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Manual Coverage
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Systems Covered
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Engine Service Repair:
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Detailed procedures for engine disassembly, assembly, diagnostics, and repair, including timing belt, cylinder head, pistons, crankshaft, and lubrication system.
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Transmission Service Repair:
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Coverage for both manual and automatic transmissions, including fluid changes, clutch service, torque converter replacement, and internal component repair.
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Brake System:
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Service and repair for ABS, hydraulic components, brake pads, rotors, calipers, and parking brake system.
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Electrical System:
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Diagnosis and repair of lighting, starting and charging system, power windows, locks, mirrors, and dashboard instrumentation.
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Suspension:
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Front and rear suspension component replacement, alignment procedures, struts, shocks, control arms, and ball joints.
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Steering:
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Power steering system diagnosis, pump and rack replacement, tie rod ends, and alignment.
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Cooling System:
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Radiator, thermostat, water pump, coolant hoses, and fan assembly service.
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Fuel Injection Fuel System:
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Fuel pump, fuel injectors, fuel filter, fuel pressure regulator, and fuel tank service.
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Emission System:
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Diagnosis and repair of catalytic converter, oxygen sensors, EGR system, and evaporative emissions control.
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Heater Air Conditional:
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HVAC system diagnosis, refrigerant service, blower motor, evaporator, and heater core replacement.
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Engine Control System:
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ECU diagnosis, sensor testing (MAP, TPS, CKP, CMP), ignition system, and fuel injection control.
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Chassis Body:
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Frame inspection, body panel repair, door mechanisms, hinges, latches, and exterior trim.
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Restraint System:
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Airbag system diagnosis, SRS module, seat belts, and related components.
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Interior:
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Dashboard removal, seat removal, trim panel replacement, and interior component repair.
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Differential Drive Axle:
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Front-wheel drive axle and differential service, including CV joints and bearings.
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Procedures Included
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General Maintenance:
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Oil changes, fluid checks and top-offs, filter replacements, tire rotation, and general inspection procedures.
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Troubleshooting:
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Systematic diagnostic guides for identifying and resolving common and complex vehicle issues, including symptom-based troubleshooting.
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Engine Repair:
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Detailed steps for engine overhaul, component replacement (e.g., head gaskets, piston rings), timing belt replacement, and rebuild procedures.
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Transmission Repair:
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Procedures for transmission fluid service, clutch replacement (manual), torque converter replacement (automatic), and transmission rebuild.
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Brake System Repair:
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Front and rear brake pad and rotor replacement, caliper servicing, brake fluid bleeding, and ABS component replacement.
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Electrical System Repair:
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Wiring harness diagnosis, component testing (alternator, starter, sensors), fuse and relay identification, and module replacement.
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Suspension Repair:
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Replacement of struts, shocks, control arms, ball joints, wheel bearings, and steering linkage components.
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Steering System Repair:
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Power steering pump and hose replacement, steering rack and pinion service, and tie rod end replacement.
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Cooling System Repair:
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Thermostat replacement, water pump replacement, radiator and hose replacement, and coolant flushes.
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Fuel System Repair:
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Fuel filter replacement, fuel pump replacement, injector cleaning and replacement, and fuel pressure testing.
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Emission System Repair:
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Oxygen sensor replacement, catalytic converter replacement, EGR valve cleaning and replacement, and EVAP system diagnosis.
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HVAC System Repair:
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Refrigerant recharge, blower motor replacement, cabin air filter replacement, and compressor replacement.
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Engine Control System Diagnosis:
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OBD-II diagnostic code interpretation, sensor testing, and actuator testing.
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Chassis Body Repair:
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Body panel alignment, rust repair, door hinge and latch adjustment, and bumper replacement.
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Restraint System Repair:
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Airbag system diagnosis, seat belt replacement, and SRS module reset procedures.
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Interior Component Repair:
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Dashboard trim replacement, seat repair, and interior lighting.
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Drive Axle Repair:
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CV axle replacement and differential fluid service.
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Technical Depth
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Depth Of Information:
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Detailed workshop procedures, including step-by-step instructions and diagrams for comprehensive repairs and maintenance.
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Diagnostic Capabilities:
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Includes troubleshooting guides, diagnostic trouble codes (DTCs), and component testing procedures for accurate problem diagnosis.
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Special Tools Required:
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Identifies specialized tools and equipment necessary for certain repair procedures, ensuring proper execution.
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Torque Specifications:
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Provides critical torque values for fasteners across all major systems to ensure correct assembly and prevent component failure.
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Wiring Diagrams:
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Includes detailed electrical wiring diagrams for the entire vehicle, crucial for diagnosing electrical issues.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000 to 7,500 miles (5,000 to 12,000 km) or 6 months, depending on driving conditions and oil type used (consult manual for exact recommendation).
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Engine Coolant Flush:
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Every 30,000 to 50,000 miles (48,000 to 80,000 km).
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Spark Plug Replacement:
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Approximately every 100,000 miles (160,000 km) for iridium-tipped plugs (check manual for specific plug type and interval).
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Fluid Specifications
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Engine Oil Type:
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SAE 5W-30 (API certified) for most conditions. Refer to manual for seasonal variations and specific SRT engine requirements.
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Transmission Fluid Automatic:
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ATF+4 (Automatic Transmission Fluid Type 9602)
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Transmission Fluid Manual:
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Refer to manual for specific manual transmission fluid type (often GL-4 or GL-5 gear oil).
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Coolant Type:
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Chrysler Preferred (OAT) or HOAT coolant, typically a 50/50 mixture with distilled water.
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Known Issues
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Common Problem 1:
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Timing belt failure on earlier 2.0L engines if not replaced at recommended intervals, leading to significant engine damage.
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Common Problem 2:
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Oil leaks, particularly from the oil pan gasket, valve cover gasket, and crankshaft seals.
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Common Problem 3:
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Issues with the HVAC blend door actuators causing improper temperature control.
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Common Problem 4:
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Power steering pump noise or leaks.
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Common Problem 5:
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Rust issues on rocker panels, wheel wells, and rear quarter panels, especially in areas exposed to road salt.
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