Manual Coverage
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Systems Covered
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Engine:
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Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting, charging, engine performance diagnostics.
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Transmission:
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Manual and automatic transmission repair, overhaul, service, diagnostics, fluid specifications, gear ratios.
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Drivetrain:
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Front and rear axle, differentials, driveshafts, CV joints, U-joints, 4WD system components (if applicable).
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Brakes:
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Disc and drum brake systems, ABS (if equipped), hydraulic components, parking brake.
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Suspension:
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Front and rear suspension systems, steering linkage, shocks, struts, springs, bushings, alignment specifications.
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Steering:
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Power steering system, steering column, steering gear/rack, tie rods, alignment.
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Electrical:
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Wiring diagrams, lighting systems, instrumentation, power accessories, charging system, starting system, ignition system, fuses, relays, ECUs.
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Body:
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Body panels, doors, windows, locks, interior trim, exterior trim, HVAC system, body hardware, glass replacement.
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Heating And Air Conditioning:
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HVAC system operation, diagnosis, repair, refrigerant handling, components.
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Restraints:
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Seat belts, airbag system (if equipped) inspection and basic service information.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication.
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Diagnostics:
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Troubleshooting guides, symptom-based diagnostics, component testing procedures, diagnostic trouble codes (DTCs) if applicable for the era.
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Repair:
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Step-by-step repair procedures for all major and minor mechanical and electrical components.
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Overhaul:
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Complete engine, transmission, and differential rebuild procedures.
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Installation:
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Procedures for replacing major components, accessories, and body parts.
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Adjustments:
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Wheel alignment, brake adjustments, clutch adjustments, idle speed adjustments.
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Wiring Diagrams:
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Detailed electrical system wiring diagrams for all major circuits.
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Technical Depth
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Depth:
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Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, including detailed diagnostic procedures.
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Diagnostic Tools:
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Information on using basic diagnostic tools and interpreting symptoms specific to the era's technology.
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Special Tools:
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Listing and description of any special tools required for specific repairs.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used (check manual for specifics).
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Transmission Fluid Change Interval:
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Automatic: 30,000-50,000 miles. Manual: Inspect periodically, change as needed or at higher mileage intervals.
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Coolant Change Interval:
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Initial change at ~30,000 miles, subsequent changes every 30,000 miles or 2 years.
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Fluid Specifications
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Engine Oil Capacity 2.5L I4:
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Approx. 5 US quarts with filter.
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Engine Oil Capacity 3.9L V6:
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Approx. 5 US quarts with filter.
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Engine Oil Capacity 5.2L V8:
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Approx. 5 US quarts with filter.
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Recommended Engine Oil:
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API Service SG or SH, SAE 5W-30 or 10W-30 (check manual for ambient temperature recommendations).
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Coolant Type:
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Chrysler's Long Life Antifreeze/Coolant (HOAT) or equivalent, typically a 50/50 mix with distilled water.
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Known Issues
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Common Problem 1:
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Intake manifold gasket leaks (especially on V8 models).
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Common Problem 2:
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Rear main seal leaks on V8 engines.
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Common Problem 3:
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Front suspension wear (ball joints, tie rod ends) due to truck usage.
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Common Problem 4:
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Power steering pump leaks or failure.
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Common Problem 5:
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Door hinge rust and sag, window regulator issues.
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Common Problem 6:
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Cracked dashboards (plastic degradation from sun exposure).
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Common Problem 7:
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Fuel pump failures.
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Common Problem 8:
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Ignition module or crank sensor failures.
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