Jounce bumper
Jounce bumper cup
Coil spring
Upper spring isolator
Lower spring isolator
Strut
Fig. 51 Stabilizer Bar Isolator Bushing
1 - STABILIZER BAR
OPERATION - STRUT ASSEMBLY (FRONT)
2 - STABILIZER BAR ISOLATOR BUSHING The strut assembly cushions the ride of the vehicle,
3 - CRADLE ASSEMBLY controlling vibration, jounce and rebound of the sus-
4 - FRONT OF CAR pension.
5 - SLIT The coil spring controls ride quality and maintains
proper ride height.
LH FRONT SUSPENSION 2 - 23
STRUT (Continued)
(4) Inspect the upper strut mount assembly. Make
sure the correct mount is on the correct side of the
vehicle. Looking down at the top of the upper mount,
2 tabs can be seen, (Fig. 53) and (Fig. 54), down
inside the mount center well. The positioning of
these tabs is critical to vehicle ride and sound. DO
NOT install a right mount on the left front strut
or a left mount on a right front strut. If the strut
is off the vehicle, a rectangular hole can be seen on
the edge of the mount mounting surface (Fig. 53) and
(Fig. 54). This is always in the 10 oclock position
when observing rubber tab positioning, whether a
left or right mount is being observed.
Fig. 55 Stabilizer Bar Link At Strut Fig. 57 Speed Sensor Cable Routing Bracket
1 - OUTER TIE ROD 1 - STRUT ASSEMBLY
2 - NUT 2 - ROUTING BRACKET
3 - STABILIZER BAR ATTACHING LINK 3 - SCREW
4 - STRUT ASSEMBLY 4 - SPEED SENSOR CABLE
5 - STEERING ARM
6 - NUT
(7) Remove brake caliper assembly from steering
knuckle and brake rotor. Refer to the Brakes. Sup-
(4) Loosen, but do not remove, the outer tie rod port caliper assembly by hanging it from frame of
end to strut arm attaching nut (Fig. 56). Release vehicle with wire or some other method (Fig. 59). Do
outer tie rod end from steering arm using Puller, not let caliper assembly hang by brake hose.
Special Tool C-3894A (Fig. 56), then remove nut and (8) Remove brake rotor from hub.
tie rod from the steering arm.
(5) If vehicle is equipped with antilock brakes,
remove the speed sensor cable routing bracket from
the strut assembly (Fig. 57).
(6) Remove the 2 guide pin bolts mounting the cal-
iper assembly to the steering knuckle (Fig. 58).
LH FRONT SUSPENSION 2 - 25
STRUT (Continued)
STEERING KNUCKLE. If bolts are turned damage to
steering knuckle will result.
(9) Remove the 2 strut assembly to steering
knuckle attaching bolts (Fig. 60).
CAUTION: The strut assembly to steering knuckle (11) Remove the strut assembly from the vehicle.
bolts are serrated were they go through strut (12) For disassembly of the strut assembly, refer to
assembly and steering knuckle. When removing Disassembly.
bolts, turn nuts off bolts DO NOT TURN BOLTS IN
2 - 26 FRONT SUSPENSION LH
STRUT (Continued)