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Manual Coverage
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Systems Covered
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Powertrain:
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Engine (3.7L Magnum V6, 4.7L Magnum V8), Fuel System, Emissions Control, Intake and Exhaust Systems, Cooling System, Lubrication System, Ignition System, Engine Control Module (ECM).
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Transmission Drivetrain:
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Manual Transmissions (NV1500, NV3500), Automatic Transmissions (42RLE, 45RFE/545RFE), Clutch System, Driveshaft, Differentials (Rear Axle).
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Chassis Suspension Steering:
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Front and Rear Suspension, Steering System (Power Steering), Wheel Alignment, Brakes (including ABS, Rear Drum/Disc variations), Wheels and Tires.
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Electrical Electronics:
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Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, Instrumentation, Audio Systems, Power Accessories, SRS (Supplemental Restraint System), Wiring Diagrams for all circuits.
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Body Interior Exterior:
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Body Panels, Doors, Glass, Seats, Interior Trim, HVAC (Heating, Ventilation, and Air Conditioning), Exterior Trim, Bumpers.
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Procedures Included
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Routine Maintenance:
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Oil and filter changes, air filter replacement, spark plug replacement, fluid checks and top-offs, tire rotation.
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Engine Repair:
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Engine removal/installation, cylinder head service, valve train adjustments, piston and connecting rod installation, crankshaft service, timing belt/chain procedures, oil pump service.
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Transmission Repair:
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Transmission removal/installation, internal component repair and replacement, clutch service, torque converter replacement, fluid and filter service.
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Braking System:
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Brake pad/shoe replacement, rotor/drum service, caliper and wheel cylinder repair, ABS system diagnosis and repair, brake bleeding.
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Electrical Diagnostics:
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Troubleshooting using wiring diagrams, component testing, diagnostic trouble code (DTC) retrieval and interpretation, module testing and replacement.
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HVAC Repair:
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Refrigerant system diagnosis and service, component replacement (compressor, condenser, evaporator), blower motor service, control head repair.
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Body Work And Trim:
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Panel replacement, door adjustment, glass replacement, interior trim removal and installation, bumper repair and replacement.
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Technical Depth
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Depth Of Coverage:
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Extensive. Covers everything from basic maintenance tasks to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
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Diagnostic Procedures:
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Includes specific diagnostic flowcharts and procedures for identifying common and complex issues across all major vehicle systems.
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Special Tools:
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Identifies and describes the use of specialized tools required for specific repair procedures.
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Tightening Torques:
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Provides precise torque specifications for all critical fasteners.
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Illustrations Diagrams:
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Features detailed illustrations, exploded views, and diagrams to clarify repair steps and component locations.
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Engine Specifications
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Primary Engine
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Engine Code:
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G
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Displacement:
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3.7 Liters (226 cubic inches)
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Configuration:
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3.7L Magnum V6 (SOHC)
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Horsepower Approx:
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210-230 hp @ 5200-5800 rpm
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Torque Approx:
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235-245 lb-ft @ 4000-4200 rpm
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Fuel System:
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Sequential Multi-port Fuel Injection (MPI)
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Recommended Fuel:
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87 Octane Unleaded Gasoline
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Optional Engine
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Engine Code:
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X
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Displacement:
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4.7 Liters (287 cubic inches)
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Configuration:
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4.7L Magnum V8 (SOHC)
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Horsepower Approx:
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235-260 hp @ 4500-5000 rpm
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Torque Approx:
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295-325 lb-ft @ 3200-3600 rpm
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Fuel System:
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Sequential Multi-port Fuel Injection (MPI)
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Recommended Fuel:
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87 Octane Unleaded Gasoline
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Performance
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Engine Cooling:
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Pressurized Liquid Cooling System
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Emission Controls:
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Catalytic Converter, On-Board Diagnostics (OBD-II), EGR (where applicable).
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Safety Features
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Ratings
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NHTSA Frontal Impact Driver:
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4 stars (for 2005 model year in typical testing).
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NHTSA Frontal Impact Passenger:
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4 stars (for 2005 model year in typical testing).
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NHTSA Side Impact Front Seat:
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4 stars (for 2005 model year in typical testing).
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NHTSA Side Impact Rear Seat:
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4 stars (for 2005 model year in typical testing).
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Active Features
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ABS:
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Standard Anti-lock Braking System (ABS) on all wheels.
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Traction Control:
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Optional (often linked with 4x4 or V8 models).
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Passive Features
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Airbags Front:
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Driver and Passenger front airbags.
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Airbags Side:
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Optional side-curtain airbags available on some trims.
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Seat Belts:
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Three-point seat belts in all seating positions, pretensioners for front seats.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically 3,000 to 5,000 miles or 6 months, whichever comes first, depending on oil type and driving conditions. Refer to manual for precise recommendations.
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Spark Plug Replacement:
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Approximately 100,000 miles for iridium-tipped spark plugs (check manual for specific type and interval).
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Transmission Fluid Change:
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Refer to manual; often around 60,000-100,000 miles, depending on usage and fluid type.
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Coolant Flush Interval:
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Typically every 30,000-60,000 miles or 2-5 years, using Mopar Antifreeze/Coolant HOAT (Hybrid Organic Acid Technology).
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Fluid Specifications
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Engine Oil Type:
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SAE 5W-30 Synthetic Motor Oil (for both 3.7L and 4.7L engines).
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Engine Oil Capacity:
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Approximately 5 quarts (4.7 liters) for 3.7L V6; Approximately 6 quarts (5.7 liters) for 4.7L V8. Verify with dipstick and manual.
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Power Steering Fluid:
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Mopar Power Steering Fluid or equivalent.
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Brake Fluid:
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DOT 3 Brake Fluid.
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Known Issues
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Common Issue Ignition:
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Coil-on-plug ignition system can develop misfires due to failing coil packs or spark plugs.
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Common Issue Suspension:
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Ball joints and tie rod ends can wear prematurely, leading to steering looseness and tire wear.
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Common Issue HVAC:
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Blend door actuators in the HVAC system can fail, causing temperature control issues.
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Common Issue Powertrain 47L:
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Early 4.7L V8s had some head gasket issues; later models were improved. Refer to manual for specific torque sequences if performing head work.
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Common Issue Transfer Case:
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Transfer case actuator or encoder motor issues can arise on 4x4 models, affecting engagement.
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