Factory Workshop Manual Make Dodge Model Stratus Sedan Engine and year V6-2.7L (2001) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8 Alarm Module: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS, WARNINGS, BEFORE ATTEMPTING COMPONENT. DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it. The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the Body Control Module (BCM), and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the assembly plant tester. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the BCM to operate the light. This is the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10 Alarm Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative remote cable. 2. Remove knee bolster. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM module to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION 1. If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE) Sentry Key Immobilizer Module Initialization. 2. Carefully position the SKIM, the mounting bracket and the antenna ring onto the steering column. 3. Install the two retaining screws. 4. Connect the wire harness connector. 5. Install the steering column upper and lower shrouds. 6. Install the knee bolster. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Relay > Component Information > Description and Operation > Page 18 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 23 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Relay > Component Information > Description and Operation > Page 27 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module Sunroof / Moonroof Module: Service and Repair Express Module REMOVAL - EXPRESS MODULE 1. Remove A-pillar trim, sun visors, and map lamps/mini console. 2. Remove sunroof opening trim lace. 3. Pull headliner down as necessary to gain access to sunroof express module. Fig.7 Sunroof Express Module & Drive Motor 4. Disconnect the express module wire harness connectors. 5. Remove express module from the keyway by sliding module towards the center of the vehicle. INSTALLATION - EXPRESS MODULE 1. Place express module in the keyway located in sunroof module and slide module outward to lock it into position. 2. Set headliner into position. 3. Connect drive motor, express module, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Install A-pillar trim, sun visors, and map lamps/mini console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module > Page 32 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL - MODULE ASSEMBLY 1. Move glass panel to the fully closed position. 2. Disconnect battery negative cable. 3. Recline both front seats. 4. Remove sunroof opening trim lace. 5. Remove control switch. 6. Disconnect wire harness. 7. Remove headliner 8. Disconnect the drain tubes from sunroof housing. Fig.6 Sunroof Module Assembly 9. Loosen fasteners attaching sunroof module assembly. 10. With the aid of a helper, remove fasteners attaching sunroof module assembly to roof panel. INSTALLATION - MODULE ASSEMBLY NOTE: There are locating pins on the roof panel near the front corners of the sunroof opening that will help position the sunroof module correctly. 1. With the Glass panel in the fully closed position. 2. Raise rear end of sunroof module assembly and guide into position and start fasteners. 3. Tighten the fasteners holding the sunroof module to roof panel. Tighten the fasteners to 11 N.m (97 in. lbs.) torque. 4. Connect the drain tubes to the sunroof housing. 5. Connect wire harness. 6. Set headliner into position. 7. Connect express module, drive motor, and control switch wire connectors. 8. Test sunroof operation, adjust as necessary. 9. Finish installing the headliner. 10. Install sunroof opening trim lace. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 37 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 38 Electronic Brake Control Module: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Anti-Lock Brake ................................................................................................................................... .............................................................. PC161 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 39 Electronic Brake Control Module: Description and Operation Fig.1 Integrated Control Unit (Typical) CONTROLLER ANTILOCK BRAKE The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the Integrated Control Unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRB III scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. when a fault is detected, the amber ABS warning indicator lamp is turned ON and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB III scan tool. If not cleared with a DRB III scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Cab Inputs - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Diagnostic communication (PCI) Cab Outputs - Amber ABS warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Diagnostic communication (PCI, via BUS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 40 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) 3. Pull up on the CAB connector lock and disconnect the 2-way electrical connector and the pump/motor connector from the CAB. 4. Remove the bolts securing the integrated control unit's (ICU's) mounting bracket to the lower radiator support. 5. Carefully move the ICU toward the right side of the car. Move the ICU far enough to access the CAB mounting screws. Be careful not to bend the brake tubes connected to the ICU. 6. Remove the screws securing the CAB to the HCU. Remove the CAB. INSTALLATION 1. Install screws to secure the CAB to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.) torque. 2. Remount the ICU mounting bracket to the lower radiator support. Tighten the mounting bolts to 28 Nm (21 ft. lbs.) torque. 3. Reconnect the 24-way electrical and the pump/motor connector. 4. Lower vehicle. 5. Connect negative battery cable. 6. Connect a DRB III to the vehicle and initialize the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center (PDC) High and Low Speed Radiator Fan Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 45 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center (PDC) High Speed Radiator Fan Relay Low Speed Radiator Fan Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center (PDC) A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 50 Compressor Clutch Relay: Diagrams Power Distribution Center (PDC) A/C Compressor Clutch Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 51 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The A/C compressor clutch relay is a electromechanical device that switches battery current to the A/C compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C heater control (Manual Temperature Control, or Automatic Temperature Control) , the Body Control Module (BCM), and the a/c pressure transducer. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 52 Compressor Clutch Relay: Testing and Inspection Fig.11 A/C Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 53 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C Erratic Operation/Poor Performance Control Module HVAC: Customer Interest A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C Erratic Operation/Poor Performance > Page 62 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 68 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 69 Control Module HVAC: Service and Repair BLOWER MOTOR POWER MODULE REPLACEMENT REMOVAL 1. Remove the HVAC housing. Fig. 30 Blower Power Module 2. Disconnect blower motor power module wiring connectors. 3. Remove the module mounting screws and remove module. INSTALLATION 1. Install module onto the housing and install mounting screws. 2. Plug in wiring connectors. 3. Install HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 74 Daytime Running Lamp Control Unit: Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 75 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 79 Head Lamp Delay Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 80 Headlamp Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 81 Headlamp Delay Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 85 Horn Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 86 Horn Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 87 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 88 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 89 Horn Relay: Description and Operation The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 90 Horn Relay: Testing and Inspection 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 96 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 99 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 100 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 101 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: Customer Interest A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 112 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: All Technical Service Bulletins A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 118 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors Body Control Module: Diagrams BCM Connectors Body Control Module C1 Body Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 121 Body Control Module C3 Body Control Module C4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 122 Body Control Module: Diagrams Junction Block/BCM Connector 8W-12-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 123 8W-12-5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 126 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 Body Control Module: Description and Operation Part 1 of 2 SYSTEM DESCRIPTION The body system on the 2001 JR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled and communicated by the PCI bus, which is described in the Vehicle Communication of this General Information. Always begin by reading the diagnostic trouble codes using the DRB III. Next, look for the symptom in the Diagnostic Information and Procedures of the Table of Contents. This will direct you to the specific tests(s) that must be performed. Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the Airbag module. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. Refer to 2001 JR Powertrain Diagnostics for more information. Erase codes in all modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 129 Body Control Module: Description and Operation Part 2 of 2 Part 2A AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 130 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III, read Airbag DTC's. If the following active codes are present: If neither of the following codes is an active code: Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or if could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 131 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Seat Belt Tensioner (SBT) The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. The JR27 convertible driver and front passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle is connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Side Impact Airbag Control Module (SIACM) Supplemental driver and passenger curtain air-bags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity #5 of the SIACM connector. If cavity #5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 132 DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. Curtain Airbags The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. ORC/SIACM Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Always begin diagnostic with the Table of Contents. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the air-bag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. Part 2B Active Codes The code becomes active as soon as the malfunction is detected or key-in, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit or component. It is impossible to erase an active code. Active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. The exception is the Loss of Ignition Run Only code which is an active code only. A stored code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be active. When a trouble code occurs, the airbag warning indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. It no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 133 AUDIO SYSTEM All radio systems available on the 2001 JR communicate on the PCI Bus. They use the bus for three reasons. The first is to communicate trouble codes, second is to receive dimming information, and third is to receive cabin equalization information. The audio system is available in a 4 speaker base system and a 6 speaker system with an external power amplifier. An in-dash CD Changer is also optional. Depending on the manufacturer of the radio, some systems have a front/rear output system and others have a left/right output system. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. The new in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with you system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Programmable Communication Interface or PCI bus). This network consists of the powertrain control module (PCM), sentry key immobilizer module (SKIM), the Transmission Control Module (TCM), the electro/mechanical instrument cluster (MIC), Compass/mini-trip Computer (CMTC) occupant restraint control (ORC) module, optional Antilock Brakes (ABS), the radio remote CD-player, optional left and right airbag control modules. The (BCM) is operational when battery power is supplied to the module, ignition switch power is needed for ignition switched functions. The body control module provides the following features: A/C switch status/evaporator temperature status BCM diagnostic support Central lock and unlock (VTSS only) Climate Control system support Door ajar switch status Door Lock Inhibit (key in ignition or headlamps/park lamps ON) Electronic Odometer Support Headlamp Time Delay Illuminated Entry with "fade to OFF" Interior lighting with battery save feature Mechanical Instrument Cluster (fuel level, dim data, odometer & warning chime) support Travel information system Power convertible top Power door lock multiplexing control Rear Window Defogger Control Remote Keyless Entry with Panic Mode Remote power deck lid release Rolling door lock control (customer programmable) Sentry key immobilizer support Vehicle Theft Security System Wiper Control (speed sensitive with return to park) The BCM receives information over the PCI Bus from the PCM in order to support certain features. The required information is as follows: Engine RPM - Engine Temperature - Injector on Time and Distance Pulses - Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 134 - Charging System Failure, Engine Temperature Limp-In, VTSS Arming Status - Engine Model - "Check Engine" lamp status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 135 The BCM provides the PCM with information on the A/C switch status and the VTSS status. The JR has several customer programmable features which can be disabled or enabled by the customer. CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 136 Ambient Temperature Sensor The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Powertrain Control Module (PCM), the Programmable Communications Interface (PCI) data bus, and portion of the Compass Mini-Trip Computer (CMTC). If any portion of the ambient temperature sensor circuit fails, the BCM Will self-diagnose the circuit and set a DTC. The CMTC Will lock the display at 54 °C (130 °F) if the sensor is exposed to temperatures above 54 ° (130 °F), or if the sensor is shorted. The CMTC Will lock the display at -40 °C (-40 °F) if the sensor is exposed to temperatures below -40 °C (-40 °F), or if the sensor circuit is open. DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and decklid are in. The DRB III will display the state of the door ajar and the decklid ajar switches in Inputs/Outputs. It's important to note, that when any door, or the decklid is closed, the switch state on the DRB III will show OPEN. When any door, or the decklid is open the switch state on the DRB III will show CLOSED. During diagnosis, if a door or the decklid is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the decklid is open and the DRB III displays the switch state as OPEN, it indicates an open ajar circuit. EXTERIOR LIGHTING SYSTEM Headlamp Delay The headlamp time delay operates when the ignition switch is turned OFF while the headlamps are still ON, and the headlamps are then turned OFF within 45 seconds after the ignition is OFF. This will provide a 90-second time delay before turning OFF the headlamps. Part 2C HEATING AND A/C SYSTEMS A single-zone HVAC system is available on all JR series vehicles. Manual Temperature Control HVAC Control The HVAC system maintains incoming air temperature, airflow, fan speed, and fresh air intake for the entire vehicle from the instrument panel mounted A/C - Heater Control. The full range of temperature that the system can produce in any mode for the entire vehicle is available by positioning the blend Control to the desired range. Air Intake When the fresh-air door is open, outside air is drawn into the HVAC housing through the cowl opening at the base of the windshield. When the fresh-air door is closed, recirculated air is drawn in to the HVAC housing from under the instrument panel. Air Distribution The HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single, central mounted outlet delivers air for defrosting the windshield. Two ducts, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and the front seat passenger floor area. A/C-heater Control, Switch Operation Blower Switch The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Mode Switch The rotary Mode Switch has a total of eight positions. The first three, for A/C request, include Recirc/Bi-level, Panel, and Bi-level. The remaining five positions, for Heat request, include Panel, Bi-level, Floor, Floor/Defrost, and Defrost. The Floor/Defrost position and the Defrost position also provided an A/C request. Mode Switch, A/C Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to any of the three A/C request positions, the Floor/Defrost position, or the Defrost position, will result in the A/C - Heater Control sending a signal to the BCM to send a message to the PCM to provide A/C compressor clutch activation. However, the BCM will only provide this request if EVAP function is found acceptable. Mode Switch, Mode Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch will result in the A/C Heater Control sending a signal to the BCM to signal the actuator to move the mode door. A potentiometer, inside the Mode Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 137 Mode Switch, Fresh-air Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to the Recirc position will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to close the fresh-air door. While rotating the mode Switch to any other position results in the A/C - Heater Control sending a signal to the BCM to signal the actuator to open the fresh-air door. When the Blower Switch is OFF, the fresh-air door closes to prevent outside air from entering the passenger compartment. Blend Switch The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Rear Window Defogger Switch The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C - Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. Diagnostic Trouble Codes All HVAC Diagnostic Trouble Codes are stored in the Body Control Module. Stored DTCs indicate that a problem has occurred in the HVAC system, and may still be present. To verify a problem is still present in the HVAC system, use the DRB III to erase all stored BCM DTCs. After erasing the DTC(s), use the DRB III to see if the DTC(s) reappear. If necessary, actuate the A/C - Heater Control switches with the ignition ON and with the engine running while monitoring the DRB III to see if the DTC(s) reappear. INTERIOR LIGHTING Courtesy Lamp Control The body controller has direct control over the majority of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door is ajar. 2. The courtesy lamp switch ON the instrument panel is closed. 3. A Remote Keyless entry unlock message is received. If the interior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 15 minutes or until either the dome lamp switch or door ajar switch changes state. Illuminated Entry Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned ON, the illuminated entry also cancels. MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster (MIC) is divided into 4 sections. Primary gauges (Speedometer and Tachometer), secondary gauges (Fuel Level, Engine Coolant Temperature), PCI bus enabled indicator lamps and hardwired enabled indicator lamps. The gauge mechanisms function in the same way. The main differences are in the face and size of the gauge. The Oil Pressure, Brake Warning, Turn Signal and Fog Lamp indicators are directly wired to the circuits that they are indicators for. These indicators are located in, but not controlled by, the MIC and are not part of any MIC self test or diagnostic. All indicators are replaceable bulbs or LEDs. The PCM sends a gauge position message to the BCM through the PCI bus. The MIC receives this message from the BCM, translates it, and positions the gauges. The BCM also sends messages to the MIC to actuate all PCI controlled indicators. These messages are received when the Ignition Switch is in the RUN or START position. When the ignition Switch is turned to the RUN position, a bulb-check is performed. This consists of activating the PCI bus controlled indicators for approximately 2 to 4 seconds. By holding the TRIP/RESET button in while turning the Ignition Switch to the RUN position, you can activate the MIC Self Test. The Following indicators are controlled by PCI bus messages: Malfunction Indicator Lamp - Charging System Warning Indicator - Engine Coolant Temperature Indicator - Cruise Engaged Indicator - Airbag Warning Indicator - Low Fuel Indicator - ABS Warning Indicator - High Beam Indicator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 138 The following indicators are hardwired and not controlled by PCI bus messages: - Seat Belt Indicator - Oil Pressure Indicator - Brake Warning Indicator - VTSS Indicator - Turn Signal Indicators - Fog Lamp Indicators POWER DOOR LOCK SYSTEM The door lock switches provide a variable amount of voltage through the Multiplexed (MUX) circuit to the BCM. Depending upon that input and various conditions that must be met (i.e. door lock inhibit, etc.), the BCM will determine the action to be taken and activate the proper relay for approximately 250 to 350 msec. If the vehicle is equipped with the vehicle theft security system it will have the central locking feature which locks and unlocks all doors from the cylinder lock switches. These switches are on separate multiplexed circuits to the BCM and have trouble codes relating to each of them. RKE Remote Keyless Entry - This feature allows locking and unlocking of the vehicle door(s) by remote control using a hand-held transmitter (sometimes referred to as a fob) to activate a radio receiver (RKE module). This module now plugs into the body control module which is directly connected to the junction block. With this feature RKE can now be added to a non-equipped vehicle by installing a module. If the vehicle is equipped with the vehicle theft security system, RKE will also arm and disarm that system. A 4-button transmitter is used which provides lock, unlock, decklid release and panic features. Decklid release is only operable while the vehicle is in the park position. The module is capable of retaining up to 4 transmitter codes. Rolling code, which increases security, is also included in this system. If the transmitter goes out of synchronization it is easily put back in by pressing the lock button when the transmitter is within range. An external antenna has been added which plugs into the module to provide greater range. RKE will also turn ON the interior lamps when a valid unlock command is received and will extinguish the interior lamps when a lock command is received and all doors are closed. Door Lock Inhibit - When the key is in the ignition and the driver front door is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic (rolling) Door Locks - This feature can be enabled or disabled by using either the DRB III or the customer programmable method. When enabled, all doors will lock when the vehicle reaches a speed of 15 mph (24 km/h) and all doors are closed. If a door is opened and the vehicle slows to below 15 mph (24 km/h), the locks will operate again once all doors are closed and the speed is above 15 mph (24 km/h). Decklid Release - Decklid release is now a function of the body control module. Trouble codes are provided to assist in the diagnosis of this system. Customer programmable features are: Horn chirp, one or two press decklid release, programming a new transmitter (using a previously programmed transmitter), rolling door locks, unlock on exit, and RKE lamp flash. POWER CONVERTIBLE TOP Top Control The body control module now controls all the functions of the convertible top. The body control module supplies a multiplexed voltage of approximately 90% of ignition voltage to the power top switch. Through a series of resistors the power top switch switches the circuit to ground depending on the position of the switch. The BCM then supplies the ground path for the up or down relay as requested. The power top switch has a 4.7-ohm diagnostic resistor that allows the BCM to detect a possible open circuit. Window Drop Relay Assembly The convertible has a new feature that allows the operator to lower all four windows and lower the top at the same time. This is accomplished by pressing the power top switch to the second detent. Through the multiplexed circuit of the power top switch the BCM will supply the ground for the window drop relay assembly. The window drop relay assembly is comprised of four separate relays that are in series with the power window circuits. The relay assembly is located in the driver door. VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 139 Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 140 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The vehicle theft security system (VTSS) is part of the body control module (BCM), which monitors vehicle doors and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 141 headlamps, courtesy lamps, and the VTSS indicator lamp. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the instrument cluster will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm and the indicator will flash at a slow rate. If the indicator lamp remains steadily lit during the arming process, this can indicate a loss of decklid cylinder lock switch. When something triggers the alarm, the system will signal the headlamps, courtesy lamps, and horn for about 3 minutes, then headlamps for an additional 15 minutes if the offending input is still present. For complaints about the Theft Alarm going OFF on its own use the DRB III and select "Body Computer" then "Input/Output Display" and read the "Last VTSS Cause" status. Tamper Alert - The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch or the RKE. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Tests - NOTE: System self tests can be entered only with the DRB III. NOTE: A Powertrain Control Module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes ON after ignition ON and stays ON, the PCI bus communication with the Powertrain Control Module possibly has been lost. WIPER SYSTEM The wiper system provides the driver with the normal wiper (low and high speeds), intermittent wipe, and wipe after wash. The driver selects the wiper function via the resistive multiplexed stalk switch mounted on the steering column. The BCM uses the input signal from the wiper stalk switch, wiper motor park switch, and the washer switch to control the wiper system. The Body Control Module (BCM) then controls the relays and timing functions to provide the driver selected features. Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 mph (6 km/h), the delay time is doubled providing a range of 1 second to 36 seconds. Park after Ignition OFF Because the wiper relays are powered from the battery the BCM can run the wipers to park after the ignition is turned OFF. Wipe after Wash When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. The wiper system utilizes the BCM to control the ON/OFF and hi/low relays fro low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode, and wiper motor park functions. The BCM uses the vehicle speed input to double the usual delay time below 10 mph (17 km/h). WARNINGS VEHICLE DAMAGE WARNINGS Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 142 When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. ROAD TEST COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition. WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool GLOSSARY OF TERMS ABS Antilock brake system ACM Airbag control module AECM Airbag electronic control module (ACM) ASDM Airbag system diagnostic module (ACM) BCM Body control module CAB Controller antilock brake CMTC Compass/mini-trip computer DAB Driver airbag DLC Data link connector DTC Diagnostic trouble code DR Driver EBL Electric back lite (rear window defogger) HVAC Heater ventilation, air conditioning MIC Mechanical instrument cluster MTC Manual temperature control OBD On board diagnostics ODO Odometer ORC Occupant restraint controller (ACM) PAB Passenger airbag PASS Passenger PCI Programmable Controller Interface (vehicle communication bus) PCM Powertrain control module PDC Power distribution center PWM Pulse width modulated RKE Remote keyless entry SAB Seat airbag SBT Seat belt tensioner SIACM Side impact airbag control module SKIM Sentry key immobilizer module SKIS Sentry key immobilizer system SQUIB Also called initiator (located inside airbag) SRS Supplemental restraint system TCM Transmission control module VFD Vacuum fluorescent display VTSS Vehicle theft security system Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - Use DRB to actuate chime - Body control module chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 145 CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status on DRB III - Seat belt switch shorted - Seat belt switch sense short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Exterior Lights On and Drivers Door Open Test 1 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LIGHTS ON AND DRIVERS DOOR OPEN POSSIBLE CAUSES - Open headlamp switch output - Body control module Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 146 Tests 1 - 3 Tests 4 - 5 SYMPTOM CHIME INOPERATIVE WITH KEY-IN IGNITION AND DRIVER DOOR OPEN POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - BCM incorrect key-in ignition switch status Chime Sounds With Driver Seat Belt Fastened Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 147 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt SW status wrong-open - Seat belt switch open - Ground wire open - Seat belt SW SEN open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 148 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVERS DOOR OPEN AND KEY REMOVED FROM IGNITION POSSIBLE CAUSES - Key-in ignition switch status wrong - Key-in ignition switch status wrong - Key-in ignition SW sense short to ground - Body control module - key-in ignition shorted Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 149 Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 150 Body Control Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 151 Down or Page Up function to display the information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 156 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 157 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 158 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 159 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 162 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 163 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 164 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 165 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 166 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 167 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 168 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 174 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Engine Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 Engine Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams 2001 JR Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 188 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 189 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (PDC) Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 194 Fuel Pump Relay: Diagrams Power Distribution Center (PDC) Fuel Pump Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 195 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the Automatic Shutdown (ASD) relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 199 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 200 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller > Page 206 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) 4-Door Models SIACM are located on the left and right "B" post, just above the seat belt retractor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 207 Air Bag Control Module: Diagrams Left Side Impact Airbag Control Module (JR-41) Occupant Restraint Controller Right Side Impact Airbag Control Module (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 208 Air Bag Control Module: Service Precautions WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description Air Bag Control Module: Description and Operation System Description AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) Supplemental driver and passenger curtain airbags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity # 5 of the SIACM connector. If cavity # 5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 211 The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds then goes OFF, there is usually an intermittent problem in the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 212 Air Bag Control Module: Description and Operation Component Description OCCUPANT RESTRAINT CONTROLLER The Occupant Restraint Controller (ORC) contains the impact sensor and energy reserve capacitor. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ORC monitors the system to determine the system readiness. The ORC stores sufficient energy to deploy the airbags in case battery power is lost prior to impact. The ORC contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few seconds every time the vehicle is started. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Page 213 Air Bag Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. 2. For a manual transmission, remove shifter knob and boot. 3. For automatic transmission models, remove shifter knob and unsnap shift indicator bezel. 4. Remove the four attaching screws to floor console. 5. Remove parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Removal. 6. Remove three mounting nuts to ORC. 7. Disconnect wire harness connectors and remove ORC from mounting studs. INSTALLATION CAUTION: Use supplied nuts only. 1. With the battery disconnected, position the ORC (arrow pointing forward) on center tunnel area mounting studs. 2. Connect wire harness connector. 3. Attach the three mounting nuts and tighten to 10 to 14 Nm (85 to 125 in. lbs.) torque. 4. Install the parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Installation. 5. Install the floor console. 6. Install the four attaching screws to floor console. 7. For automatic transmission models, install the shift indicator bezel and shifter knob. 8. For a manual transmission, install the shifter boot and knob. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center (PDC) Engine Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 218 Starter Relay: Diagrams Power Distribution Center (PDC) Engine Starter Motor Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 219 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 220 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 226 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 227 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 236 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 241 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 242 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 243 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 249 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 255 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 260 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 261 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 262 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 267 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 273 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 279 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 284 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 285 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 286 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 287 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 288 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 289 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 294 Rear Window Defogger Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 295 Heated Glass Element Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 296 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 297 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 298 Heated Glass Element Relay: Description and Operation The rear window defogger relay is an electromechanical device that switches fused battery current to the rear glass heating grid and the Light-Emitting Diode (LED) indicator of the rear window defogger switch, when the Body Control Module (BCM) rear window defogger timer and logic circuitry grounds the relay coil. The rear window defogger relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The rear window defogger relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. when the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 299 Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. 40 amp EBL fuse in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay (EBL) from the Junction Block. 3. Using voltmeter, test battery voltage: a Test rear window defogger relay terminals 13 for battery voltage. If voltage is OK, go to Step b. If voltage is not OK, repair A4 circuit. b Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step c. If voltage is not OK, repair A31 circuit. c Use a known good relay. If not OK, repair circuits as necessary. Refer to Wiring Diagrams. If OK, replace relay. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 300 Heated Glass Element Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Open the driver's door and remove instrument panel end cover. 3. Remove Rear Window Defogger (EBL) relay from the Junction Block. INSTALLATION 1. Install Rear Window Defogger (EBL) relay in the Junction Block. 2. Install the instrument panel end cover. 3. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center (PDC) Front Wiper On/Off and High/Low Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 305 Wiper Relay: Diagrams Power Distribution Center (PDC) Front Wiper ON/OFF Relay Front Wiper High/Low Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 311 Lock Cylinder Switch: Diagrams Decklid Cylinder Lock Switch (VTSS) Driver Cylinder Lock Switch (VTSS) Passenger Cylinder Lock Switch (JR-41) (VTSS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 312 Lock Cylinder Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Refer to Body, Door - Front, Trim Panel, Removal. Central Locking Switch 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection Remote Switch: Testing and Inspection 1. Remove switch from instrument panel. (Refer to POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). Fig.2 Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 3. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection > Page 316 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, pry the trim bezel from the instrument panel. 3. Disconnect wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION 1. Install switch to trim bezel. 2. Connect wire harness connector to switch. 3. Install trim bezel to instrument panel. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 321 Power Door Lock Switch: Testing and Inspection VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check fuse 13 in the Junction Block for a blown fuse. Refer to Wiring Diagrams for circuit information. Door Lock Switch Continuity DOOR LOCK SWITCH Remove the switch from its mounting location. Using an ohmmeter, refer to the table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 322 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove door trim panel, refer to Body, Door - Front, Trim Panel, Removal. 3. Disconnect switch wire connector. 4. Remove switch using a trim stick (special tool #C-4755) or equivalent. INSTALLATION 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the door trim panel, refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 326 Power Seat Switch: Service Precautions WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 327 Power Seat Switch: Description and Operation Vehicles equipped with power seats utilize a eight-way power seat switch. This eight-way power seat switch features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the eight-way power seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. The power seat tracks can be adjusted in eight different ways using the power seat switches. See the owners manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 328 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from its mounting position. Refer to the procedure. Switch Continuity Test Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table and the seat switch connector. If there is no continuity in any of the switch positions, replace switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 329 Power Seat Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Power Seat Switch 2. Remove the seat cushion side shield from the front seat. Refer to the Body for the procedure. 3. Remove the knobs from the seat switch by gently prying straight off. 4. Remove the switch attaching screws. 5. Remove switch from cushion side shield INSTALLATION 1. Position the switch and install the four switch attaching screws. 2. Install the knobs on the switch. 3. Connect wiring electrical connector on switch. 4. Install the seat cushion side shield. Refer to Body for the procedure. 5. Connect the negative battery cable remote terminal on the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures CONTROL SWITCH REMOVAL Fig.1 Sunroof Control Switch 1. Using a flat blade tool, release switch from the headliner. 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 334 Sunroof / Moonroof Switch: Removal and Replacement SUNROOF CONTROL SWITCH REMOVAL Fig. 1 1. Using a flat blade tool, release switch from the headliner (Fig. 1). 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Decklid Release Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 338 Trunk / Liftgate Switch: Service and Repair REMOVAL 1. Open hood and disconnect the negative battery cable remote terminal from the remote battery post. 2. Remove left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Removal. 3. Disconnect the wire connector. 4. Pinch four tabs around side of decklid release switch on the rear side of the left lower instrument panel trim, and push switch through opening. INSTALLATION 1. Position the decklid release switch over opening of the left lower instrument panel trim, and push switch through opening. 2. Connect the wire connector. 3. Install the left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 343 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch on the side of the reservoir. 2. Using a small screwdriver, release the retaining tabs on the opposite end of brake fluid level switch (on right side of reservoir) securing it to the reservoir. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications ABS Wheel Speed Sensor Mounting Bolt 75 ft.lb Front Sensor 0.017 - 0.067 in Rear Sensor 0.015 - 0.052 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 349 Wheel Speed Sensor: Connector Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 350 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Left Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 351 Right Wheel Front Speed Sensor Right Wheel Front Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 352 Wheel Speed Sensor: Testing and Inspection INSPECTION - TONE WHEEL Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ Wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the tone wheel is incorporated into the hub and bearing assembly and the hub and bearing must be replaced. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL This procedure is for the removal and installation of one of the two front wheel speed sensors. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Vehicle Lifting for the required lifting procedure to be used for this vehicle. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 355 5. Remove bolt attaching speed sensor to steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly. Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. INSTALLATION This procedure is for the removal and installation of one of the two front wheel speed sensors. CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 356 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 357 CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber as shown. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 358 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Fold down rear seat back. 2. Disconnect speed sensor connector at vehicle wiring harness found at lower outside comer of seat back 3. Raise vehicle. 4. Remove rear tire and wheel assembly from vehicle. 5. Remove speed sensor harness sealing grommet retainer from the rear frame rail of the vehicle. 6. Remove speed sensor harness sealing grommet and harness from hole in body of vehicle. 7. Remove speed sensor routing clips from the rear upper control arm. 8. Remove bolt, then wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor harness is critical to continued system operation. Be sure that harness is installed properly to avoid harness contact with moving parts or overextension, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 359 1. Install speed sensor head into brake adapter. Install bolt through routing clip and secure wheel speed sensor in place. Tighten bolt to 8 Nm (75 inch lbs.) 2. Install speed sensor harness routing clip on upper control arm. Install and securely tighten the routing clip attaching bolt. 3. Install connector end of speed sensor harness through hole at frame rail. 4. Install speed sensor harness sealing grommet into hole. Install the sealing grommet retainer and attaching bolt. Securely tighten retainer attaching bolt. 5. Install the tire and wheel assembly on vehicle. 6. Lower vehicle. 7. Connect speed sensor harness connector to vehicle wiring harness behind rear seat back. Install sleeve back over the speed sensor harness connection to prevent rattling. 8. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 365 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 366 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 367 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 368 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed control switches are located on the steering wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 373 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM. The switch names are: ON, OFF, SET COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST RESUME, ACCEL, TAP-UP TAP-DOWN, COAST and CANCEL. Refer to the Speed Control for more information. Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 374 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO the RESTRAINT SYSTEMS for more information. 1. Remove the negative battery cable. 2. Turn OFF ignition. Fig.4 Speed Control Switch 3. Remove screw from back of the switch. 4. Rock switch away from airbag and steering wheel. 5. Disconnect two-way electrical connector. 6. Repeat for the other switch. INSTALLATION 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw into the back of the switch. 4. Repeat for the other switch. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: All Technical Service Bulletins Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 393 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 394 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 395 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 396 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Description and Operation Air Door Position Sensor / Switch: Description and Operation BLEND SWITCH The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient air temperature sensor is located on the inside of front bumper beam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 404 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 405 Ambient Temperature Sensor / Switch HVAC: Description and Operation Fig.21 Ambient Temp Sensor The ambient air temperature sensor is located on the inside of front bumper beam. This sensor informs the ATC system of the ambient temperature outside vehicle. The ambient temp sensor is used by the ATC system to adjust blower speed, temperature offsets, evaporator temperatures and mode control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 406 Ambient Temperature Sensor / Switch HVAC: Service and Repair Fig.22 Ambient Temp Sensor REMOVAL 1. Remove sensor mounting push pin. 2. Disconnect sensor wiring connector. INSTALLATION 1. Connect the sensor wiring harness connector. 2. Install the sensor fastener push pin. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER SWITCH The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is located at the coldest point on the face of the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor / Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 415 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 416 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 418 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 419 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 420 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 421 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Evaporator Temperature Sensor / Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 431 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 433 A/C Evaporator Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 434 HVAC Actuators & EVAP Temperature Senser Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 435 Evaporator Temperature Sensor / Switch: Description and Operation Fig.15 Evaporator Temperature Sensor The evaporator temperature sensor is located at the coldest point on the face of the evaporator. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The sensor is used to switch the clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the Body Control Module. The clutch is switched OFF when the sensor temperature reaches 1.1 °C (34 °F). The clutch is switched back ON when the sensor temperature reaches 2.2 °C (36 °F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 436 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Lower glove compartment door. Fig.16 Evaporator Probe Wiring 3. Reach through glove compartment door opening and disconnect evaporator temperature sensor wiring connector. Fig.17 Evaporator Probe 4. Using a flat blade pry tool, pull back on the locking tab. Twist access plate clockwise one-quarter turn and pushed inside the A/C housing. Then orientated the plate in such a way that it can be removed from the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 437 Fig.18 Remove Probe 5. Pull probe out of evaporator core. INSTALLATION 1. Install new sensor into the evaporator. NOTE: The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Install glove compartment door. 5. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 441 A/C Pressure Transducer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 442 Refrigerant Pressure Sensor / Switch: Description and Operation A/C PRESSURE TRANSDUCER The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. This switch prevents compressor operation when the discharge line pressure approaches extreme levels. The transducer is a factory-calibrated unit and cannot be adjusted or repaired. If faulty or damaged, it must be replaced. When discharge line pressure rises above 2971 kPa (431 psi) the switch contacts open and interrupt the A/C clutch relay signal from the PCM. The switch contacts also open when pressure drops below 206 kPa (30 psi). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 443 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. 1. Disconnect the wire harness connector from the A/C pressure transducer 2. Remove transducer with a 14 mm open-end wrench. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. INSTALLATION NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. 1. Thread pressure transducer on to discharge line. 2. Tighten pressure transducer to 6 Nm (50 in. lbs.). 3. Connected wire connector to transducer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 447 Sun Sensor (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 448 Solar Sensor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 449 Solar Sensor: Description and Operation Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. The sun sensor is not a thermistor type sensor but rather a photo diode. For this reason the sun sensor responds to sun light intensity rather than temperature. It is used to aid in determining proper mode door position, temperature door position and blower speed. The sun sensor is also used to sense day/night conditions for automatic headlight control if so equipped, and has an LED indicator for the vehicle security system. The sun sensor is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 450 Solar Sensor: Testing and Inspection SUN SENSOR TEST WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The sun sensor is located so the sun hits the sensor in the same way that it hits the driver and the passenger. It is important that the area in front of the sensor be unobstructed. Check that the following items are not in the way of the sun sensor. - Windshield wipers that are adjusted too high. - Stickers on the windshield that are directly in front of the sensor. - Top cover installed not properly. Sun sensor should be 1/4 inch. above the top cover. - Caps or papers which might cover the sensor. Some ATC equipped vehicles may exhibit a lack of passenger comfort in sunny weather such as in the early afternoon. Verify that the ATC system is functioning properly. Inspect the location of the sun sensor. The sun sensor must protrude approximately 1/4 inch above the instrument panel top cover to insure proper operation. If the sensor does not protrude 1/4 inch, perform the following procedure: - Confirm that the top cover is properly installed - Remove the top cover - Remove fasteners from sun sensor - Install one 1/4-20 nut per fastener under the sun sensor so that it is shimmed higher - Reinstall the sun sensor. Do not overtighten screw. If a longer screw is required, use 8-15x1 inch. Refer to the proper Diagnostic Information for the electrical test. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 451 Solar Sensor: Service and Repair SUN SENSOR REPLACEMENT REMOVAL 1. Disconnect negative battery cable. 2. Remove instrument panel top cover. Refer to Instrument Panel for the procedures. Fig.20 Sun Sensor 3. Remove two Sun Sensor mounting screws. 4. Lift sensor off the instrument panel and disconnect the wiring. 5. Remove the sensor from the vehicle. INSTALLATION 1. Connect wiring connector to sensor and position on instrument panel. 2. Install the two sensor fasteners. 3. Install instrument panel top cover. Refer to Instrument Panel System for the procedures. NOTE: Sun sensor must protrude approximately 1/4 inch above instrument panel top cover to ensure proper operation. 4. Connect negative battery Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 456 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 460 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 461 Fuel Gauge Sender: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 1). Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 462 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector (Fig. 3). 4. Push level sensor signal and ground terminals out of the connector (Fig. 3). Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove (Fig. 4). 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection To test the key left in ignition function: - The ignition switch must be in the OFF position with key in ignition. - Driver's door open. - Chime should sound until key is removed from ignition or drivers door is closed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations The brake lamp switch is located under the instrument panel at the brake pedal arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 470 Brake Light Switch: Description and Operation The brake lamp switch is located under the instrument panel at the brake pedal arm. It controls operation of the vehicle's brake lamps. Also, if the vehicle is equipped with speed control, the brake lamp switch will deactivate speed control when the brake pedal is depressed. When the brake pedal is depressed, the plunger on the outside of the switch extends outward. This action closes the electrical contacts within the switch, completing the circuit to the brake lamps at the rear of the vehicle, thus illuminating the brake lamps and the Center-High-Mounted Stop Lamp (CHMSL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 471 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. Refer to ADJUSTMENTS. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Refer to REMOVAL for the proper procedure. Fig.2 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. Refer to INSTALLATION for the proper procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 472 Brake Light Switch: Adjustments 1. Remove the brake lamp switch from its bracket. The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch if necessary. 3. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Connect the wiring harness connector to the brake lamp switch if previously disconnected. 5. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 6. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 7. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 473 Brake Light Switch: Service and Repair REMOVAL 1. Remove the brake lamp switch from its bracket . The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch. INSTALLATION NOTE: Prior to installing brake lamp switch into the mounting bracket, the plunger must be moved to its fully extended position using the procedure in Step 1. 1. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the brake lamp switch. 3. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 474 CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 4. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 5. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: Customer Interest Trip Computer/Radio Display/IP/Dome Lights - Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 483 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: All Technical Service Bulletins Trip Computer/Radio Display/IP/Dome Lights Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 489 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 490 Combination Switch: Testing and Inspection 1. Remove multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-function Switch, Removal and Installation. Multi-Function Switch Continuity Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 491 Fig.22 Multi-Function Switch Connectors 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the table and. The switch assembly is mounted over the center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 492 Combination Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove the upper steering column shroud. Refer to Steering, Column, Shroud, Removal. Fig.23 Multi-Function Switch Mounting 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION Position the switch on the steering column and install the retaining screws. 1. Tighten multi-function switch to column retaining screws to 2.3 Nm (20 in. lbs.) torque. 2. Install the steering shrouds and screws. Refer to Steering, Column, Shroud, Installation. 3. Tighten steering column cover retaining screws to 2 Nm (17 in. lbs.) torque. 4. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 496 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Open glove box door. 3. Push switch through from behind. 4. Disconnect wire harness from switch. 5. Remove bulb from switch. INSTALLATION 1. Install bulb to switch. 2. Connect wire harness to switch. 3. Install switch to instrument panel. 4. Close glove box door. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 503 Hazard Warning Switch: Description and Operation Fig.15 Hazard Warning Switch HAZARD WARNING SWITCH The hazard warning switch push button protrudes from the top of the steering column. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The hazard warning system is actuated by a push button located on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on top of the button. Push and release the button to turn the hazard function ON or OFF. The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position. Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 504 The multi-function switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Leveling Switch (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn switch is molded into the airbag trim cover. The horn switch can not be serviced separately. For service procedures, refer to RESTRAINTS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 514 Turn Signal Switch: Description and Operation Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH The multi-flinction switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 524 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 525 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 526 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 527 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 531 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 532 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 533 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 534 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 539 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 540 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 541 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 542 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 543 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 547 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 548 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 549 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove. 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 553 Intake Air Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 554 Intake Air Temperature Sensor: Description and Operation Fig. 19 TPS And Inlet Air Temp Sensor INLET AIR TEMPERATURE SENSOR The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 558 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Plastic Manifold .............................................................................................................. .....................................................1.7 Nm (15 in. lbs) MAP Sensor Aluminum Manifold ......................................................................................................... ....................................................3.3 Nm (30 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 562 Manifold Pressure/Vacuum Sensor: Locations The MAP sensor mounts to the driver side of the intake manifold plenum Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 563 Manifold Absolute Pressure Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 564 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 23 MAP Sensor Fig. 24 Generator And MAP Sensor The MAP sensor mounts to the driver side of the intake manifold plenum or. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 565 direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key on is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the CCD bus) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg (Table 1). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Always use the Diagnostic Test Procedures for MAP sensor testing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 566 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove sensor. INSTALLATION 1. The sensor mounts onto intake manifold plenum. Tighten screws to 4.5 Nm (40 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 571 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 572 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 573 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 574 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications O2 Sensors .......................................................................................................................................... ........................................................27 Nm (20 ft. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The O2S are located at the outlet ends of the catalytic converter Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 580 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 583 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 584 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 585 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 586 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 587 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 588 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 589 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 590 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 591 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 592 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 593 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 594 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 595 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 596 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 597 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 599 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Oxygen Sensor: Connector Views Oxygen Sensor 1/1 Right Bank Up Oxygen Sensor 1/2 Right Bank Down Oxygen Sensor 2/1 Left Bank Up Oxygen Sensor 2/2 Left Bank Down Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 602 Oxygen Sensor Connector (Component Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 603 Oxygen Sensor: Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Oxygen Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 605 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 608 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 609 Oxygen Sensor: Description and Operation Fig. 26 O2 Sensors The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Separate controlled sensor ground ground circuits are run through the PCM for the upstream O2 sensors. As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor; one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM pulse width modulation the ground side of the heater to regulate the temperature. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 610 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement Oxygen Sensor: Service and Repair Downstream (1/2, 2/2) Sensor Replacement REMOVAL Fig. 26 O2 Sensors The O2S are located at the outlet ends of the catalytic converter. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Remove the negative battery cable. 2. Raise and support the vehicle. 3. Disconnect the wire connector from the O2S. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 4. Remove the O2S Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION The O2S are located at the outlet ends of the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Install the O2S. Tighten to 28 Nm (20 ft. lbs.) torque. 3. Connect the O2S wire connector. 4. Lower the vehicle. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement > Page 613 Oxygen Sensor: Service and Repair Upstream (1/1, 2/1) Sensor Replacement REMOVAL The engines uses two heated oxygen sensors, one in each exhaust manifold. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 1. Remove the negative battery cable. 2. Remove the air cleaner box for the rear O2 sensor. 3. Disconnect the heated oxygen sensor electrical connector. 4. Use a Special tool # 8439 to remove oxygen sensor. INSTALLATION The engines uses two heated oxygen sensors, one in each exhaust manifold. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Use a Special tool # 8439 to install oxygen sensor. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 3. Connect the heated oxygen sensor electrical connector. 4. Install the air cleaner box. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Page 617 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 621 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 622 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 623 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 627 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 628 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 629 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 630 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 635 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 636 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 637 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 638 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 639 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 640 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 641 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 642 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 643 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 646 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 649 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 650 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 651 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 653 Vehicle Speed Sensor (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 658 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 659 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 660 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 666 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 667 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 668 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 669 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 674 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 675 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 676 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 677 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 678 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 687 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 693 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 694 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 695 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 696 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 697 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 698 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Driver Seat Belt Switch (JR-41) (Except Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Page 716 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 725 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 726 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 730 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 731 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 732 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 733 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 737 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 740 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 741 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 742 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 745 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation REAR WINDOW DEFOGGER SWITCH The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C-Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. The rear window defogger control switch and circuit are integrated into the HVAC control assembly. Refer to the HVAC control assembly for additional information. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for 15 minutes upon initial actuation. Then 10 minutes with each subsequent actuation or until either the switch or ignition is turned OFF. An indicating lamp illuminates the rear window defogger switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Page 750 Heated Glass Element Switch: Testing and Inspection The rear window defogger control switch and timer circuit may be tested in the vehicle with or without a scan tool, such as the DRB III. Testing With Scan Tool Using a scan tool, refer to the proper Body Diagnostic Procedures. Testing Without Scan Tool 1. Remove the HVAC control head from the instrument panel however, do not disconnect any of the electrical connectors if possible. 2. Using a ohmmeter, check leads between Pins 5 and 1 of the HVAC electrical connector. Depress the rear window defogger button and the resistance reading should be 360 ohms (± 10%). If not OK, replace HVAC. If OK, check for the following possible causes: Rear window relay (EBL) - Blown fuse - Cut wire - Poor ground - Poor connection - Defective BCM - Bulkhead connector inoperative Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Master Power Window Switch Passenger Power Window Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 754 Power Window Switch: Testing and Inspection Master Window Switch Continuity Test Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 755 Passenger Window Switch Continuity Test For switch testing, remove the switch. (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL) Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct and. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 756 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch mounting fasteners. INSTALLATION 1. Install switch and mounting fasteners. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications Front Wheel Alignment Camber Preferred +0.1 deg Acceptable -0.5 to +0.7 deg Cros Camber Preferred 0.0 deg Acceptable 0.7 deg Caster Preferred +3.1 deg Acceptable +2.1 to +4.1 deg Cross Caster Preferred 0.0 deg Acceptable 1.0 deg Toe (Right or Left) Preferred +0.05 deg Acceptable -0.05 to +0.15 deg Total Toe Preferred +0.1 deg Acceptable -0.1 to +0.3 deg Curb Height 28.0 +/- 0.75 in Rear Wheel Alignment Camber Preferred -0.1 deg Acceptable -0.5 to +0.3 deg Toe (Right or Left) Preferred +0.05 deg Acceptable -0.05 to +0.15 deg Total Toe Preferred +0.1 deg Acceptable -0.1 to +0.3 deg Thrust Angle Preferred 0.0 deg Acceptable 0.0 +/- 0.15 deg Curb Height 28.0 +/- 0.75 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 765 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION - WHEEL ALIGNMENT Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. On this vehicle, the suspension angles that can be adjusted are as follows: Front Camber (using special procedure) - Toe Rear Camber - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Testing and Inspection; Procedures; Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Fig. 1 Camber is the inward or outward tilt of the top of the tire and wheel assembly. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. ID achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is +0.3° and the right camber is 0.0°, the cross camber would be +0.3°. CASTER Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 766 Fig. 2 Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster angle. CROSS CASTER Cross caster is the difference between left and right caster. TOE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 767 Fig. 3 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equally distant. TOE-OUT ON TURNS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 768 Fig. 4 Toe-out on turns is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 769 Fig. 5 Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Fig. 6 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection STANDARD PROCEDURE- PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications, check for broken or sagged springs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 772 Alignment: Service and Repair Wheel Alignment STANDARD PROCEDURE - WHEEL ALIGNMENT 1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. NOTE: Set the rear wheel alignment first before proceeding to the front to set the front wheel alignment. 5. If rear camber or toe is not within specifications, proceed to REAR CAMBER AND TOE below. If rear camber and toe are within specifications, but front camber and caster are not, proceed to FRONT CAMBER AND CASTER which can be found following REAR CAMBER AND TOE. If rear camber and toe, and front camber and caster are within specifications, proceed to FRONT TOE. Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating, bending or modifying any component of the suspension. REAR CAMBER AND TOE Fig. 7 Rear Camber on this vehicle is adjustable. The rear camber on this vehicle is adjusted using the adjusting screw located in the forward and rear lateral links of the vehicles rear suspension. CAUTION: When checking the rear alignment on this vehicle, the alignment rack must be equipped with rear skid plates. 1. For either rear wheel needing alignment, loosen the adjusting screw jam nuts on both the front and the rear lateral links. CAUTION: Do not attempt to move the adjusting screws without properly loosening the tam nuts. Note that each adjusting screw has one right handed nut and one left-handed nut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 773 Fig. 8 CAUTION: When setting rear camber and toe on the vehicle, the maximum lengths of the adjustable lateral link at the locations shown must not be exceeded. If these maximum lengths are exceeded, inadequate retention of adjustment link to the inner and outer link may result. 2. Rough-in the rear camber setting as close as possible to the preferred specification by mainly adjusting the rear lateral link adjusting screw. Some adjustment of the forward lateral link adjusting screw will also be required to get the rear camber setting to the preferred specification. 3. Adjust the forward lateral link adjusting screw to set rear toe to the preferred specification. NOTE: Adjusting toe will cause a slight change in the camber setting. If during the setting of toe, camber is no longer at the preferred specification, continue to adjust camber and toe until both are at their preferred specifications. 4. While holding adjustment screws from turning, use a crow foot and torque wrench, and tighten all lateral link adjusting screw jam nuts to a torque of 92 Nm (68 ft. lbs.). This will securely hold the adjusting screws from turning. 5. Proceed to FRONT CASTER AND CAMBER, or FRONT TOE if front caster and camber are within specifications. FRONT CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as NET BUILD. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using a procedure listed here. Before performing the camber adjustment procedure, inspect the suspension components for any signs of damage or bending. CAMBER ADJUSTMENT PROCEDURE Fig. 9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 774 1. Open the hood and mark the position of all four shock assembly mounting bolts on the shock tower on the side of the vehicle requiring front camber adjustment. 2. Raise the vehicle by the frame until the tires and front suspension are not supporting the weight of the vehicle. 3. Loosen the shock assembly mounting bolts on the side marked in step 1. Loosen the bolts enough to allow adequate space for removal of the plastic locating pins that align the upper mounting bracket with the shock tower. 4. Remove and discard both plastic locating pins from the shock assembly upper mounting bracket using a punch or pliers. NOTE: Do not leave the plastic locating pins in the cavity of the shock tower or mount. Objectionable noise may result. 5. Position the shock assembly inboard or outboard as required to adjust the camber. Make sure the fore and aft position is in the same as indicated by the marks made prior to adjustment, and also the forward and rearward bolts are moved equal amounts inward or outward. NOTE: Do not attempt to enlarge any existing holes to increase adjustment range. 6. Torque the upper shock assembly mounting bolts to 90 Nm (68 ft. lbs.) 7. Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. 8. Check and adjust the front camber as necessary. 9. If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure. FRONT TOE 1. Center the steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Fig. 10 2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front toe to the preferred toe specification. 3. Tighten tie rod jam nuts to 61 Nm (45 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 775 Alignment: Service and Repair Curb Height Measurement STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, maximum left-to-right differential is not to exceed 20 mm (0.79 inch). 3. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Deadhead Pressure 880 kpa (130 psi) Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 781 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 782 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 783 Tests 3 - 5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 784 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel Pump Relay - Fuel Pressure Out Of Specs - Restricted Fuel Supply Line - Fuel Pump Inlet Strainer Plugged - Fuel Pump Module - Fuel Pump Capacity (Volume) Out Of Specs - Fuel Pump Relay Fused B+ Circuit - Fuel Pump Relay Output Circuit Open - Fuel Pump Ground Circuit Open/High Resistance Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 785 - Fuel Pump Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 550-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test using a scan tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect inlet air temperature sensor electrical connector (Fig. 7). 3. Disconnect fresh air makeup hose from throttle body air inlet hose (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 793 4. Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. 5. Push in on locking tabs to disengage air inlet hose from air cleaner housing. Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver (Fig. 10). 6. Remove throttle body air inlet hose. 7. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Clean any debris from inside air cleaner housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 794 2. Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. 3. Install throttle body air inlet hose into air cleaner housing. Push in on hose until an audible "click" is heard from locking tabs. 4. Install hose on throttle body. Tighten hose clamp (Fig. 9). 5. Connect fresh air makeup hose (Fig. 8). 6. Connect inlet air temperature sensor electrical sensor (Fig. 7). 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 799 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered (Fig. 2). The firing order is 1-2-3-4-5-6. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 804 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ...................................................................... 0.050 in Tightening Torque ........................................... .......................................................................................................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 812 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................... Champion Platinum Power CHA 3032 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum Cylinder Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 816 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Disconnect and remove all ignition coils from spark plugs. 4. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the -500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 26 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type belts (Fig. 1) or (Fig. 2). One belt drives the power steering pump, the other drives the generator and air conditioning compressor. Both belts on the 2.7L engine are manually tensioned. The power steering belt on the 2.4L engine is manually tensioned. The air conditioning/generator belt on the 2.4L engine has an automatic belt tensioner. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 823 Drive Belt: Testing and Inspection Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. ACCESSORY DRIVE BELT DIAGNOSIS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 824 Drive Belt: Service and Repair REMOVAL AIR CONDITIONING COMPRESSOR/GENERATOR BELT 1. Raise vehicle on hoist. 2. Remove right front wheel and belt splash shield. 3. Loosen tensioner locking bolt and pivot bolt. 4. Rotate tensioner clockwise to allow enough slack to remove belt. POWER STEERING PUMP BELT 1. Raise vehicle on hoist. 2. Remove right front wheel and belt splash shield. 3. Remove the air conditioning compressor/generator belt. 4. Loosen belt adjusting bolt. It is not necessary to loosen the pivot bolt on the power steering pump. There is a bushing incorporated into the power steering pump/bracket that allows it to pivot. 5. Remove power steering belt. CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: Excessive wear - Frayed cords - Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 4). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley. AIR CONDITIONING COMPRESSOR/GENERATOR BELT 1. Install air conditioning compressor/generator belt on pulleys (Fig. 6). 2. Insert a 1/2" drive breaker bar into the square opening on the tensioner. 3. Hold counterclockwise pressure on tensioner and tighten tensioner locking bolt and pivot bolt. 4. Install belt splash shield and right front wheel. 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 825 POWER STEERING PUMP BELT 1. Install power steering belt on pulleys (Fig. 6). 2. Insert a 1/2" drive breaker bar into the square opening on the power steering pump bracket. 3. Hold clockwise pressure on power steering pump bracket and tighten adjusting bolt. 4. Install air conditioning compressor/generator belt. 5. Install belt splash shield and right front wheel. 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect inlet air temperature sensor electrical connector (Fig. 7). 3. Disconnect fresh air makeup hose from throttle body air inlet hose (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 831 4. Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. 5. Push in on locking tabs to disengage air inlet hose from air cleaner housing. Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver (Fig. 10). 6. Remove throttle body air inlet hose. 7. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Clean any debris from inside air cleaner housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 832 2. Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. 3. Install throttle body air inlet hose into air cleaner housing. Push in on hose until an audible "click" is heard from locking tabs. 4. Install hose on throttle body. Tighten hose clamp (Fig. 9). 5. Connect fresh air makeup hose (Fig. 8). 6. Connect inlet air temperature sensor electrical sensor (Fig. 7). 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair For further information regarding this component or the system it is a part of please refer to AUTOMATIC TRANSMISSION FLUID; SERVICE AND REPAIR. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 843 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation Fig. 8 Fuel Pump Module FUEL PUMP MODULE The fuel pump module contains the fuel pump, fuel reservoir, level sensor, inlet strainer, and fuel pressure regulator/filter (Fig. 8). The Chrysler fuel pump module is an in-tank unit with an integral fuel level sensor and pressure regulator. The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized. Serviceable components on the module include: Inlet strainer - Fuel level sensor - Fuel Filter/Pressure regulator The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine OFF conditions. The fuel system use a positive displacement, gerotor; with a permanent magnet electric motor. This fuel system does not contain the traditional fuel return lines. The regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank. The maximum deadhead pressure is approximately 880 kpa (130 psi). The regulator adjusts fuel system pressure to approximately 400 kpa ±34 kPa (58 psi ±5 psi). The inlet strainer, level sensor and fuel pressure regulator/filter are the only serviceable items. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 847 Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Fig. 18 Inlet Strainer 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 18). Fig. 19 Inlet Strainer Removed 3. Remove strainer O-ring from the fuel pump reservoir body (Fig. 19). 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 12 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 851 Oil Filter: Service and Repair OIL FILTER REMOVAL 1. Raise vehicle on hoist. 2. Position a suitable collecting container under oil filter location (Fig. 96). 3. Remove oil filter using a suitable oil filter wrench (Fig. 96). Dispose of oil filter following environmental guidelines. INSTALLATION 1. Wipe filter base clean, then inspect gasket sealing surface. 2. Lubricate gasket of new filter with clean engine 0il. 3. Install oil filter (Fig. 96) and tighten to 16 Nm (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary. 4. Fill crankcase with proper engine oil to correct level if drained. Start engine and check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation HOSE CLAMPS - DESCRIPTION DESCRIPTION The cooling system uses spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopar equipment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. OPERATION The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, use Special Tool 6094, Special Tool 8495, or equivalent, constant tension clamp pliers to compress the hose clamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation > Page 856 Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL 1. Drain cooling system. 2. Raise vehicle on hoist. 3. Disconnect lower radiator hose and heater hose from the inlet tube. 4. Remove fasteners that hold the inlet tube to the block. 5. Rotate inlet tube while removing from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. 2. Lube O-ring with coolant and install into the cylinder block opening. 3. Install fasteners and tighten to 12 Nm (105 inch lbs.). 4. Reconnect lower radiator hose and heater hose to inlet tube. 5. Lower vehicle. 6. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line The discharge line is made from reinforced rubber with a nylon liner on the inner walls. The line has a light weight aluminum fittings at the compressor and condenser end. The O-rings used to seal the connections are made from a special type of rubber not affected by R-134a refrigerant. O-rings must replaced whenever the line is removed and installed. CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 862 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line The suction line is made from reinforced rubber with a nylon liner on the inner walls. The line has a light weight aluminum fitting at the compressor end and a quick connect fitting at the expansion valve end. The quick connect has two O-rings to seal the connection made from a special type of rubber not affected by R-134a refrigerant. The O-rings must be replaced whenever the line is removed and installed. CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover refrigerant from A/C system with R134a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. Fig.12 Air Conditioning Lines 3. Remove discharge line from A/C condenser. Fig.13 Discharge Line 4. Remove discharge line from A/C compressor. NOTE: Cap compressor and condenser while system is open to prevent moisture from entering system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 865 Fig.14 Discharge Line INSTALLATION 1. Install discharge line on the compressor with new O-ring and tighten bolt to 22 Nm (200 in. lbs.). 2. Install discharge line on the condenser with new O-ring and tighten nut to 22 Nm (200 in. lbs.). 3. Connect pressure transducer wiring harness. 4. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 866 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Recover refrigerant from A/C system with R134a refrigerant recovery machine. 2. Remove suction line from the compressor. 3. Remove clip from the line at the expansion valve. 4. Disconnect quick connector on expansion valve with Quick Connector Kit 7193. Fig.15 Suction Line 5. Remove suction line from expansion valve. NOTE: Cap compressor and expansion valve while system is open to prevent moisture from entering system. INSTALLATION 1. Install suction line to expansion valve with new O-rings. 2. Install clip on the line quick connect at the expansion valve. 3. Install suction line to compressor with new O-ring and tighten bolt to 22 Nm (200 in. lbs.). 4. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 867 Hose/Line HVAC: Service and Repair Tubing and Fittings Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. CAUTION: - The system must be completely empty before opening any fitting or connection in the refrigeration system. Open fittings with caution even after the system has been emptied. If any pressure is noticed as a fitting is loosened, retighten fitting and evacuate the system again. - A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. - The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. - When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. - All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Hose Tube Nuts 23 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 871 Power Steering Line/Hose: Description and Operation HOSES DESCRIPTION Fig. 10 The power steering fluid hoses connect the components of the power steering system. The power steering fluid supply hose is a special rubber hose that connects the power steering fluid reservoir to the power steering pump. The hose is secured at each end using a standard adjustable clamp. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at each end to connect it to either the power steering pump or the gear. The power steering fluid return hose is a special rubber hose that connects the power steering gear to the fluid reservoir. It has a special metal tubing section that acts as cooler running in front of the radiator module. A standard tube nut fitting with an O-ring is used to connect it to the power steering gear. The hose is secured to the reservoir using a standard adjustable clamp. OPERATION The power steering fluid hoses transfer fluid from one power steering system component to the next. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 872 Power Steering Line/Hose: Service and Repair REMOVAL- RETURN HOSE WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. The return hose can be serviced as two separate pieces. They are the Return Hose With Tube and the Return Hose To Reservoir. RETURN HOSE WITH TUBE 1. Siphon power steering fluid from power steering fluid reservoir. 2. Remove vehicles front fascia. 3. If not previously lifted, raise vehicle. 4. Remove left front wheel and tire assembly. 5. Remove wheel opening forward splash shield. 6. Remove power steering fluid pressure hose, then return hose from power steering gear. 7. Remove air shield below left end of bumper reinforcement. Fig. 10 8. Remove clamp and return hose (to reservoir) from right end of return hose tube below the bumper reinforcement. 9. Remove tube mounting clips from bumper reinforcement. 10. Remove the return hose tube from routing clips along left frame rail. 11. Move the steering gear end of return hose tube to outside of frame rail. 12. Pull return hose with tube forward, snaking it between ABS ICU and frame rail. Remove return hose from vehicle. RETURN HOSE TO RESERVOIR 1. Siphon power steering fluid from power steering fluid reservoir. 2. Remove screw fastening power steering fluid reservoir to engine coolant recovery bottle. 3. Lift reservoir off guide on engine coolant recovery bottle. 4. Remove hose clamp attaching power steering fluid return hose to reservoir. 5. Remove power steering fluid return hose from reservoir. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 873 6. Remove vehicles front fascia. 7. If not previously lifted, raise vehicle. 8. Remove clamp and return hose (to reservoir) from right end of return hose tube below the bumper reinforcement. 9. Remove the return hose from routing clip on inside of right frame rail. 10. Remove power steering fluid return hose. INSTALLATION - RETURN HOSE WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. The return hose can be serviced as two separate pieces. They are the Return Hose With Tube and the Return Hose To Reservoir. RETURN HOSE WITH TUBE 1. Install hose with tube in vehicle using the reverse of removal. Guide return hose with tube rearward, snaking it between ABS ICU and frame rail. 2. Install the return hose tube into the routing clips along left frame rail. 3. Install tube along bottom of bumper reinforcement using routing clips. 4. Install return hose (to reservoir) on right end of return hose tube below the bumper reinforcement. Install clamp securing hose in place. 5. Install air shield below left end of bumper reinforcement. 6. Using a lint free towel, wipe clean open power steering hose ends and power steering gear port. 7. Install new O-rings on the power steering hose ends to the steering gear. 8. Lubricate O-rings using fresh clean power steering fluid. 9. Install power steering fluid return hose to power steering gear. Tighten tube nut to 31 Nm (275 inch lbs.). 10. Install power steering fluid pressure hose to power steering gear. Tighten tube nut to 31 Nm (275 inch lbs.). 11. Install wheel opening forward splash shield. 12. Install front fascia. 13. Install left front wheel and tire assembly. Progressively tighten all wheel lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.) torque. 14. Lower vehicle. 16. Fill reservoir with fluid and bleed system using Power Steering Pump Initial Operation standard procedure. 16. Check for leaks. RETURN HOSE TO RESERVOIR 1. Install return hose into routing clip on inside of right frame rail. 2. Install return hose (to reservoir) on right end of return hose tube below the bumper reinforcement. Install clamp securing hose in place. 3. Install front fascia. 4. Lower vehicle. 5. Install power steering fluid return hose on power steering fluid reservoir fitting. Be sure hose clamp is installed on hose past upset bead on power steering reservoir fitting. 6. Slide reservoir down over guide on engine coolant recovery bottle. 7. Install power steering fluid reservoir mounting screw. 8. Fill reservoir with fluid and bleed system using Power Steering Pump Initial Operation standard procedure. See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair 9. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 878 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 879 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 880 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and MIN, indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Although there is a range, the preferred level is FULL. If necessary, adjust the brake fluid level, bringing it to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 9.0 Liters ( 9.5 qts ) Note: Includes heater and recovery bottle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 885 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 886 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 887 Coolant: Description and Operation DESCRIPTION CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. Do not mix coolant types. If coolant other than leopard Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent is added, the mixed coolant will have a reduced service schedule. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar) Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent ethylene glycol based coolant with corrosion inhibitors (called MOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. Mixing of coolants other than specified (non-HOAT), will reduce the 5 year/100,000 mile corrosion protection. OPERATION The cooling system is designed around the coolant. The coolant must accept heat from the engine metal, in the cylinder head area near the exhaust valves and engine block. The coolant carries heat to the radiator where the tube/fin radiator can transfer the heat to the air. Properly mixed, the coolant raises the boiling point, prevents freezing in cold climates, and prevents corrosion. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASED COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPENED OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN AND PETS. DISPOSE OF GLYCOL BASED COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 888 Coolant: Testing and Inspection CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 889 Coolant: Service and Repair COOLANT-ADDING ADDITIONAL NOTE: The pressure cap should not be removed. When additional coolant is needed, it should be added to the coolant recovery/pressure container. Use only 50/50 concentration of ethylene glycol type antifreeze and distilled water. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 894 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 895 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 896 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 897 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 898 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity ...................................................................................................................................... ...................................................... 8.7Liters (9.2 Qt) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 901 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 902 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 903 Fluid - A/T: Testing and Inspection FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF +4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator (Fig. 178). The fluid level should be within the WARM range of the dipstick at 70° F fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 904 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 179). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF +4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 905 Fluid - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 180). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 181). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening, DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 906 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula (R) or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 181). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. 1b prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil w/Filter ............................................................................................................................... ........................................................................ 5.0 Qt Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 913 Engine Oil: Fluid Type Specifications Engine Oil Type Below 100°F (38°C) ............................................................................................................................. ...................................................................... 5W-30 Above -20°F (-29°C) ......................................... ....................................................................................................................................................... 10W-30 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 914 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading (Fig. 95). Add only when the level is at or below the ADD mark. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 917 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE 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 SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Change engine oil and filter at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Hoist and support vehicle on safety stands. 4. Remove oil fill cap (Fig. 95). 5. Place a suitable drain pan under crankcase drain. 6. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged 7. Remove oil filter. 8. Install drain plug in crankcase. 9. Install new oil filter. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil, (Fig. 95). 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full flow, disposable type oil filter. When replacing oil filter, use a Mopar filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 922 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 923 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 924 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill the the indicated level on the side of the reaervoir. The power steering fluid level should be at normal ambient temperature (70°F - 80°F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 927 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 928 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 929 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. The fluid level can be read through the exterior of the power steering fluid reservoir. The reservoir exterior is marked "FILL RANGE" and "ADD." The fluid shows through the reservoir indicating its level. The fluid level should be within the "FILL RANGE" when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Remove the cap and fill as necessary. Do not overfill the power steering system. Use only Mopar Power Steering Fluid, or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant ............................................................................................................................... ..................................................... (27 oz. or 1.69 lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 934 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 935 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 936 http://www.macsw.org/ Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 937 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ............................................................. 150 ml (5 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator ........................................................................................................................................... ............................................................... 59 ml (2 oz.) Receiver-Drier ..................................................................................................................................... ............................................................... 30 ml (1 oz.) Refrigerant Lines ................................................................................................................................. ............................................................ 44 ml (1.5 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 942 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ............................................................... SP-15 PAG Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 943 Refrigerant Oil: Description and Operation REFRIGERANT OIL - DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The TRS9O compressor used in this vehicle is designed to use an SP-15 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. Recap the oil container immediately after use to prevent moisture contamination. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 944 Refrigerant Oil: Testing and Inspection REFRIGERANT OIL - TESTING It is important to have the correct amount of lubricant in the A/C system to ensure proper lubrication of the compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkylene glycol PAG lubricant. Only PAG refrigerant lubricant approved for use with R-134a should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It is not necessary to check or add lubricant unless it has been lost. Lubricant loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. A/C Component Refrigerant Oil Capacities Refrigerant Oil Level When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with (R-134a) refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser and receiver/drier will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities table. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The receiver/drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On an A/C system, the evaporator retains 60 ml (2 oz.) of oil. The condenser retains 30 ml (1 oz.) of oil, and system capacity may be 150 ml (5.00 oz.) of oil. 150 ml minus 90 ml equals 60 ml (2.00 oz.). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is SP-15 PAG (polyalkylene glycol). Verify Refrigerant Lubricant Level 1. Discharge refrigerant system using a recycling/reclaiming equipment if a charge is present. 2. Disconnect refrigerant lines from A/C compressor. Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction and discharge ports on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Refer to the A/C Component Refrigerant Oil Capacities chart above. Add lubricant through the suction and discharge ports on compressor. This is not to exceed 150 ml (5.00 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. 7. Most reclaim/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise using only the mounting flange. 2. Thread Bleeding Tubes, Special Tool 8358, into master cylinder primary and secondary ports. Position outlet ends of bleeding tubes in reservoir with the outlets below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with Mopar(R) brake fluid or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap on master cylinder fluid reservoir. 8. Install master cylinder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 949 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system. CAUTION: ^ Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. ^ Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 950 Use bleeder tank, Special Tool C-3496-B or equivalent, with master cylinder reservoir adapter, Special Tool 8224, to pressurize the hydraulic system for bleeding. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 3. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat this procedure at all the remaining bleeder screws. 5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 6. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 951 Brake Bleeding: Service and Repair Antilock Brake System ANTILOCK BRAKE SYSTEM BLEEDING STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII(R) scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 955 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 960 Circuit Breaker: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 961 Circuit Breakers (JB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block > Page 966 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 967 Fuse: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 968 Fuses (JB) Power Distribution Center Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 969 Fuses (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 972 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 973 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 974 Fuse: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block > Page 979 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 982 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 983 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 984 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 985 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 986 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 987 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 988 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 997 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 998 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Fuse Block: Connector Views Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Junction Block (Bottom) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Junction Block/Body Control Module - 12 Way Junction Block C1 Junction Block C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 Junction Block C3 Junction Block C4 Junction Block C5 Junction Block C6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Junction Block C7 Junction Block C8 Junction Block C9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Junction Block C10 Junction Block C11 (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Fuse Block: Electrical Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 8w-12-2 Wiring Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 8w-12-7 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 8w-12-8 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 8w-12-9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 8w-12-10 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 8w-12-11 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 8w-12-12 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 8w-12-13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 8w-12-14 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 8w-12-15 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 8w-12-16 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 8w-12-17 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1021 8w-12-20 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1022 8w-12-21 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1023 8w-12-22 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1024 8w-12-23 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1025 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1026 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1029 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1030 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1031 Fuse Block: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1032 Fuse Block: Description and Operation An electrical Junction Block (JB) is located in the left end cap of the instrument panel. The JB combines the functions previously provided by a separate fuse block module and relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. Fig.1 Junction Block Location The JB is positioned on a mounting bracket up and under the left instrument panel (Fig. 1). It is secured by three screws. The JB is concealed behind the left instrument panel endcap. The left instrument panel endcap is a snap-fit fuse access cover that conceals the JB fuses and includes the fuse layout to ensure proper fuse identification. The left instrument panel endcap must be removed to access components other than the fuses in the JB. All of the current entering and leaving the JB does so through wire harnesses, which are connected to the JB through integral connector receptacles molded into the JB housing. The JB houses blade-type fuses, blade-type automatic resetting circuit breakers, full International Standards Organization (ISO) relays, and ISO micro-relays. Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses, circuit breakers, relays, and are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire Junction Block assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1033 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig.2 Junction Block/BCM Location The Junction Block (JB) and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle (Fig. 2). Fig.3 Battery Negative Remote Cable 1. Open hood then disconnect and isolate the battery negative remote cable from the remote terminal on the left shock tower (Fig. 3). 2. Open the front driver's door and remove end cap. 3. Remove center bezel. 4. Remove instrument cluster hood. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1034 12. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 13. Disconnect BCM from the Junction Block. INSTALLATION 1. Connect BCM to the Junction Block. 2. Install the BCM to the Junction Block and install the attaching screws. 3. Install Junction Block/BCM to vehicle. 4. Connect BCM wire connectors. 5. Install Junction Block mounting screws. 6. Connect wire harness connectors to Junction Block. 7. Install silencer. 8. Install instrument cluster hood. 9. Install center bezel. 10. Install end cap. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block > Page 1039 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1042 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1043 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1044 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 1052 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION - SPARE TIRE (TEMPORARY) The compact temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the temporary spare tire. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 1062 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1063 Wheels: Specifications Specifications Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1064 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Fig. 1 All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the rim flange of the wheel and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1065 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. WARNING: REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1066 Wheels: Service and Repair CLEANING - ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Any of the "DO NOT USE" items listed below WILL damage chrome plated and painted aluminum wheels. DO NOT USE: any abrasive metal cleaner - any abrasive cleaning pad or brush - any cleaner that contains an acid (this will immediately react with and discolor the chromium surface) - chrome polish (unless it is buffed off immediately after application) - oven cleaner - a car wash that uses carbide-tipped wheel cleaning brushes Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Hub Nut 150 ft.lb Wheel Stud Lug Nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1071 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB / BEARING - FRONT DESCRIPTION The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The hub and bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub and bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective. 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. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 1074 Wheel Bearing: Description and Operation Rear HUB / BEARING - REAR DESCRIPTION The hub and bearing is a combined rear wheel hub and wheel bearing unit. All vehicles are equipped with permanently lubricated and sealed for life rear hub and bearing assemblies. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing is mounted to the rear knuckle's spindle using a retaining nut. The tire and wheel assembly, and rear brake drum or disc attaches to the studs protruding from the hub flange with wheel mounting studs. OPERATION The hub and bearing has internal bearings that allow it to rotate with the tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING - FRONT The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 1077 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING - REAR The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT SUSPENSION REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 12 5. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a socket while loosening and removing nut with wrench. Fig. 13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1080 6. Remove the tie rod end from the steering knuckle arm, using Remover, Special Tool MB-991113. Fig. 14 7. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Fig. 15 8. Remove cotter pin and castle nut from the stud of the lower ball joint. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 9 below. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1081 Fig. 16 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 17 11. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1082 Fig. 18 12. Remove the cotter pin and nutfrom the upper ball joint stud to steering knuckle attachment. Fig. 19 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C3894-A. 14. Remove steering knuckle from vehicle. 15. Mount steering knuckle securely in a vise. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1083 Fig. 20 16. Remove the 3 boltsattaching the hub/bearing assembly to the steering knuckle. 17. Remove the hub and bearing assembly out from the front of the steering knuckle. NOTE: If bearing will not come out of steering knuckle, it can be tapped out using a soft faced hammer. INSTALLATION 1. Thoroughly clean all hub and bearing assembly mounting surfaces on steering knuckle. 2. Install the replacement hub and bearing assembly in steering knuckle aligning bolt boles in bearing flange with holes in steering knuckle. 3. Install the 3 mounting boltsand tighten evenly to ensure bearing is square to face of steering knuckle. The tighten the 3 mounting boltsto a torque of 110 Nm (80 ft. lbs.). 4. Slide drive shaft back into front hub and bearing assembly. 5. Install the steering knuckle on the lower control arm ball joint. 6. Install the steering knuckle to lower ball joint castle nut. 7. Install upper ball joint stud in steering knuckle. 8. Install the steering knuckle to upper ball joint stud castle nut. 9. Using a crow foot and torque wrench, tighten the upper and lower ball joint castle nuts to the following torque specifications. - Lower ball joint castle nut 74 Nm (56 ft. lbs.). - Upper ball joint castle nut 62 Nm (45 ft. lbs.). 10. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1084 Fig. 21 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 11. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding the stud of the tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 12. Install brake rotor, and caliper, shoes and adapter assembly. 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto the driveshaft stub axle. 14. With vehicle brakes applied to keep stub axle from turning, tighten hub nut to a torque of 203 Nm (150 ft. lbs.) of torque. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Tighten nuts to a torque of 135 Nm (100 ft. lbs.). 16. Lower vehicle. 17. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1085 Wheel Bearing: Service and Repair Rear REAR SUSPENSION REMOVAL - HUB AND BEARING 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the rear brake caliper and rotor. Remove the brake rotor by pulling the rotor straight off the wheel mounting studs. 4. Remove dust cap from rear hub and bearing assembly by prying it off. 5. Remove hub and bearing retaining nut. 6. Remove rear hub and bearing from the spindle by pulling it straight off the spindle by hand. INSTALLATION - HUB AND BEARING 1. Install the hub and bearing assembly on the knuckle spindle. Install a NEW retaining nut. Tighten the retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install the hub and bearing dust cap using a soft faced hammer. 3. Install the brake rotor on the hub and bearing. 4. Install the disc brake caliper. 5. Install the rear tire and wheel assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half the specified torque. Repeat pattern, fully tightening the stud nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1090 Wheel Fastener: Specifications Wheel Mounting Lug Nut Hex Size 19mm Wheel Mounting Stud Size M12 x 1.5mm Wheel Mounting Lug nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS FRONT REMOVAL CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly, DO NOT hammer the studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper and adapter as an assembly. 4. Remove any retainer clips, then remove brake rotor form hub. 5. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150 on hub and bearing assembly flange 6. Tighten down on special tool, this will push the wheel stud out of the hub and bearing flange. INSTALLATION CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly, DO NOT hammer the studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1093 1. Install replacement wheel stud into Range of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install brake rotor on front hub. 4. Install disc brake caliper and adapter as an assembly on knuckle. 5. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1094 Wheel Fastener: Service and Repair Rear WHEEL MOUNTING STUDS REAR REMOVAL CAUTION: DO NOT hammer studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. 1. Remove the hub and bearing from the vehicle. CAUTION: Take care to keep hub and bearing assembly from falling during stud removal. Damage to the hub and bearing could result. 2. Position the hub and bearing assembly under a hydraulic press ram, supported by a 21 mm deepwell impact socket under the stud to be replaced 3. Press the stud out of the hub flange and into the socket well. 4. Remove the hub and bearing assembly from the press. 5. Remove the stud from the socket. INSTALLATION CAUTION: DO NOT hammer studs into the hub flange. If a stud is installed in such a manner, damage to the hub and bearing assembly may occur leading to premature bearing failure. 1. Install wheel stud into stud hole in hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1095 2. Position the hub and bearing assembly face down with stud pointing down into the well of the 21 mm socket. The hydraulic press ram must line up with the stud. 3. Press the stud into the hub flange until it bottoms. 4. Remove the hub and bearing assembly from the press. 6. Install the hub and bearing on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Minimum Cylinder Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1101 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Disconnect and remove all ignition coils from spark plugs. 4. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the -500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 26 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications Camshaft Bearing: Specifications Camshaft Bearing Bore Specifications Camshaft Bearing Journal Diameter .................................................................................................................................................... 0.9449 - 0.9441 inch Camshaft Bearing Clearance ............................................................................. .................................................................................. 0.0020 - 0.0035 inch Maximum ............................................................................................................................................. .............................................. 0.0015 inch Camshaft Bearing Cap-Bolts ............................................................................................................... ................................................................ 105 in. lbs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Camshaft Bearing Bore Specifications > Page 1107 Camshaft Bearing: Specifications Camshaft Bearing Cap Torque & Sequence Tighten the camshaft bearing cap bolts using the sequence shown to 12 Nm (105 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bore Diameter 0.9469 - 0.09476 in Bearing Journal Diameter 0.9449 - 0.9441 in Bearing Clearance 0.0020 - 0.0035 in Bearing Clearance (Max.) 0.0051 in End Play 0.0051 - 0.0110 in Valve Timing Intake Valve Opens (ATDC) 2 deg ATDC Closes (ABDC) 44 deg ABDC Duration 222 deg Valve Timing-Exhaust Valve Opens (BBDC) 36 deg BBDC Closes (ATDC) 4 deg ATDC Duration 220 deg Valve Overlap 2 deg Camshaft Bearing Cap-Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1114 Camshaft: Description and Operation DESCRIPTION The assembled fabricated camshafts are composed of five bearing journals machined into a hollow steel tube (Fig. 24). Six steel lobes, a secondary timing drive sprocket, and a primary sprocket/thrust flange are pressed onto the camshaft tube using a unique assembly process. Camshaft end play is controlled by the primary camshaft sprocket attachment flange on the intake camshafts and by a thrust flange on the exhaust camshafts. OPERATION The camshaft has precisely machined (egg shaped) lobes to provide accurate valve timing and duration. The camshaft is driven by the crankshaft via drive sprockets and chains. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1115 Camshaft: Service and Repair REMOVAL 1. Remove the primary timing chain. 2. Remove secondary chain tensioner mounting bolts. NOTE: Camshaft bearing caps have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "1E" 3. Slowly loosen camshaft bearing cap bolts in reverse order of installation (Fig. 25). 4. Remove camshaft bearing caps. 5. Remove camshafts, secondary chain, and tensioner together as an assembly. 6. Remove tensioner and camshaft chain from camshafts. 7. Inspect camshafts. INSPECTION 1. Inspect camshaft bearing journals for damage and binding (Fig. 26). If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Inspect camshaft sprockets for excessive wear. Replace camshafts if necessary. 3. Check the cam lobe surfaces for abnormal wear and damage. Replace camshaft if defective. Measure the actual wear (Fig. 26) and replace, if out of limits-standard value is 0.0254 mm (0.001 inch); wear limit is 0.254 mm (0.010 inch) INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1116 CAUTION: When the timing chain is removed and the cylinder heads are installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage. 1. Assemble camshaft chain on the cams. Ensure that plated links are facing toward the front. Align the plated links to the dot on the camshaft sprockets (Fig. 28). 2. If camshaft chain tensioner is already in the compressed and locked position, proceed to step (4). 3. When the camshaft chain tensioner is removed, it is necessary to compress and lock the tensioner using the following procedures: a. Place tensioner into a soft jaw vise (Fig. 27). b. SLOWLY compress tensioner until fabricated lock pin or the equivalent can be inserted into the locking holes. c. Remove compressed and locked tensioner from the vise. 4. Insert the compressed and locked camshaft chain tensioner in-between the camshafts and chain. 5. Rotate the cams so that the plated links and dots are facing the 12:00 O'clock position (Fig. 28). 6. Install cams to cylinder head. Ensure that rocker arms are correctly seated and in proper positions. 7. Install camshaft bearing caps. Ensure that bearing caps are installed in same position as removed. 8. Tighten cam bearing cap bolts gradually in sequence shown in (Fig. 25) to 12 Nm (105 in. lbs.). 9. Install secondary chain tensioner bolts and tighten to 12 Nm (105 in. lbs.). 10. Remove locking pin from secondary tensioners. 11. Measure camshafts end play. 12. Install the primary timing chain. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS Proper noise diagnosis is essential in locating the source of a NVH complaint. Locating a lash adjuster (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur. Refer to LASH ADJUSTER (TAPPET) NOISE CHART indicating possible lash adjuster (tappet) noise sources and possible sources that could lead to a misdiagnosis. Refer to LASH ADJUSTER (TAPPET) NOISE CHART for possible causes and correction of a lash adjuster (tappet) type noise. LASH ADJUSTER (TAPPET) NOISE CHART 1 of 2 LASH ADJUSTER (TAPPET) NOISE CHART 2 of 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1120 Lifter / Lash Adjuster: Service and Repair REMOVAL 1. Remove cylinder head cover(s). 2. Remove rocker arm(s). CAUTION: If lash adjusters and rocker arms are to be reused, always mark position for reassembly in their original positions. 3. Remove lash adjuster(s). INSTALLATION 1. Install hydraulic lash adjuster making sure adjusters are at least partially full of oil. This can be verified by little or no plunger travel when lash adjuster is depressed. 2. Install rocker arm(s) and cylinder head covers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are composed of steel stampings with an integral roller bearing (Fig. 44). The rocker arms incorporate a 0.5 mm (0.0197 inch) oil hole in the lash adjuster socket for roller/camshaft lobe lubrication (Fig. 44). OPERATION The rocker arm is the pivot point between the camshaft lobe and the valve. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Page 1124 Rocker Arm Assembly: Service and Repair REMOVAL 1 Remove Cylinder head cover(s). CAUTION: Always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or lifter damage. 2 Rotate engine until the cam lobe is on its base circle (heel), on the rocker arm being removed. CAUTION: Depress valve spring only enough to remove rocker arm. 3 Using Special Tools 8215-A and 8216-A Adapter, depress valve spring only enough to release tension on rocker arm (Fig. 45). 4 Remove rocker arm from cylinder head. CAUTION:if rocker arms are to be reused, identify position of rocker arms for reassembly in their original positions. 5 Repeat procedure for each rocker arm removed. 6 Inspect the rocker arm for damage. INSPECTION Inspect the cam follower assembly for wear or damage (Fig. 46). Replace as necessary. INSTALLATION 1 Lubricate rocker arms with clean engine oil before installation. 2 Rotate engine until cam lobe is on its base circle (heel) of rocker arm being installed. 3 Using Special Tools 8215-A and 8216-A Adaptor, depress valve spring only enough to install rocker arm (Fig. 45). 4 Install rocker arm in original position (if reused) over valve and lash adjuster. Release tension on valve spring. NOTE: Inspect rocker arm for proper engagement into lash adjuster and valve tip. 5 Repeat procedure for each rocker arm being installed. 6 Install cylinder head cover(s). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance ............................................................................................................................... .................................................. 0.0007 - 0.0031 inch Piston Pin Bore Diameter ............................... ....................................................................................................................................... 0.9452 0.9455 inch Bearing Bore Out Of Round (Maximum) ............................................................................................................................................................ 0.0002 inch Total Weight (Less Bearing) ............................................................................................ .................................................................................... 22.8223 oz Connecting Rod Journals Diameter .............................................................................................................................................. .................................................. 2.283 - 2.284 inch Bearing Clearance .............................................. ............................................................................................................................. 0.00075 - 0.0034 inch Out of Round (Maximum) ............................................................................................................. .................................................................. 0.0006 inch Taper (Maximum) .......................................... ................................................................................................................................................. 0.0006 inch Connecting Rod Cap - Bolts ................................................................................................................ ................................................... 20 ft. lbs. + 1/4 turn Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1129 Connecting Rod Bearing: Service and Repair FITTING CONNECTING ROD BEARING Fit all connecting rods on one bank until complete. The bearing caps: are not interchangeable and should be marked at removal to ensure correct assembly. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces as engine damage may occur. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Also, assure that the hole in upper bearing half aligns with oil squirt hole in rod. Install cap with the tangs on the same side as the rod. CAUTION: Assure that hole in upper bearing half aligns with hole in connecting rod as engine damage may occur. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 inch). Bearings are available 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. 1. For measuring Main Bearing Clearance and Connecting Rod Bearing Clearance use plastigage (Fig. 50). Refer to Specifications for bearing clearance specifications. CONNECTING ROD BOLTS NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down due to stretching, the bolt(s) must be replaced (Fig. 51). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1130 NOTE: Connecting rod bolts are retained in the rod cap with a light press fit. If bolts are to be removed, use a hammer and punch to drive bolts from connecting rod cap using care not to damage fractured cap surface. 1. Examine connecting rod bolt for stretching. Stretching can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. 2. Before installing the bolts, lubricate the threads with engine oil. 3. Install bolts finger tight. Then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to specification. CONNECTING ROD SIDE CLEARANCE 1. Mount a dial indicator to a stationary point on engine. Locate probe perpendicular to and resting against the connecting rod cap being checked. Move connecting rod all the way to rear of its travel. Zero the dial indicator. Move connecting rod forward to limit of travel and read the dial indicator (Fig. 52). Compare measurement to specification listed in engine specifications. Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Bearing Clearance 0.0007 - 0.0031 in Piston Pin Bore Diameter 0.9452 - 0.9455 in Bearing Bore Out of Round (Maximum) 0.0002 in Total Weight (Less Bearing) 22.8223 oz (US) Connecting Rod Journals Diameter 2.283 - 2.284 in Bearing Clearance 0.00075 - 0.0034 in Out of Round (Maximum) 0.0006 in Taper (Maximum) 0.0006 in Connecting Rod Cap - Bolts 20 + 1/4 Turn ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1135 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Journals Diameter 2.4997 - 2.5004 in Bearing Clearance 0.0014 - 0.0021 in Bearing Clearance (Max) 0.0034 in Out-of-Round 0.0006 in Taper (Max) 0.0006 inch End Play 0.0019 - 0.0108 inch End Play (Max) 0.017 inch Crankshaft Main Bearing Cap Tie Bolts 250 inch lbs. Inner Cap Bolts 15 ft. lbs. + 1/4 turn Outer Cap Bolts 20 ft. lbs. + 1/4 turn Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1140 Crankshaft Main Bearing: Specifications Torque Specifications The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, and lastly the main cap tie (horizontal) bolts. 1. Inner Main Bearing Cap Bolts .................................................................................................................................... 20 Nm (15 ft. lbs.) + 1/4 Turn 2. Windage Tray Bolts ..................................................................................................................................................... 27 Nm (20 ft. lbs.) + 1/4 turn 3. Main Cap Tie (horizontal) Bolts ................................................................................................................................................. 28 Nm (250 in. lbs.) Crankshaft Main Bearing Journals Diameter .............................................................................................................................................. .................. 63.49 - 63.51 mm (2.4997 - 2.5004 inch) Bearing Clearance ................................................................................................................................................. 0.035 0.053 mm (0.0014 - 0.0021 inch) Bearing Clearance (Max.) .............................................................. .................................................................................................. 0.087 mm (0.0034 inch) Out of Round (Max.) ....................................................................................................................................... ............................... 0.015 mm (0.0006 inch)) Taper (Max.) ................................................................ .................................................................................................................... 0.015 mm (0.0006 inch) End Play ............................................................................................................................................................ 0.0475 - 0.2725 mm (0.0019 - 0.0108 inch) End Play (Max.) .............................................................. ..................................................................................................................... 0.43 mm (0.017 inch) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1141 Crankshaft Main Bearing: Service and Repair MAIN BEARING FITTING The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the block and crankshaft have grade identification marks. The grade marks for the cylinder block main bearing bore grade is located on the pan rail just below the left side engine mount bracket (Fig. 65). These marks are read left to right, corresponding to main bore 1, 2, 3, 4. The grade marks for the crankshaft are located on the rearmost crankshaft counter weight as shown in (Fig. 64). The crankshaft journal grade marks are read left to right, corresponding with journal number 1,2,3,4. Refer to the MAIN BEARING SELECTION CHART to properly select the main bearings. For an example, if the main bore grade is 3 and the journal grade is 2, the proper select fit bearing would be 2.+0.003 mm (+0.0002 inch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1142 NOTE: Service main bearings have a number from 1-5 marked in ink on the bearing surface (Fig. 66). For verification, use the MAIN BEARING SELECTION CHART for number to size identification. The upper main bearing has a oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block. NOTE: Although cylinder bores are graded for size, there is only one piston size. MAIN BEARING SELECTION CHART-2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications Crankshaft Seal Retainer: Specifications Rear Seal Retainer Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications > Page 1146 Crankshaft Seal Retainer: Service and Repair REMOVAL 1. Remove crankshaft rear oil seal and oil pan. 2. Remove seal retainer attaching screws (Fig. 71). 3. Remove retainer and gasket (Fig. 71). INSTALLATION 1. Clean sealing surfaces and replace gasket as needed. 2. Install gasket and loose assemble seal retainer to block. NOTE: The following steps must be performed to prevent oil leaks at sealing joints. 3. Attach Special Tools 8225 to pan rail using the oil pan fasteners. NOTE: Make sure that the "2.7L" stamped on the special tool is facing the cylinder block (flat side of tools against pan rail). 4. While applying firm pressure to the seal retainer against Special Tools 8225 (Fig. 72), tighten seal retainer screws to 12 Nm (105 in. lbs.). 5. Install oil pan and crankshaft rear oil seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Diameter 2.4997-2.5004 in Out of Round 0.0006 in Taper (Max) 0.0006 in Bearing Clearance 0.0014-0.0021 in Bearing Clearance (Max) 0.0034 in Crankshaft End Play 0.0019-0.0108 in End Play Max. 0.017 in Connecting Rod Journal Diameter 2.1067-2.106 in Taper (Max.) 0.0006 in Out of Round (Max.) 0.0006 in Bearing Clearance 0.001-0.0026 in Main Bearing Cap -Tie Bolts 250 in.lb -Inner Cap Bolts 15 + 1/4 turn ft.lb Outer Cap Bolts 20 + 1/4 turn ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1150 Crankshaft: Description and Operation DESCRIPTION The crankshaft is constructed of a forged micro alloy steel. The six throw, nine counterweight crankshaft is supported by four select fit main bearings with the number three serving as the thrust washer location (Fig. 47). The select fit identification markings will be on the rear side of the number nine (rearmost) counter weight. The six separate connecting rod throws are an even-firing design, which reduces torque fluctuations while a vibration damper is used to control torsional vibration. The crankshaft oil seals are an one piece design. The front seal is retained by the timing chain cover and the rear seal in a housing that attaches to the cylinder block. OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures CRANKSHAFT END PLAY 1. Mount a dial indicator to a stationary point at front of engine. Locate the probe perpendicular against nose of crankshaft (Fig. 53). 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. For crankshaft end play clearances refer to Specifications. REMOVAL-CRANKSHAFT SPROCKET 1. Remove primary timing chain. CAUTION: Use care not to turn crankshaft while removing crankshaft sprocket, as damage to valves and or pistons could occur. 2. Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equivalent to damper bolt head and position Special TDO1S 5048-1, 5048-6, and 8539 on sprocket and crankshaft nose (Fig. 54). Remove sprocket using care not to rotate the crankshaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1153 Crankshaft: Removal and Replacement REMOVAL 1. Remove engine from vehicle. 2. Mount engine on an engine stand. 3. Drain engine oil and remove oil filter. 4. Remove oil pan and oil pick-up tube. 5. Remove idler pulley bracket for accessory drive belt. 6. Remove upper intake manifold. 7. Remove cylinder head covers. 8. Remove timing chain cover. 9. Remove primary timing chain. 10. Remove crankshaft sprocket. 11. Remove oil pump. 12. Remove crankshaft rear oil seal retainer. 13. Remove structural windage tray (Fig. 56). 14. Turn crankshaft until connecting rod cap to be removed is accessible. NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 15. Mark connecting rod bearing cap positions using a permanent ink marker or scribe tool. 16. Remove connecting rod bearing caps. Use care to prevent damage to the crankshaft bearing surfaces. CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or damage to the engine may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1154 17. Remove main bearing cap bolts and tie bolts (Fig. 55) 18. Remove main bearing caps (Fig. 55). CAUTION: When removing crankshaft, use care not to damage bearing surfaces on the crankshaft 19. Remove crankshaft from cylinder block (Fig. 57). INSTALLATION CRANKSHAFT SPROCKET 1. Install crankshaft sprocket using Special Tools 6780-1 and 8179 (Fig. 58) until sprocket bottoms against crankshaft step flange. Use care not to rotate crankshaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1155 2. Verify that crankshaft sprocket is installed to proper depth by measuring from sprocket outer face to end of crankshaft (Fig. 59). Measurement should read: 39.05 + 0.50 mm (1.5374 +0.020 inch). 3. Install primary timing chain. CRANKSHAFT NOTE: Upper and lower bearing halves are NOT interchangeable. CAUTION: Main bearings are select fit. 1. Lubricate upper main bearing halves with engine oil (Fig. 60). CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. 2. Install crankshaft (Fig. 57). NOTE: Make sure that the coated and oil groove side of crankshaft thrust washer faces the crankshaft thrust surface. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1156 3. Push crankshaft forward. Lubricate and install the front thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface (Fig. 61). 4. Move crankshaft rearward. Lubricate and install the rear thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface. 5. Lubricate lower main bearings with engine oil. 6. Install main bearings and caps. NOTE: Lubricate main bearing cap bolts with engine oil before installation. The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, and lastly the main cap tie (horizontal) bolts. 7. Install the inside main bearing cap bolts and tighten to 20 Nm + 1/4 Turn (15 ft. lbs. + 1/4 Turn) (Fig. 62). 8. Measure crankshaft end play. 9. Install connecting rods and measure side clearance. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1157 10. Install windage tray (Fig. 63). Lubricate bolts with engine oil and tighten to 27 Nm + 1/4 Turn (20 ft. lbs. + 1/4 Turn). 11. Install the main cap tie (horizontal) bolts and tighten to 28 Nm (250 in. lbs.) (Fig. 62). 12. Install rear crankshaft oil seal retainer and oil seal. 13. Install oil pump assembly. 14. Install crankshaft sprocket. 15. Install timing chain. 16. Install timing chain cover. 17. Install cylinder head covers. 18. Install idler pulley bracket for accessory drive belt. 19. Install oil pick-up tube and O-ring. 20. Install oil pan and oil filter. 21. Install oil dipstick tube. 22. Install engine assembly. 23. Fill engine crankcase with proper oil to correct level. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation DESCRIPTION The engine block heater is mounted in the cylinder block, near the right rear corner (Fig. 13). The block heater is a dry cylinder type design and is powered by 110 volt AC. The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged. OPERATION When power is applied (110 volt A.C.) to the block heater, the heating element transfers heat through the aluminum engine block and into the coolant without directly penetrating the cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1161 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1162 Engine Block Heater: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Detach power cord plug from heater (Fig. 15). 3. Remove block heater attaching screw located below heater terminals. 4. Remove block heater from cylinder block. INSTALLATION 1. Thoroughly clean cylinder block heater cavity. 2. Insert heater assembly into block such that mounting hole is located below heater terminals (Fig. 15). 3. Install mounting screw and tighten to 12 Nm (105 in. lbs.). CAUTION: To prevent damage, the power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds. 4. Attach power cord to heater. 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Damper Bolt 125 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1166 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle on hoist. 3. Remove right front wheel and belt splash shield. 4. Remove accessory drive belts. 5. Remove dampener bolt. 6. Remove dampener by using Special Tools 8194 Insert and 8454 Puller (Fig. 85). INSTALLATION 1. Install damper using Special Tools 8179 Screw, with Nut and Thrust Bearing from 6792, and 6792-1 Installer (Fig. 86). 2. Install damper center bolt. Tighten center bolt to 170 Nm (125 ft. lbs.). 3. Install accessory drive belts. 4. Install belt splash shield and right front wheel. 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1167 6. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Material Aluminum Alloy Piston Diameter 3.3851 +/- 0.0017 in Clearance at Size Location -0.0003 to +0.0016 in Piston Weight 11.1466 - 11.4994 oz (US) Piston Ring Groove Diameter - No. 1 3.063 - 3.070 in Piston Ring Groove Diameter - No. 2 2.988 - 2.996 in Piston Ring Groove Diameter - No. 3 3.011 - 3.019 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1171 Piston: Description and Operation DESCRIPTION The pistons are made of a high strength aluminum alloy with an anodized top ring groove. Piston skirts are coated with a solid lubricant for scuff resistance. The connecting rods are made of powdered metal with a "fractured cap" design. The connecting rod attaches to the piston with a full floating pin retained by lock rings. The piston and connecting rod are serviced as an assembly (Fig. 73). OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures STANDARD PROCEDURE - FITTING PISTONS The pistons have been cast and machined to one size and weight. The piston and rod assemblies are matched to weigh the same for engine balance. Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in (Fig. 74). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Refer to Specifications. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). PISTON PINS The pistons have been cast and machined to one size and weight. The piston and rod assemblies are matched to weigh the same for engine balance. The piston pin is full floating and is held in place by lock rings. Do not switch pistons with other rods. Pistons and connecting rods are serviced as an assembly for balance. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1174 Piston: Removal and Replacement REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 2. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig. 75). CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 3. Remove connecting rod cap. Install Special Tool 8189 Connecting Rod Guides into the connecting rod being removed (Fig. 76). Remove each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 4. After removal, install bearing cap on the mating rod to prevent damage to the fractured cap to rod surfaces. INSTALLATION 1. Install the piston rings. 2. Before installing piston and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1175 3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 84). 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation. CAUTION: Ensure the hole in bearing half aligns with hole in connecting rod, as damage to engine may occur. 5. Position bearing onto connecting rod. Ensure that hole in bearing half is aligned to hole in connecting rod. Lubricate bearing surface with clean engine oil. 6. Install Special Tools 8189 Connecting Rod Guides into connecting rod (Fig. 76). 7. The pistons are marked on top with an arrow and with an "F" (Front) above the pin boss. These marks must be pointing toward the front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the block (Fig. 78). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1176 8. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal (Fig. 77). CAUTION: Do not interchange piston assemblies bank to bank, as engine damage may occur. 9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 10. Lubricate rod bolts and bearing surface with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 Nm (20 ft. lbs.) Plus 1/4 turn. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Type Full Floating Pin Diameter 0.8661 - 0.8662 in Clearance in Piston 0.0002 - 0.0005 in Clearance in Rod 0.0003 - 0.0008 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Top Compression Ring 0.008 - 0.014 in 2nd Compression Ring 0.0146 - 0.0249 in Oil Control (Steel Rails) 0.010 - 0.030 in Ring Side Clearance Compression Ring-Top 0.0013 - 0.0032 in Compression Ring-Second 0.0016 - 0.0031 in Oil Ring (Steel Rails) 0.0022 - 0.0080 in Ring Width Compression Rings 0.0579 - 0.0587 in Oil Ring (Steel Rails) 0.0176 - 0.0186 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting Piston Ring: Service and Repair Piston Ring Fitting PISTON RING FITTING 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) front bottom of cylinder bore. Check gap with feeler gauge (Fig. 79). Refer to SPECIFICATIONS for clearance measurements. 2. Check piston ring to groove clearance (Fig. 80). Refer to SPECIFICATIONS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1185 Piston Ring: Service and Repair Piston Ring - Removal and Installation REMOVAL 1. Remove piston and connecting rod. 2. Remove No. 1 and No.2 piston rings (Fig. 82) from piston using a ring expander tool (Fig. 83). 3. Remove upper oil ring side rail (Fig. 82). 4. Remove lower oil ring side rail (Fig. 82). 5. Remove oil ring expander (Fig. 82). INSTALLATION 1. Measure clearance of piston rings to the cylinder bore and piston. CAUTION: Install piston rings in the following order: Oil ring expander. - Upper oil ring side rail. - Lower oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 2. Install oil ring expander. Install the side rail by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander during this step (Fig. 81). 3. Install upper side rail first and then the lower side rail. NOTE: The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston (Fig. 82) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 1186 4. Install No. 2 piston ring and then No. 1 piston ring (Fig. 83). 5. Position piston ring end gaps as shown in (Fig. 84). 6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1194 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The rocker arms are composed of steel stampings with an integral roller bearing (Fig. 44). The rocker arms incorporate a 0.5 mm (0.0197 inch) oil hole in the lash adjuster socket for roller/camshaft lobe lubrication (Fig. 44). OPERATION The rocker arm is the pivot point between the camshaft lobe and the valve. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Page 1198 Rocker Arm Assembly: Service and Repair REMOVAL 1 Remove Cylinder head cover(s). CAUTION: Always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or lifter damage. 2 Rotate engine until the cam lobe is on its base circle (heel), on the rocker arm being removed. CAUTION: Depress valve spring only enough to remove rocker arm. 3 Using Special Tools 8215-A and 8216-A Adapter, depress valve spring only enough to release tension on rocker arm (Fig. 45). 4 Remove rocker arm from cylinder head. CAUTION:if rocker arms are to be reused, identify position of rocker arms for reassembly in their original positions. 5 Repeat procedure for each rocker arm removed. 6 Inspect the rocker arm for damage. INSPECTION Inspect the cam follower assembly for wear or damage (Fig. 46). Replace as necessary. INSTALLATION 1 Lubricate rocker arms with clean engine oil before installation. 2 Rotate engine until cam lobe is on its base circle (heel) of rocker arm being installed. 3 Using Special Tools 8215-A and 8216-A Adaptor, depress valve spring only enough to install rocker arm (Fig. 45). 4 Install rocker arm in original position (if reused) over valve and lash adjuster. Release tension on valve spring. NOTE: Inspect rocker arm for proper engagement into lash adjuster and valve tip. 5 Repeat procedure for each rocker arm being installed. 6 Install cylinder head cover(s). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover-Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover Valve Cover: Service and Repair Left Side Cover CYLINDER HEAD COVER LEFT REMOVAL 1. Disconnect negative battery cable. 2. Remove upper intake manifold. 3. Disconnect electrical connectors from ignition coils and capacitor. Reposition electrical harness. 4. Remove ground strap from cylinder head cover stud. 5. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness. 6. Remove fastener attaching ignition coil capacitor. 7. Loosen all cylinder head cover attaching bolts (Fig. 29). NOTE: Cylinder head cover attaching bolts are captured to the cover. 8. Remove cylinder head cover. INSTALLATION 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary (Fig. 30). 2. Install cylinder head cover and hand start all fasteners. Verify that all double-ended studs are in the correct locations as shown in (Fig. 29). 3. Tighten cylinder head cover attaching bolts and double-ended studs to 12 Nm (105 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover > Page 1204 4. Install ignition coil capacitor and fastener. 5. Connect all electrical connectors and harness clips. 6. Install ground strap to cylinder head cover stud. 7. Install upper intake manifold. 8. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover > Page 1205 Valve Cover: Service and Repair Right Side Cover CYLINDER HEAD COVER RIGHT REMOVAL 1. Disconnect negative battery cable. 2. Remove upper intake manifold. 3. Disconnect electrical connectors from ignition coils and capacitor. Reposition electrical harness. 4. Remove make up air hose from cylinder head cover grommet. 5. Remove ground strap from cylinder head cover stud. 6. Disconnect electrical harness retaining clips from cylinder head cover studs. Reposition electrical harness. 7. Remove fastener attaching ignition coil capacitor. 8. Remove ignition coils. 9. Loosen all cylinder head cover attaching bolts (Fig. 31). NOTE: Cylinder head cover attaching bolts are captured to the cover. 10. Remove cylinder head cover. INSTALLATION 1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gaskets as necessary (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover > Page 1206 2. Install cylinder head cover and hand start all fasteners. Verify that all double-ended studs are in the correct locations as shown in (Fig. 31). 3. Tighten cylinder head cover attaching bolts and double-ended studs to 12 Nm (105 in. lbs.). 4. Install ignition coils. 5. Install ignition coil capacitor and fastener. 6. Connect ground strap to cylinder head cover stud. 7. Connect make up air hose to cylinder head cover grommet. 8. Connect all electrical connectors and harness clips. 9. Install upper intake manifold. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Guide Bore Diameter (Std.) 0.2353 - 0.2363 in Valve Guide Height Intake & Exhaust 0.5217 - 0.5414 in Measured from cylinder head surface to top of guide Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle 45 - 45.5 deg Valve Seat Runout (Max.) 0.002 ft Intake Valve Seat Width 0.0394 - 0.0591 in Exhaust Valve Seat Width 0.0492 - 0.0689 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length Intake & Exhaust (Approximately) 1.7965 in Spring Force Intake & Exhaust (Valve Closed) 56.0 - 64.0 lbf at 1.4961 in Intake (Valve Open) 147.9 - 162.1 lbf at 11.1417 in Exhaust (Valve Open) 138.0 - 150.8 lbf at 1.1811 in Number of Coils Intake & Exhaust 7.35 Wire Diameter Intake & Exhaust 0.1520 in Installed Height Spring seat to bottom of retainer 1.4961 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1216 Valve Spring: Description and Operation DESCRIPTION The valve springs are made from high strength, chrome-silicon steel (Fig. 15). The springs are common for intake and exhaust applications. The valve spring seat is integral with the valve stem seal, which incorporates a garter spring to maintain consistent lubrication control to the valve stem. OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1217 Valve Spring: Service and Repair REMOVAL IN VEHICLE 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative cable from remote jumper terminal. 3. Remove air cleaner housing and inlet hose. 4. Remove upper intake manifold. 5. Remove cylinder head covers. 6. Remove crankshaft vibration damper, timing chain cover, and timing chain. 7. Remove camshafts and rocker arms. 8. With air hose attached to spark plug adapter installed in the cylinder being serviced, apply 620.5 689 kPa (90 - 100 psi) air pressure. This is to hold valves in place while servicing components. 9. Using Special Tool MD 998772A with adapter 6779, compress valve spring and remove valve locks, retainer, and valve spring. 10. Remove valve stem seal. OFF VEHICLE 1. With cylinder head removed, compress valve springs using a Special Tool C-3422-B, Valve Spring Compressor. 2. Remove valve retaining locks, valve spring retainers, valve springs and valve spring seat/stem seal assembly (Fig. 39). INSPECTION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1218 Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 40). As an example; the compression length of a spring to be tested is 38.00 mm (1.496 inch). Turn the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Specifications to obtain specified height and allowable tensions. Replace any springs that do not meet specifications. INSTALLATION IN VEHICLE 1. The valve stem seal/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install locks. 2. Follow the same procedure on the remaining cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston is at TDC on the cylinder that the valve spring is to be removed. 3. Remove spark plug adapter tool and Special Tool MD 998772A. 4. Install rocker arm(s). 5. Install camshafts, timing chain, and timing chain cover. 6. Install cylinder head covers. 7. Install upper intake manifold. 8. Install air cleaner housing and inlet hose. 9. Connect negative cable. OFF VEHICLE 1. If removed, install valve(s). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1219 2. If valves or seats have been reground, check valve tip height (A) (Fig. 41). If valve tip height for intake valve is greater than 47.59 mm (1.8737 inch) or 49.14 mm (1.9347 inch) for exhaust valve, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 3. Install valve seat/spring seat assembly over valve guides on all valve stems (Fig. 42). Ensure that the garter spring is intact around the top of the rubber seal. Install valve springs, valve retainers. 4. Compress valve springs with a valve spring compressor install locks and release tool. If valves and/or seats are reground, measure the installed height of springs (B) (Fig. 41), make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.5256 inch), install a 0.762 mm (0.030 inch) spacer in head counterbore under the valve spring seat to bring spring height back within specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle 44.5 - 45.5 deg Head Diameter Intake 1.3256 - 1.3358 in Exhaust 1.0894 - 1.1000 in Length-(Overall) Intake 4.2476 - 4.2673 in Exhaust 4.1685 - 4.1882 in Stem Diameter Intake 0.2337 - 0.2344 in Exhaust 0.2326 - 0.2333 in Stem-to-Guide Clearance Intake (New) 0.0009 - 0.0026 in Exhaust (New) 0.002 - 0.0037 in Intake (Max. Rocking Method) 0.0114 in Exhaust (Max., Rocking Method) 0.0146 in Valve Lift Intake (Zero Lash) 0.3543 inch Exhaust (Zero Lash) 0.3150 inch Valve Stem Tip Height Intake 1.8551 +/- 0.00184 inch Exhaust 1.9162 +/- 0.00184 inch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1223 Valve: Description and Operation DESCRIPTION The valves are made of heat resistant steel, and have chrome plated stems to prevent scuffing (Fig. 15). The four valves per cylinder (two intake and two exhaust) are actuated by roller rocker arms, which pivot on stationary lash adjusters. All valves use three bead lock keepers to retain springs and to promote valve rotation. OPERATION The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1224 Valve: Testing and Inspection INSPECTION VALVES 1. Clean and inspect valves thoroughly. Replace burned, warped and cracked valves. 2. Measure valve stems for wear (Fig. 36). For valve specifications, Refer to SPECIFICATIONS. NOTE: Valve stems are chrome plated and should not be polished (Fig. 36). VALVE GUIDES 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Measure valve stem-to-guide clearance as follows: 3. Install valve into cylinder head so it is 15 mm (0.590 inch) off the valve seat. A small piece of hose may be used to hold valve in place. 4. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 37). 5. Move valve to and from the indicator. For clearance specifications, Refer to SPECIFICATIONS. NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. Remove cylinder head(s). 2. Remove valve spring. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. 4. Remove valve. Identify each valve to ensure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. 2. If valves or seats have been reground, check valve tip height (A) (Fig. 38). If valve tip height for intake valve is greater than 47.59 mm (1.8737 inch) or 49.14 mm (1.9347 inch) for exhaust valve, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 3. Install valve spring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1227 Valve: Service and Repair Refacing Valves & Seats VALVE AND VALVE SEAT REFACING The intake and exhaust valves have a 44.5 to 45 degree face angle. The valve seats have a 45 to 45.5 degree face angle. The valve face and valve seat angles are shown in (Fig. 33). VALVES Inspect the remaining margin after the valves are refaced. VALVE SEATS 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, then lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face, then raise valve seat with a 65 degree stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. 4. When seat is properly positioned the width of the intake 1.00 to 1.50 mm (0.0394 to 0.0591 inch) and exhaust seats should be 1.25 to 1.75 mm (0.049 to 0.069 inch) (Fig. 33). 5. Check the valve spring installed height after refacing the valve and seat (Fig. 34). VALVE AND SPRING INSTALLED HEIGHT 1. Coat valve stems with clean engine oil and insert them in cylinder head. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1228 2. If valves or seats have been refaced, check valve tip height (A) (Fig. 34). If valve tip height for intake valve is greater than 47.59 (1.8737 inch) or 49.14 (1.9347 inch) for exhaust valve, grind valve tip until within specifications. Make sure measurement is taken from cylinder head surface to the top of valve stem. 3. Install valve seal/spring seat assembly over valve guides on all valve stems (Fig. 36). Ensure that the garter spring is intact around the top of the rubber seal. 4. Position valve springs and retainer on spring seat (Fig. 35). 5. Compress valve spring with a valve spring compressor. 6. Install retainer locks and release tool. 7. If valves and/or seats are refaced, measure the installed height of springs (B) (Fig. 34). Measurement is taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.5256 inch), install a 0.762 mm (0.030 inch) spacer in head counterbore under the valve spring seat to bring spring height back within specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation DESCRIPTION The accessory drive consist of two Poly-V type belts (Fig. 1) or (Fig. 2). One belt drives the power steering pump, the other drives the generator and air conditioning compressor. Both belts on the 2.7L engine are manually tensioned. The power steering belt on the 2.4L engine is manually tensioned. The air conditioning/generator belt on the 2.4L engine has an automatic belt tensioner. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1233 Drive Belt: Testing and Inspection Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. ACCESSORY DRIVE BELT DIAGNOSIS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1234 Drive Belt: Service and Repair REMOVAL AIR CONDITIONING COMPRESSOR/GENERATOR BELT 1. Raise vehicle on hoist. 2. Remove right front wheel and belt splash shield. 3. Loosen tensioner locking bolt and pivot bolt. 4. Rotate tensioner clockwise to allow enough slack to remove belt. POWER STEERING PUMP BELT 1. Raise vehicle on hoist. 2. Remove right front wheel and belt splash shield. 3. Remove the air conditioning compressor/generator belt. 4. Loosen belt adjusting bolt. It is not necessary to loosen the pivot bolt on the power steering pump. There is a bushing incorporated into the power steering pump/bracket that allows it to pivot. 5. Remove power steering belt. CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: Excessive wear - Frayed cords - Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 4). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION NOTE: When installing drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley. AIR CONDITIONING COMPRESSOR/GENERATOR BELT 1. Install air conditioning compressor/generator belt on pulleys (Fig. 6). 2. Insert a 1/2" drive breaker bar into the square opening on the tensioner. 3. Hold counterclockwise pressure on tensioner and tighten tensioner locking bolt and pivot bolt. 4. Install belt splash shield and right front wheel. 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1235 POWER STEERING PUMP BELT 1. Install power steering belt on pulleys (Fig. 6). 2. Insert a 1/2" drive breaker bar into the square opening on the power steering pump bracket. 3. Hold clockwise pressure on power steering pump bracket and tighten adjusting bolt. 4. Install air conditioning compressor/generator belt. 5. Install belt splash shield and right front wheel. 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Mount Bracket to Block-Bolts 45 ft.lb Isolator-Nuts 45 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1239 Engine Mount: Adjustments ENGINE SUPPORT ADJUSTMENT The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right and left engine support assemblies as required. Adjust drive train position, if required, for the following conditions: Drive shaft distress: See Group 2, Suspension and Driveshaft. - Any front end structural damage (after repair). - Support Assembly replacement. ENGINE SUPPORT ADJUSTMENT 1. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 2. Loosen the right engine support assembly vertical fasteners. 3. Loosen the left engine support assembly vertical bolts. 4. Pry the engine right or left as required to achieve the proper drive shaft assembly length. Refer to driveshaft identification and related assembly length measuring. 5. Tighten right engine support assembly vertical bolts to 61 Nm (45 ft. lbs.) and tighten left engine support assembly bolts to 61 Nm (45 ft. lbs.). 6. Recheck drive shaft length. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount FRONT MOUNT REMOVAL 1. Raise vehicle. 2. Remove front mount to bracket horizontal through bolt (Fig. 91). 3. Remove front mount vertical bolts (Fig. 91). 4. Remove front mount. INSTALLATION 1. Position front mount on lower radiator crossmember. 2. Loose install front mount to bracket through bolt. 3. Install front mount vertical bolts. Tighten bolts to 61 Nm (45 ft. lbs.) (Fig. 77). 4. Tighten horizontal through bolt to 61 Nm (45 ft. lbs.) (Fig. 77). 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1242 Engine Mount: Service and Repair Left Mount LEFT MOUNT REMOVAL 1. Disconnect negative battery cable. 2. Remove throttle body air inlet hose and air cleaner housing assembly. 3. Remove two nuts securing speed control servo bracket to left shock tower. Reposition servo. 4. Support transmission with floor jack and wooden block. 5. Remove the three vertical bolts from mount to transmission bracket (A) (Fig. 74). 6. Slightly lower transmission with floor jack. 7. Remove mount to frame rail fasteners (B) and remove mount (Fig. 74). INSTALLATION 1. Position mount to frame rail. Install mount to frame rail fasteners (B) (Fig. 88). Torque fasteners to 33 Nm (24 ft. lbs.). 2. Raise transmission into position with floor jack. 3. Install three vertical bolts from mount to transmission bracket (A) (Fig. 88). Torque fasteners to 61 Nm (45 ft. lbs.). 4. Remove floor jack and wooden block. 5. Install speed control servo to left shock tower. Torque fasteners to 6.7 Nm (60 in. lbs.) 6. Install throttle body air inlet hose and air cleaner housing assembly. 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1243 Engine Mount: Service and Repair Rear Mount REAR MOUNT REMOVAL 1. Remove throttle body air inlet hose and air cleaner housing assembly. 2. Remove three vertical bolts attaching rear mount bracket to transaxle case (Fig. 89). 3. Raise vehicle on hoist. 4. Remove rear mount bracket through bolt (Fig. 89). 5. Remove horizontal bolt attaching rear mount bracket to transaxle case (Fig. 89). 6. Remove mount bracket. 7. Remove rear mount to suspension crossmember attaching bolts. 8. Remove rear mount. INSTALLATION 1. Position rear mount on suspension crossmember and loosely install bolts. 2. Position mount bracket on transaxle and install bolts. Tighten to 110 Nm (80 ft. lbs.) (Fig. 76). 3. Install rear mount to bracket through bolt and tighten to 61 Nm (45 ft. lbs.) (Fig. 75). 4. Tighten rear mount to crossmember bolts to 61 Nm (45 ft. lbs.) (Fig. 75). 5. Lower vehicle. Install throttle body air inlet hose and air cleaner housing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1244 Engine Mount: Service and Repair Right Mount RIGHT MOUNT REMOVAL 1. Remove coolant pressure container. 2. Remove heater tube front attaching screw. 3. Raise vehicle on a hoist and remove inner splash shield. 4. Remove heater tube rear attaching screw. 5. Remove the right engine support assembly vertical fasteners from frame rail (Fig. 90). 6. Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly with floor jack and wooden block on oil pan. 7. Remove the bolts attaching the engine support assembly to the engine bracket (Fig. 90). 8. Remove right engine mount. INSTALLATION 1. Position right engine mount and install frame rail to mount bolts. Tighten bolts to 61 Nm (45 ft. lbs.) (Fig. 76). 2. Install the mount to engine support bracket bolts and tighten to 61 Nm (45 ft. lbs.) (Fig. 76). 3. Raise vehicle on a hoist. 4. Install heater tube rear attaching screw. 5. Install inner splash shield and lower vehicle. 6. Install heater tube front attaching screw. 7. Install coolant bottle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure OIL PRESSURE @ Curb Idle Speed 5 psi (at normal operating temperature) If oil pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 45 -105 psi Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Additives/Supplements Engine Oil: Technical Service Bulletins Engine Oil - Additives/Supplements NUMBER: 09-003-01 GROUP: Engine DATE: May 4, 2001 SUBJECT: Engine Oil Additives/Supplements OVERVIEW: This bulletin reinforces a requirement to cease the current practice of using supplemental oil additive treatments in all DaimlerChrysler engines. MODELS: 2001 (AB) Ram Van/Wagon 2001 (AN) Dakota 2001 (BR/BE) Ram Pickup 2001 (DN) Durango 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 (KJ) Liberty 2001 (LH) Concorde/Intrepid/LHS/300M 2001 (PL) Neon 2001 (PR) Prowler 2001 (PT) PT Cruiser 2001 (RG) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (ST) Sebring Coupe 2001 (SR) Viper 2001 (TJ) Wrangler 2001 (WG) Grand Cherokee (International Markets) 2001 (WJ) Grand Cherokee 2001 (XJ) Cherokee NOTE: THIS BULLETIN APPLIES TO ALL DAIMLERCHRYSLER MODELS/ENGINES BUILT BEFORE AND AFTER THE 2001 MODEL YEAR. DISCUSSION Engine oil additives/supplements (EOS) should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: ^ Doubling the level of Phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% Phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee our emissions performance to 80,000 miles and new requirements of 150,000 miles. ^ Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. ^ Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil w/Filter ............................................................................................................................... ........................................................................ 5.0 Qt Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1255 Engine Oil: Fluid Type Specifications Engine Oil Type Below 100°F (38°C) ............................................................................................................................. ...................................................................... 5W-30 Above -20°F (-29°C) ......................................... ....................................................................................................................................................... 10W-30 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1256 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading (Fig. 95). Add only when the level is at or below the ADD mark. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1259 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE 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 SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Change engine oil and filter at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Hoist and support vehicle on safety stands. 4. Remove oil fill cap (Fig. 95). 5. Place a suitable drain pan under crankcase drain. 6. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged 7. Remove oil filter. 8. Install drain plug in crankcase. 9. Install new oil filter. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil, (Fig. 95). 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full flow, disposable type oil filter. When replacing oil filter, use a Mopar filter or equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 12 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1263 Oil Filter: Service and Repair OIL FILTER REMOVAL 1. Raise vehicle on hoist. 2. Position a suitable collecting container under oil filter location (Fig. 96). 3. Remove oil filter using a suitable oil filter wrench (Fig. 96). Dispose of oil filter following environmental guidelines. INSTALLATION 1. Wipe filter base clean, then inspect gasket sealing surface. 2. Lubricate gasket of new filter with clean engine 0il. 3. Install oil filter (Fig. 96) and tighten to 16 Nm (12 ft. lbs.) of torque after gasket contacts base. Use filter wrench if necessary. 4. Fill crankcase with proper engine oil to correct level if drained. Start engine and check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 250 in.lb Nuts 105 in.lb Drain-Plug 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1267 Oil Pan: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove engine oil dipstick and tube. 3. Raise vehicle on hoist. 4. Drain engine oil and remove oil filter. 5. Remove structural collar (Fig. 97). 6. Remove exhaust cross-under pipe. 7. Remove torque converter housing cover. 8. Remove lower bolt attaching the A/C compressor to oil pan. CAUTION: Assure removal of the two bolts attaching the timing cover to the oil pan, as damage to the timing cover and/or oil pan may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1268 9. Remove oil pan attaching fasteners. Remove oil pan and gasket (Fig. 98). INSTALLATION 1. Clean oil pan and sealing surfaces. Inspect oil pan and timing chain cover gaskets. Replace as necessary. 2. Apply a 1/8 inch bead of Mopar Engine RTV GEN II to the front T-joints (oil pan gasket to timing cover gasket interface) (Fig. 98). 3. Install oil pan gasket to block. NOTE: To prevent oil leaks at oil pan to timing chain cover, the following tightening sequence procedure must be performed. 4. Install oil pan and fasteners (Fig. 98) using the following tightening sequence: a. Install oil pan bolts and nuts finger tight only just tight enough to compress the gasket's rubber seal. b. Install timing chain cover to pan bolts and tighten to 12 Nm (105 in. lbs.). c. Tighten oil pan bolts to 28 Nm (250 in. lbs.). d. Tighten oil pan nuts to 12 Nm (105 in. lbs.). 5. Install lower bolt attaching the A/C compressor to oil pan. Tighten bolt to 28 Nm (21 ft. lbs.). 6. Install torque converter housing cover. 7. Install oil filter and drain plug. 8. Install exhaust cross-under pipe. 9. Install structural collar (Fig. 97). 10. Lower vehicle. 11. Install engine oil dipstick and tube. 12. Fill engine crankcase with proper oil to correct level. 13. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: All Technical Service Bulletins Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 1286 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1287 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1288 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1289 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: All Technical Service Bulletins Engine Oil Pressure Light ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Page 1303 Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pump Pick Up Tube-Bolt 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure OIL PRESSURE @ Curb Idle Speed 5 psi (at normal operating temperature) If oil pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 45 -105 psi Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair Oil Pressure Regulator Valve: Service and Repair REMOVAL 1. Remove the oil pan. 2. Remove the pressure relief valve by remove the threaded retaining cap from the oil pump housing. CAUTION: Oil pump pressure relief valve must be installed as shown in (Fig. 99) or engine damage may occur. 3. Remove spring and relief valve (Fig. 99). INSTALLATION 1. Lubricate relief valve with oil. CAUTION: The pressure relief valve must be installed as shown in (Fig. 99), or engine damage may occur. 2. Install relief valve, spring and retainer cap (Fig. 99). Tighten cap to 12 Nm (105 in. lbs.). 3. Install the oil pan. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications LOWER INTAKE MANIFOLD Tighten manifold attaching bolts in sequence shown. Torque to 12 Nm (105 in. lbs.). UPPER INTAKE MANIFOLD Tighten manifold attaching bolts in sequence shown. Torque to 12 Nm (105 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1318 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts ........................................................................................................................................................... 13.6 Nm (120 in. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1319 Intake Manifold: Description and Operation DESCRIPTION The two piece intake manifold is made of a composite material. The intake manifold features a compact, low rumble design that maximizes engine performance while minimizing induction noise. A Manifold Tuning Valve (MTV) is used on some models. OPERATION The intake air plenum chambers absorb air pulsations created during each cylinder's intake stroke. The manifold tuning valve (if equipped) connects both sides of the intake manifold plenums at specific engine speeds to maximize low RPM torque, without reducing high RPM power. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1320 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If engine RPM'S change, the area of the suspected leak has been found. 4. Repair as required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Intake Manifold: Service and Repair Intake Manifold REMOVAL INTAKE MANIFOLD UPPER 1. Disconnect negative battery cable. 2. Remove throttle body air inlet hose and air cleaner housing assembly. 3. Remove throttle cable shield. Remove throttle and speed control cables from throttle arm and bracket. 4. Remove throttle cable bracket. 5. Disconnect electrical connectors from the following components: - Manifold Absolute Pressure (MAP) Sensor - Throttle Position Sensor (TPS) Sensor - Idle Air Control (IAC) Motor - Manifold Tuning Valve (MTV) 6. Disconnect Vapor Purge hose, Brake Booster hose, Speed Control Servo, Positive Crankcase Ventilation (PCV) hose. 7. Remove EGR upper tube. 8. Loosen upper fastener at throttle body support bracket. 9. Remove manifold attaching bolts (Fig. 112). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1323 10. Remove upper manifold (Fig. 111). 11. Inspect manifold. INTAKE MANIFOLD LOWER 1. Release fuel system pressure. 2. Remove upper intake manifold. 3. Disconnect electrical connectors from the fuel injectors. 4. Remove fuel supply hose from fuel rail. 5. Remove screw attaching fuel rail support bracket to the throttle body support bracket. 6. Remove bolts attaching fuel rail. 7. Remove fuel rail and injectors as an assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1324 8. Remove manifold attaching bolts (Fig. 113). 9. Remove lower manifold. 10. Inspect manifold. INSPECTION Check for: Damage and cracks of each section. - Clogged water passages in the end cross-over. - Clogged fuel and EGR passages. INSTALLATION INTAKE MANIFOLD UPPER 1. Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears. NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation. 2. Position upper manifold onto lower manifold (Fig. 111). 3. Install manifold attaching bolts and tighten in sequence shown in (Fig. 112) to 12 Nm (105 in. lbs.). 4. Tighten upper fastener at throttle body support bracket. 5. Install EGR upper tube to manifold. 6. Connect speed control servo, PCV, brake booster, and vapor purge hoses. 7. Connect electrical connectors to the following components: - Manifold Absolute Pressure (MAP) Sensor - Throttle Position Sensor (TPS) Sensor - Idle Air Control (IAC) Motor - Manifold Tuning Valve (MTV) 8. Install throttle cable bracket. 9. Connect throttle and speed control cables to bracket and throttle arm. Install throttle cable shield. 10. Install throttle body air inlet hose and air cleaner housing assembly. 11. Connect negative battery cable. INTAKE MANIFOLD LOWER 1. Clean and inspect sealing surfaces of cylinder head and manifold. Gaskets can be reused provided they are free of cuts or tears. 2. Position manifold on cylinder head surfaces. NOTE: For ease of installing upper intake manifold, install a bolt 2 - 3 turns to the rearmost attaching hole of intake. This will properly position lower manifold. 3. Install fuel rail with injectors. 4. Install manifold attaching bolts and tighten in sequence shown in (Fig. 113) to 12 Nm (105 in. lbs.). Remove bolt used for aligning manifold. 5. Connect the fuel injector electrical connectors. NOTE: Make sure fuel injectors are located in the correct location and position, as upper intake manifold interference could occur. 6. Install screw attaching fuel rail support bracket to the throttle body support bracket. 7. Connect fuel supply hose to fuel rail. 8. Install upper intake manifold. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1325 Intake Manifold: Service and Repair Intake Manifold Vacuum Port Repair INTAKE MANIFOLD VACUUM PORT REPAIR The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be replaced. To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure: NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum chamber. 1. File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis). 2. Drill out the nipple (port) base using a 7/16" drill bit (Fig. 110). 3. Using a 1/4"-18 NPT pipe tap, cut internal threads (Fig. 110). Use caution to start tap in a axis same as original nipple. 4. Apply Mopar Thread Sealant to threads of repair nipple(s). 5. Install repair nipple(s). Do not over torque repair nipple(s). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: All Technical Service Bulletins Engine Oil Pressure Light ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Page 1340 Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove transaxle from vehicle. 2. Remove drive plate. 3. Insert a 3/16" wide flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 69) through the dust lip against the metal case of the seal. Pry out seal. CAUTION: Do not allow the screwdriver blade to contact the crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 grit sand paper to prevent seal damage during installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1345 1. Place Special Tool 6926-1 Guide on crankshaft (Fig. 70). This is a pilot tool with a magnetic base. 2. Position seal over pilot tool. Assure that lip of seal is facing towards the crankshaft during installation. The pilot tool remains on crankshaft during seal installation. 3. Using Special Tool 6926-2 Installer, and C-4171 Handle (Fig. 70), drive seal into the retainer housing until seal is flush with housing surface. 4. Install drive plate and transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Testing and Inspection Cylinder Head Gasket: Testing and Inspection CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: Loss of engine power - Engine misfiring - Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: Engine overheating - Loss of coolant - Excessive steam (white smoke) emitting from exhaust - Coolant foaming CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident. CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Remove crankshaft vibration damper. 2. Install Special Tool 8194, Insert into crankshaft nose. Remove seal using Special Tool 6771, Remover (Fig. 67). INSTALLATION 1. Install new seal using Special Tools 6780-2 Sleeve, 6780-1 Installer, and 8179 Stud (Fig. 68). 2. Install crankshaft vibration damper. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair REMOVAL 1. Remove valve spring. 2. Remove valve stem seal by using a valve seal tool (Fig. 43). INSTALLATION 1. The valve stem seat/valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do not force seal against top of guide. 2. Install valve spring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: All Technical Service Bulletins Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 1373 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1374 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1375 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1376 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Camshaft Sprocket Bolts 250 in.lb Camshaft Chain Tensioner (Secondary) Bolts 105 in.lb Crankshaft Damper Bolt 125 ft.lb Timing Chain Cover M6 Bolts 105 in.lb M10 Bolts 40 ft.lb Timing Chain Guide Access Plug 15 ft.lb Timing Chain Tensioner (Primary) 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1384 Timing Chain: Service and Repair REMOVAL TIMING CHAIN 1. Disconnect negative battery cable. 2. Drain cooling system. 3. Remove upper intake manifold. 4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover. CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. 5. Align crankshaft sprocket timing mark to mark on oil pump housing (Fig. 118). The mark on oil pump housing is 60° ATDC of #1 cylinder. CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage. 6. Remove power steering pump and bracket as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1385 7. Remove primary timing chain tensioner retainer cap and tensioner from right cylinder head (Fig. 119). 8. Disconnect and remove camshaft position sensor from left cylinder head (Fig. 120). 9. Remove timing chain guide access plugs from cylinder heads (Fig. 120). NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction. 10. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (if equipped) and sprocket (Fig. 120). 11. Remove left side camshaft sprocket attaching bolts and remove sprocket (Fig. 120). 12. Remove lower chain guide and tensioner arm (Fig. 120). 13. Remove the primary timing chain. 14. For removal of crankshaft sprocket, Refer to CRANKSHAFT -REMOVAL. CRANKSHAFT SPROCKET 1. Remove primary timing chain. CAUTION: Use care not to turn crankshaft while removing crankshaft sprocket, as damage to valves and or pistons could occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1386 2. Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equivalent to damper bolt head and position Special Tools 5048-1, 5048-6, and 8539 on sprocket and crankshaft nose (Fig. 121). Remove sprocket using care not to rotate the crankshaft. INSTALLATION TIMING CHAIN 1. Inspect all sprockets and chain guides. Replace if worn. 2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT - INSTALLATION. 3. If removed, install right and left side short chain guides (Fig. 120). Tighten attaching bolts to 28 Nm (250 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1387 4. Align crankshaft sprocket timing mark to the mark on oil pump housing (Fig. 122). NOTE: Lubricate timing chain and guides with engine oil before installation. 5. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (Fig. 122). 6. Lower the primary chain with left side sprocket through the left cylinder head opening. NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation. 7. Loosely position left side camshaft sprocket over camshaft hub. 8. Align timing (plated) link to the crankshaft sprocket timing mark (Fig. 122). 9. Position primary chain onto water pump drive sprocket. 10. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (Fig. 122) and loosely position over camshaft hub. 11. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets (Fig. 122). 12. Install left side lower chain guide and tensioner arm (Fig. 120). Tighten attaching bolts to 28 Nm (250 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1388 NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary. 13. Install chain guide access plugs to cylinder heads (Fig. 120). Tighten plugs to 20 Nm (15 ft. lbs.). NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner (Fig. 123). 14. Purge oil from timing chain tensioner using the following procedure: a. Place the check ball end of tensioner into the shallow end of Special Tool 8186 (Fig. 123). b. Using hand pressure, slowly depress tensioner until oil is purged from tensioner (Fig. 123). 15. Reset timing chain tensioner using the following procedure: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1389 a. Position cylinder plunger into the deeper end of Special Tool 8186 (Fig. 124). b. Apply a downward force until tensioner is reset (Fig. 124). NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball. CAUTION: Ensure the tensioner is properly reset. The tensioner body must bottom against the top edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming. 16. Install the reset chain tensioner into the right cylinder head (Fig. 119). 17. Position tensioner retaining plate and tighten bolts to 12 Nm (105 in. lbs.) (Fig. 119). 18. Starting at the right cylinder bank, first position the camshaft damper (if equipped) on camshaft hub, then insert a 3/8" square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 in. lbs.) (Fig. 120). 19. Turn the left side camshaft by inserting a 3/8" square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 in. lbs.) (Fig. 120). 20. Rotate engine slightly clockwise to remove timing chain slack, if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1390 21. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly (Fig. 125). Then release the tensioner arm. Verify the tensioner is activated (extends). 22. Install power steering pump and bracket assembly. 23. Install camshaft position sensor and connect electrical connector. 24. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers. 25. Install upper intake manifold. NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds. 26. Fill cooling system. 27. Connect negative battery cable. CRANKSHAFT SPROCKET 1. Install crankshaft sprocket using Special Tools 6780-1 and 8179 (Fig. 126) until sprocket bottoms against crankshaft step flange. Use care not to rotate crankshaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1391 2. Verify that crankshaft sprocket is installed to proper depth by measuring from sprocket outer face to end of crankshaft (Fig. 127). Measurement should read: 39.05 - 40.50 mm (1.5374 - 1.0020 inch). 3. Install primary timing chain. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Access Plug 15 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner (Primary) 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Cover M6 Bolts 105 in.lb M10 Bolts 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1401 Timing Cover: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Drain cooling system. 3. Remove coolant pressure container. 4. Raise vehicle on hoist. 5. Remove right front wheel and belt splash shield. 6. Remove accessory drive belts. 7. Remove crankshaft vibration dampener. 8. Remove AC/Generator belt tensioner/bracket assembly. 9. Disconnect heater hose from tube at right front frame rail area. 10. Lower vehicle. 11. Remove screws securing heater supply tube to right frame rail. Reposition heater supply tube. 12. Place a floor jack with wooden block under oil pan to support engine. 13. Remove right engine mount. 14. Remove upper timing chain cover bolts. 15. Raise vehicle on hoist. 16. Remove remaining bolts securing timing chain cover to engine (Fig. 116). 17. Remove timing chain cover. 18. Discard timing chain cover gasket. Remove front crankshaft oil seal from cover. INSTALLATION 1. Inspect and clean timing chain cover sealing surfaces. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1402 2. Before installing timing cover gasket apply a 1/8 inch bead of Mopar Engine RTV GEN II to the parting lines between the oil pan and cylinder block (Fig. 117). 3. Install timing cover and gasket. Tighten M10 cover bolts to 54 Nm (40 ft. lbs.) and M6 bolts to 12 Nm (105 in. lbs.) (Fig. 116). 4. Install front crankshaft oil seal using Special Wool 6780-2 sleeve and 6780-1 installer. 5. Lower vehicle. 6. Install right engine mount. 7. Install screws attaching heater supply tube to right front frame rail area. 8. Raise vehicle on hoist. 9. Connect heater hose to supply tube at right front frame rail area. 10. Install AC/Generator belt tensioner/bracket assembly. 11. Install crankshaft vibration damper. 12. Install accessory drive belts. 13. Install belt splash shield and right front wheel. 14. Lower vehicle. 15. Install coolant pressure container. 16. Fill cooling system. 17. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Deadhead Pressure 880 kpa (130 psi) Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1408 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1409 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1410 Tests 3 - 5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1411 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel Pump Relay - Fuel Pressure Out Of Specs - Restricted Fuel Supply Line - Fuel Pump Inlet Strainer Plugged - Fuel Pump Module - Fuel Pump Capacity (Volume) Out Of Specs - Fuel Pump Relay Fused B+ Circuit - Fuel Pump Relay Output Circuit Open - Fuel Pump Ground Circuit Open/High Resistance Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1412 - Fuel Pump Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 550-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test using a scan tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect inlet air temperature sensor electrical connector (Fig. 7). 3. Disconnect fresh air makeup hose from throttle body air inlet hose (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1420 4. Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. 5. Push in on locking tabs to disengage air inlet hose from air cleaner housing. Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver (Fig. 10). 6. Remove throttle body air inlet hose. 7. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Clean any debris from inside air cleaner housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1421 2. Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. 3. Install throttle body air inlet hose into air cleaner housing. Push in on hose until an audible "click" is heard from locking tabs. 4. Install hose on throttle body. Tighten hose clamp (Fig. 9). 5. Connect fresh air makeup hose (Fig. 8). 6. Connect inlet air temperature sensor electrical sensor (Fig. 7). 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1426 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered (Fig. 2). The firing order is 1-2-3-4-5-6. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1431 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ...................................................................... 0.050 in Tightening Torque ........................................... .......................................................................................................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1439 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................... Champion Platinum Power CHA 3032 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum Cylinder Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1443 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Disconnect and remove all ignition coils from spark plugs. 4. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the -500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 26 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump - Bolts 105 in.lb Water Outlet Connector - Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1450 Water Pump: Description and Operation DESCRIPTION The 2.7L pump has a die cast aluminum housing and a plastic swept vane impeller. It bolts directly to the cylinder block, behind the timing chain cover. The water pump is driven by the back side of the engine's primary timing chain. OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1451 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1452 Water Pump: Service and Repair REMOVAL NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain at weep passage). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident on side of the cylinder block from the weep hole passage (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN RESULT. 1. Disconnect negative battery cable. 2. Drain cooling system. NOTE: The water pump is driven by the primary timing chain. 3. Remove the timing chain cover, timing chain, and all chain guides. 4. Remove bolts attaching water pump to block. 5. Remove water pump and gasket. CLEANING Clean gasket mating surfaces as necessary. INSPECTION Inspect and replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1453 2. Coolant leaks; if the shaft seal is leaking, this will be evident by traces of thick deposits of dried glycol running down from the pump weep passage and components below. A thin black stain below pump weep hole/passage is considered normal operation. 3. Impeller rubs inside of cylinder block. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole. Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the weep passage. This indicates a shaft seal failure and pump must be replaced. Be sure to perform a thorough analysis before replacing water pump. INSTALLATION 1. Clean all sealing surfaces. 2. Install water pump and gasket. Tighten mounting bolts to 12 Nm (105 inch lbs.). 3. Install timing chain guides, timing chain, and timing chain cover. 4. Reconnect negative battery cable. 5. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 9.0 Liters ( 9.5 qts ) Note: Includes heater and recovery bottle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1459 Coolant: Fluid Type Specifications This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, Use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 mile formula (MS-9769), P/N 5011764AB or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1460 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1461 Coolant: Description and Operation DESCRIPTION CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. Do not mix coolant types. If coolant other than leopard Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent is added, the mixed coolant will have a reduced service schedule. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar) Antifreeze/Coolant, 5 Year/100,000 Mile Formula or equivalent ethylene glycol based coolant with corrosion inhibitors (called MOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. Mixing of coolants other than specified (non-HOAT), will reduce the 5 year/100,000 mile corrosion protection. OPERATION The cooling system is designed around the coolant. The coolant must accept heat from the engine metal, in the cylinder head area near the exhaust valves and engine block. The coolant carries heat to the radiator where the tube/fin radiator can transfer the heat to the air. Properly mixed, the coolant raises the boiling point, prevents freezing in cold climates, and prevents corrosion. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASED COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPENED OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN AND PETS. DISPOSE OF GLYCOL BASED COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1462 Coolant: Testing and Inspection CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1463 Coolant: Service and Repair COOLANT-ADDING ADDITIONAL NOTE: The pressure cap should not be removed. When additional coolant is needed, it should be added to the coolant recovery/pressure container. Use only 50/50 concentration of ethylene glycol type antifreeze and distilled water. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation HOSE CLAMPS - DESCRIPTION DESCRIPTION The cooling system uses spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopar equipment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. OPERATION The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, use Special Tool 6094, Special Tool 8495, or equivalent, constant tension clamp pliers to compress the hose clamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation > Page 1467 Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL 1. Drain cooling system. 2. Raise vehicle on hoist. 3. Disconnect lower radiator hose and heater hose from the inlet tube. 4. Remove fasteners that hold the inlet tube to the block. 5. Rotate inlet tube while removing from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. 2. Lube O-ring with coolant and install into the cylinder block opening. 3. Install fasteners and tighten to 12 Nm (105 inch lbs.). 4. Reconnect lower radiator hose and heater hose to inlet tube. 5. Lower vehicle. 6. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Specifications Coolant Outlet: Specifications Coolant Outlet Connector-Bolts ........................................................................................................... ............................................................ 105 inch lbs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Specifications > Page 1471 Coolant Outlet: Service and Repair REMOVAL WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Drain cooling system. 2. Remove upper intake manifold. 3. Disconnect Engine Coolant Temperature (ECT) sensor connector. 4. Disconnect hoses at coolant outlet connector. Use Special Tool 8495 Pliers to remove clamps. 5. Remove bolts attaching coolant outlet connector. 6. Remove coolant outlet connector. INSTALLATION 1. Clean sealing surfaces. Inspect gaskets for tears and cuts. Replace as necessary. 2. Install coolant outlet connector and tighten bolts to 12 Nm (105 inch lbs.). 3. Connect hoses at coolant outlet connector. Use Special Tool 8495 Pliers to install clamps. 4. Connect engine coolant temperature sensor connector. 5. Install upper intake manifold. 6. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation DESCRIPTION The coolant pressure container consists of a pressure chamber and a overflow chamber. The coolant pressure container is mounted in the right side engine compartment. An overflow hose connects the pressure chamber to the overflow chamber. NOTE: Coolant will normally be in the pressure chamber side of the coolant bottle. The overflow chamber should normally be empty OPERATION The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling losses. The overflow chamber allows coolant recovery in case of an overheat. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 1475 Coolant Reservoir: Service and Repair REMOVAL 1. Drain coolant below the coolant pressure container level. 2. Remove the power steering reservoir attaching screw. 3. Remove the air conditioning receiver/dryer attaching screw. 4. Disconnect the hose from coolant outlet connector to the bottle. 5. Remove pressure container attaching screws. 6. Reposition pressure container and disconnect the heater hose at the container. 7. Remove coolant pressure container. INSTALLATION 1. Connect heater hose to coolant pressure container. 2. Install container in mounting position and install attaching screws. 3. Connect the coolant outlet connector hose to the bottle. 4. Install the air conditioning receiver/dryer attaching screw. 5. Install the power steering reservoir attaching screw. 6. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Fan Module to Radiator-Fasteners 65 in.lb Fan Motor to Shroud-Fasteners 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Radiator Fan Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1501 Radiator Cooling Fan Motor: Description and Operation DESCRIPTION The radiator fan module includes a support shroud with two electrically driven motors with fan blades. The radiator fan module is fastened to the radiator. The motors, shroud, and fan blades are serviced separately. OPERATION The radiator fans are controlled by the Powertrain Control Module (PCM), which energizes a high speed or low speed fan relay. The electric motor drives the cooling fan to produce air flow across the radiator fins. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1502 Radiator Cooling Fan Motor: Testing and Inspection RADIATOR FAN CONTROL Fan control is accomplished three ways. The fan runs when the air conditioning pressure reaches a set psi see charts below. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the Powertrain Control Module (PCM). The PCM turns on the fan through a fan relay. On models equipped with automatic transmission, a transmission fluid thermistor may have some influences on fan operation. See Wiring Diagrams Manual for circuity and diagnostics provided. The Powertrain Control Module (PCM) provides fan control for the following conditions: ^ The fan will not run during cranking until the engine starts no matter what the coolant temperature is. ^ Fan will run when the air conditioning clutch is engaged, low pressure cutout switch is closed and once set compressor head pressure is reached. See charts. ^ Fan will run according to the following information charts. RADIATOR FAN OPERATION-2.0L ENGINE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1503 RADIATOR FAN OPERATION-2.4L ENGINE RADIATOR FAN OPERATION-2.7L ENGINE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1504 Radiator Cooling Fan Motor: Service and Repair REMOVAL 1. Remove upper radiator crossmember. 2. Disconnect radiator fan electrical connector . 3. Remove fasteners and upper clip attaching fan assembly to radiator. 4. Remove radiator fan assembly by lifting upward. INSPECTION There are no repairs to be made to the fan. If the fan is warped, cracked, or otherwise damaged, it must be replaced with only the recommended replacement part for adequate strength, performance and safety. INSTALLATION 1. Install radiator fan to radiator. Install retaining clip and tighten fasteners to 5 Nm (45 inch lbs.) . 2. Connect radiator fan electrical connector. 3. Install upper radiator crossmember. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center (PDC) High and Low Speed Radiator Fan Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1508 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center (PDC) High Speed Radiator Fan Relay Low Speed Radiator Fan Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1513 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1514 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1515 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1516 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1520 Heater Core: Description and Operation Fig.17 Heater Core The heater core is located in the HVAC housing. The core is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core. As coolant flows through the heater core, heat is transferred to the heater core fins and tubes. Air directed through the heater core fins, picks up the heat. The temperature control door controls heater output air temperature by controlling the air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if damaged. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1521 Heater Core: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove HVAC housing from the vehicle. Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair Fig.18 Recirculation Motor 3. Disconnect connector from recirculation motor. Fig.19 HVAC Harness 4. Remove wiring harness connector from the top of the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1522 Fig.20 Evaporator Seal 5. Remove seal around evaporator coil inlet/outlet. 6. Remove retaining screw from the top of the housing. Fig.21 HVAC Housing 7. Separate the upper from the housing from the lower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1523 Fig.22 Heater Core 8. Lift heater core out of lower housing. INSTALLATION 1. Install new heater core into lower housing. 2. Install upper housing onto lower housing and install screws. 3. Install evaporator seal 4. Install HVAC harness on upper housing 5. Connect recirculation motor connector. 6. Install HVAC housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. NOTE: It is not necessary to remove draincock during a routine coolant drain. 1. Drain the cooling system. 2. Open the draincock by turning it counterclockwise until it stops. 3. Turn the draincock back (clockwise) 1/8 turn. 4. Pull the draincock from the radiator tank. INSTALLATION 1. Align draincock stem to radiator tank opening. 2. Push draincock into the radiator tank opening. 3. Tighten the draincock by turning clockwise until it stops. 4. Fill the cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation DESCRIPTION The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97 - 124 kPa (14 - 18 psi). There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant reserve/recovery system container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. OPERATION The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve container. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing Radiator Cap: Testing and Inspection Cooling System Pressure Relief Testing COOLING SYSTEM PRESSURE RELIEF TESTING WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, THE COOLING SYSTEM BUILDS UP PRESSURE. TO PREVENT SCALDING OR OTHER INJURY, THE PRESSURE CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT AND/OR UNDER PRESSURE. The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69 - 124 kPa (10 - 18 psi), and hold pressure at 55 kPa (8 psi) minimum. There is no need to remove the pressure cap at any time except for the following purposes: ^ Check and adjust coolant freeze point ^ Refill system with new coolant ^ Conducting service procedures ^ Checking for leaks WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE. WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS, PUSH DOWN ON THE CAP AND REMOVE IT COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing > Page 1533 Radiator Cap: Testing and Inspection Radiator Cap Testing COOLING SYSTEM PRESSURE CAP TESTING Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap. CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System Tester, but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1534 Radiator Cap: Service and Repair CLEANING Use only a mild soap to clean the pressure cap. INSPECTION Hold the cap in your hand, right side up. The vent valve at the bottom of the cap should open with a slight pull. If the rubber gasket has swollen, preventing the valve from opening, replace the cap. If any light can be seen between vent valve and the rubber gasket, replace the cap. Use only a replacement cap that has a spring to hold the vent shut. A replacement cap must be of the type designed for coolant reserve systems. This design ensures system pressurization. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center (PDC) High and Low Speed Radiator Fan Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1539 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center (PDC) High Speed Radiator Fan Relay Low Speed Radiator Fan Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1545 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1546 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1547 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1548 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature 180 F Thermostat Fully Open 203 F Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1552 Thermostat: Description and Operation DESCRIPTION The thermostat is located on the lower left side of engine, near the front. The thermostat is on the inlet side of the water pump. It has an air bleed located in the thermostat flange. The air bleed allows internal trapped air during cooling system filling to be released. OPERATION The engine cooling thermostat is a wax pellet driven, reverse poppet choke type. The thermostat is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). The thermostat also will automatically reach wide open so it will not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. The thermostat is operated by a wax filled container (pellet), which is sealed. When heated coolant reaches a predetermined temperature, the wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1553 Thermostat: Testing and Inspection The thermostat is operated by a wax filled container (pellet), which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. The thermostat that opens too soon type failure mode is included in the on-board diagnosis. The check engine light will not be lit by an open too soon condition. If it has failed open, a Diagnostic Trouble Code (DTC) will be set. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. For other probable causes, Refer to ENGINE DIAGNOSIS AND TESTING. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1554 Thermostat: Service and Repair REMOVAL 1. Disconnect negative cable from remote jumper terminal. WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. 2. Drain cooling system. 3. Raise vehicle on hoist. 4. Remove right front wheel and belt splash shield. 5. Remove accessory drive belts. 6. Remove lower generator mounting bolt. 7. Lower vehicle. 8. Disconnect generator electrical connectors. 9. Disconnect AC clutch and AC pressure sensor electrical connectors. Reposition wiring harness. 10. Remove oil dipstick and tube. Plug hole in oil pan where dipstick tube mounts. WARNING: IF HOLE FOR DIPSTICK TUBE IN OIL PAN IS NOT PLUGGED, COOLANT WILL ENTER OIL PAN.SERIOUS ENGINE DAMAGE CAN OCCUR. 11. Remove remaining generator mounting bolts. Remove generator. 12. Disconnect hoses at thermostat housing. 13. Remove thermostat housing bolts. 14. Remove thermostat and housing. INSTALLATION 1. Clean gasket sealing surfaces. NOTE: Install thermostat with the bleed valve located at the 12 o'clock position. 2. Install thermostat and gasket into the thermostat housing. 3. Install thermostat and housing to cylinder block. Tighten attaching bolts to 12 Nm (105 inch lbs.) . 4. Connect hoses at thermostat housing. 5. Install generator and attaching bolts. CAUTION: Before removing plug in oil pan, clean residual coolant from area. 6. Remove plug in oil pan and install engine oil dipstick tube. 7. Reconnect AC clutch and AC pressure sensor connectors. 8. Reconnect generator connectors. 9. Raise vehicle on hoist. 10. Install accessory drive belts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1555 11. Install belt splash shield and right front wheel. 12. Lower vehicle. 13. Reconnect negative battery cable. 14. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing-Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 1559 Thermostat Housing: Service and Repair REMOVAL 1. Drain cooling system below thermostat housing level. 2. Remove thermostat. 3. Disconnect engine coolant temperature sensor connector. 4. Disconnect heater supply hose. 5. Remove housing attaching bolts. 6. Remove housing and gasket. INSTALLATION 1. Clean all gasket sealing surfaces. 2. Install gasket and housing. Tighten bolts to 28 Nm (20 ft. lbs.). 3. Reconnect engine coolant temperature sensor connector. 4. Install thermostat. 5. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump - Bolts 105 in.lb Water Outlet Connector - Bolts 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1563 Water Pump: Description and Operation DESCRIPTION The 2.7L pump has a die cast aluminum housing and a plastic swept vane impeller. It bolts directly to the cylinder block, behind the timing chain cover. The water pump is driven by the back side of the engine's primary timing chain. OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1564 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1565 Water Pump: Service and Repair REMOVAL NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain at weep passage). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident on side of the cylinder block from the weep hole passage (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN RESULT. 1. Disconnect negative battery cable. 2. Drain cooling system. NOTE: The water pump is driven by the primary timing chain. 3. Remove the timing chain cover, timing chain, and all chain guides. 4. Remove bolts attaching water pump to block. 5. Remove water pump and gasket. CLEANING Clean gasket mating surfaces as necessary. INSPECTION Inspect and replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1566 2. Coolant leaks; if the shaft seal is leaking, this will be evident by traces of thick deposits of dried glycol running down from the pump weep passage and components below. A thin black stain below pump weep hole/passage is considered normal operation. 3. Impeller rubs inside of cylinder block. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole. Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the weep passage. This indicates a shaft seal failure and pump must be replaced. Be sure to perform a thorough analysis before replacing water pump. INSTALLATION 1. Clean all sealing surfaces. 2. Install water pump and gasket. Tighten mounting bolts to 12 Nm (105 inch lbs.). 3. Install timing chain guides, timing chain, and timing chain cover. 4. Reconnect negative battery cable. 5. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic Converter to Exhaust 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Front Catalytic Converter: Service and Repair Front FRONT REMOVAL 1. Disconnect negative battery cable. 2. Disconnect upstream oxygen sensor connector. 3. Remove 3 converter attaching nuts that are visible from the engine compartment. 4. Raise vehicle on hoist. 5. Remove exhaust cross-under pipe. 6. Remove remaining bolt attaching converter to exhaust manifold. 7. Remove catalytic converter. 8. Remove and discard gasket. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a horoscope or equivalent. Remove both oxygen sensors and insert borescope. If horoscope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Front > Page 1573 NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to Appropriate Diagnostic Information for test procedures. INSTALLATION 1. Clean manifold to converter sealing surfaces. 2. Position new gasket on converter inlet flange. 3. Ensure exhaust manifold heat shield is in position, and loosely install converter with lower attaching bolt to exhaust manifold. 4. Lower vehicle. 5. Install 3 nuts attaching converter to manifold. Torque nuts to 28 Nm (250 inch lbs.). 6. Reconnect upstream oxygen sensor. 7. Raise vehicle. 8. Torque remaining attaching bolt to 28 Nm (250 inch lbs.). 9. Install cross-under pipe. 10. Lower vehicle. 11. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Front > Page 1574 Catalytic Converter: Service and Repair Rear CATALYTIC CONVERTER REAR REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle on hoist. 3. Remove entire exhaust system from vehicle 4. Remove exhaust cross-under pipe. 5. Disconnect upstream oxygen sensor. 6. Remove nuts attaching converter to exhaust manifold. 7. Remove exhaust manifold heat shield. 8. Remove catalytic converter. 9. Remove and discard gasket. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a horoscope or equivalent. Remove both oxygen sensors and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to Appropriate Diagnostic Information for test procedures. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Front > Page 1575 1. Clean manifold to converter sealing surfaces. 2. Position new gasket on converter inlet flange. 3. Install converter to exhaust manifold. 4. Install exhaust manifold heat shield into position. 5. Install nuts attaching converter to manifold. Torque nuts to 28 Nm (250 inch lbs.). 6. Connect upstream oxygen sensor. 7. Install cross-under pipe. 8. Install exhaust system on vehicle. 9. Lower vehicle. 10. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications Cross-Under Pipe-Fasteners 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications > Page 1579 Exhaust Crossover Pipe: Service and Repair REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Raise vehicle on hoist. 2. Disconnect downstream oxygen sensor connectors. 3. Remove oil pan to transmission structural collar. 4. Disconnect exhaust system pipe from cross-under pipe. 5. Remove fasteners attaching cross-under pipe to catalytic converters. 6. Remove cross-under pipe. INSTALLATION 1. Install new gasket to lower part of rear catalytic converter. If installing new cross-under pipe, transfer oxygen sensors to new pipe. 2. Loosely install cross-under pipe to catalytic converters. Snug nuts up equally using hand pressure. 3. Tighten 2 nuts for cross-under pipe to rear catalytic converter to 28 Nm (250 inch lbs.). 4. Tighten 2 nuts for cross-under pipe to front catalytic converter to 28 Nm (250 inch lbs.). 5. Connect exhaust system pipe to cross-under pipe. Tighten attaching fasteners to 28 Nm (250 inch lbs.) 6. Install oil pan to transmission structural collar. 7. Reconnect downstream oxygen sensor connectors. 8. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 23 Nm (200 in.lb) Tighten bolts starting at the center working outwards. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1583 Exhaust Manifold: Description and Operation DESCRIPTION The exhaust manifolds are made of cast nodular iron. The outlets are designed for attachment of catalytic converters. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1584 Exhaust Manifold: Service and Repair REMOVAL FRONT EXHAUST MANIFOLD 1. Disconnect negative battery cable. 2. Disconnect and remove oxygen sensor. 3. Raise vehicle on hoist. 4. Remove exhaust cross-under pipe. 5. Remove front catalytic converter. 6. Lower vehicle. 7. Remove exhaust manifold attaching bolts and remove manifold. REAR EXHAUST MANIFOLD 1. Disconnect negative battery cable. 2. Remove throttle body air inlet hose and air cleaner housing assembly. 3. Remove bolts attaching EGR tube from exhaust manifold and EGR valve. Discard gaskets. 4. Raise vehicle on hoist. 5. Remove exhaust system from vehicle. 6. Remove exhaust cross-under pipe. 7. Remove rear catalytic converter. 8. Disconnect and remove rear upstream oxygen sensor. 9. Remove rear exhaust manifold heat shield. 10. Remove exhaust manifold attaching bolts and remove manifold. INSPECTION 1. Inspect exhaust manifolds for damage or cracks. 2. Inspect the exhaust manifold gasket for obvious discoloration or distortion. 3. Check distortion of the cylinder head mounting surface with a straightedge and thickness gauge. INSTALLATION FRONT EXHAUST MANIFOLD 1. Install exhaust manifold and gasket. Tighten bolts starting at the center working outward to 23 Nm (200 inch lbs.). 2. Raise vehicle on hoist. 3. Install front catalytic converter and manifold heat shield. Tighten fasteners to 28 Nm (250 inch lbs.). 4. Install exhaust cross-under pipe. Tighten fasteners to 28 Nm (250 inch lbs.). 5. Lower vehicle. 6. Install oxygen sensor and connect electrical connector. 7. Connect negative battery cable. REAR EXHAUST MANIFOLD 1. Install exhaust manifold and gasket. Tighten bolts working from center outwards to 23 Nm (200 inch lbs.). 2. Install rear catalytic converter and manifold heat shield. Tighten fasteners to 28 Nm (250 inch lbs.). 3. Install oxygen sensor and connect electrical connector. 4. Install exhaust cross-under pipe. Tighten fasteners to 28 Nm (250 inch lbs.). 5. Install exhaust system. Tighten fasteners to 28 Nm (250 inch lbs.). 6. Lower vehicle. 7. Install EGR tube using new gaskets. Tighten screws to 11 Nm (95 inch lbs.). 8. Install throttle body air inlet hose and air cleaner housing assembly. 9. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe to Cross-Under Pipe 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1588 Exhaust Pipe: Service and Repair CROSS UNDER PIPE TO RESONATOR PIPE REMOVAL NOTE: In the following procedure it is not necessary to separate the muffler/pipe assembly from the resonator/pipe assembly. They can both be removed as an assembly. WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Raise vehicle on hoist and apply penetrating oil to resonator/pipe assembly band clamp, and the fasteners that connect the exhaust system to the cross under pipe. 2. Remove ground strap from muffler. 3. Loosen band clamp for resonator/pipe assembly. CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur. 4. Remove support isolators from muffler supports. 5. Remove resonator/pipe and muffler/pipe as an assembly. 6. Remove fasteners that attach exhaust pipe to cross-under pipe. 7. Remove exhaust pipe. INSTALLATION NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components. 1. Loosely attach exhaust pipe to cross-under pipe. 2. Loosely install resonator/pipe and muffler/pipe assembly to exhaust pipe. 3. Install support isolators to muffler supports. 4. Align exhaust pipe and resonator/muffler pipe assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners attaching exhaust pipe to cross-under pipe to 28 Nm (250 inch lbs.). 5. Tighten resonator/pipe assembly band clamp to 54 Nm (40 ft. lbs.). 6. Connect ground strap to muffler. 7. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-001-02 > Feb > 02 > Exhaust System - Rattle/Vibration Sound Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Rattle/Vibration Sound NUMBER: 11-001-02 GROUP: Exhaust DATE: Feb. 18, 2002 SUBJECT: Rattle Or Vibration Sound From Under The Center Console OVERVIEW: This bulletin involves installing a revised exhaust center isolator. MODELS: 2001 - 2002 (JR) Sebring Sedan/Sebring Convertible/Stratus Sedan NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DEC. 17, 2001 (MDH 1217XX). SYMPTOM/CONDITION: A rattle or vibration sound that can be heard from under the vehicle near the center console. The sound may be more pronounced during cold start up and then disappear when engine reaches operating temperature. DIAGNOSIS: Listen to the vehicle at idle or just off idle during cold start up. Sound most frequently occurs when the ambient temperature is below 0°C (32°F). If the sound is heard or the vehicle operator describes the condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. 1. Raise vehicle on an appropriate hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-001-02 > Feb > 02 > Exhaust System - Rattle/Vibration Sound > Page 1597 2. Spray water based lubricant on the exhaust center isolator and retaining pins (Fig. 1). 3. Pry the exhaust center isolator oft its mounting pins to remove. Discard the old isolator. 4. Lubricate the revised isolator with water based lubricant and install it on the mounting pins by hand. 5. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-001-02 > Feb > 02 > Exhaust System - Rattle/Vibration Sound Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Rattle/Vibration Sound NUMBER: 11-001-02 GROUP: Exhaust DATE: Feb. 18, 2002 SUBJECT: Rattle Or Vibration Sound From Under The Center Console OVERVIEW: This bulletin involves installing a revised exhaust center isolator. MODELS: 2001 - 2002 (JR) Sebring Sedan/Sebring Convertible/Stratus Sedan NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO DEC. 17, 2001 (MDH 1217XX). SYMPTOM/CONDITION: A rattle or vibration sound that can be heard from under the vehicle near the center console. The sound may be more pronounced during cold start up and then disappear when engine reaches operating temperature. DIAGNOSIS: Listen to the vehicle at idle or just off idle during cold start up. Sound most frequently occurs when the ambient temperature is below 0°C (32°F). If the sound is heard or the vehicle operator describes the condition, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. 1. Raise vehicle on an appropriate hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-001-02 > Feb > 02 > Exhaust System - Rattle/Vibration Sound > Page 1603 2. Spray water based lubricant on the exhaust center isolator and retaining pins (Fig. 1). 3. Pry the exhaust center isolator oft its mounting pins to remove. Discard the old isolator. 4. Lubricate the revised isolator with water based lubricant and install it on the mounting pins by hand. 5. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Body Heat Shield-Fasteners 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1607 Heat Shield: Description and Operation DESCRIPTION The exhaust system heat shields are attached to the under body of the vehicle. OPERATION Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converter. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Raise vehicle on hoist and apply penetrating oil to band clamp of component being removed. 2. Remove ground strap from muffler. 3. Loosen band clamp for muffler/pipe assembly. CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur. 4. Remove support isolators from muffler supports. 5. Remove muffler/pipe assembly from resonator pipe. NOTE: Band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off the exhaust pipe. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used for the following reasons: ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. INSTALLATION NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components. 1. Loosely install muffler/pipe assembly onto resonator pipe. 2. Install support isolators to muffler supports. 3. Align muffler/pipe assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten band clamp to 64 Nm (40 ft. lbs.). 4. Connect ground strap to muffler. 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair Exhaust Resonator: Service and Repair RESONATOR/PIPE ASSEMBLY REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. 1. Raise vehicle on hoist and apply penetrating oil to band clamps of components being removed. 2. Remove muffler/pipe assembly. 3. Loosen band clamp for resonator/pipe assembly. 4. Remove resonator/pipe assembly. NOTE: Band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off the exhaust pipe. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used for the following reasons: ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. INSTALLATION NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components. 1. Loosely install resonator/pipe assembly and muffler/pipe assembly. 2. Install support isolators to muffler supports. 3. Align resonator/pipe assembly and muffler/pipe assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten resonator/pipe assembly band clamp to 54 Nm (40 ft. lbs.). 4. Tighten muffler/pipe assembly band clamp to 54 Nm (40 ft. lbs.). 5. Connect ground strap to muffler. 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: Customer Interest A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 1625 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: All Technical Service Bulletins A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 1631 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors Body Control Module: Diagrams BCM Connectors Body Control Module C1 Body Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1634 Body Control Module C3 Body Control Module C4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1635 Body Control Module: Diagrams Junction Block/BCM Connector 8W-12-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1636 8W-12-5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1639 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 Body Control Module: Description and Operation Part 1 of 2 SYSTEM DESCRIPTION The body system on the 2001 JR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled and communicated by the PCI bus, which is described in the Vehicle Communication of this General Information. Always begin by reading the diagnostic trouble codes using the DRB III. Next, look for the symptom in the Diagnostic Information and Procedures of the Table of Contents. This will direct you to the specific tests(s) that must be performed. Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the Airbag module. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. Refer to 2001 JR Powertrain Diagnostics for more information. Erase codes in all modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1642 Body Control Module: Description and Operation Part 2 of 2 Part 2A AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1643 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III, read Airbag DTC's. If the following active codes are present: If neither of the following codes is an active code: Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or if could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1644 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Seat Belt Tensioner (SBT) The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. The JR27 convertible driver and front passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle is connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Side Impact Airbag Control Module (SIACM) Supplemental driver and passenger curtain air-bags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity #5 of the SIACM connector. If cavity #5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1645 DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. Curtain Airbags The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. ORC/SIACM Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Always begin diagnostic with the Table of Contents. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the air-bag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. Part 2B Active Codes The code becomes active as soon as the malfunction is detected or key-in, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit or component. It is impossible to erase an active code. Active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. The exception is the Loss of Ignition Run Only code which is an active code only. A stored code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be active. When a trouble code occurs, the airbag warning indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. It no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1646 AUDIO SYSTEM All radio systems available on the 2001 JR communicate on the PCI Bus. They use the bus for three reasons. The first is to communicate trouble codes, second is to receive dimming information, and third is to receive cabin equalization information. The audio system is available in a 4 speaker base system and a 6 speaker system with an external power amplifier. An in-dash CD Changer is also optional. Depending on the manufacturer of the radio, some systems have a front/rear output system and others have a left/right output system. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. The new in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with you system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Programmable Communication Interface or PCI bus). This network consists of the powertrain control module (PCM), sentry key immobilizer module (SKIM), the Transmission Control Module (TCM), the electro/mechanical instrument cluster (MIC), Compass/mini-trip Computer (CMTC) occupant restraint control (ORC) module, optional Antilock Brakes (ABS), the radio remote CD-player, optional left and right airbag control modules. The (BCM) is operational when battery power is supplied to the module, ignition switch power is needed for ignition switched functions. The body control module provides the following features: A/C switch status/evaporator temperature status BCM diagnostic support Central lock and unlock (VTSS only) Climate Control system support Door ajar switch status Door Lock Inhibit (key in ignition or headlamps/park lamps ON) Electronic Odometer Support Headlamp Time Delay Illuminated Entry with "fade to OFF" Interior lighting with battery save feature Mechanical Instrument Cluster (fuel level, dim data, odometer & warning chime) support Travel information system Power convertible top Power door lock multiplexing control Rear Window Defogger Control Remote Keyless Entry with Panic Mode Remote power deck lid release Rolling door lock control (customer programmable) Sentry key immobilizer support Vehicle Theft Security System Wiper Control (speed sensitive with return to park) The BCM receives information over the PCI Bus from the PCM in order to support certain features. The required information is as follows: Engine RPM - Engine Temperature - Injector on Time and Distance Pulses - Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1647 - Charging System Failure, Engine Temperature Limp-In, VTSS Arming Status - Engine Model - "Check Engine" lamp status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1648 The BCM provides the PCM with information on the A/C switch status and the VTSS status. The JR has several customer programmable features which can be disabled or enabled by the customer. CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1649 Ambient Temperature Sensor The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Powertrain Control Module (PCM), the Programmable Communications Interface (PCI) data bus, and portion of the Compass Mini-Trip Computer (CMTC). If any portion of the ambient temperature sensor circuit fails, the BCM Will self-diagnose the circuit and set a DTC. The CMTC Will lock the display at 54 °C (130 °F) if the sensor is exposed to temperatures above 54 ° (130 °F), or if the sensor is shorted. The CMTC Will lock the display at -40 °C (-40 °F) if the sensor is exposed to temperatures below -40 °C (-40 °F), or if the sensor circuit is open. DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and decklid are in. The DRB III will display the state of the door ajar and the decklid ajar switches in Inputs/Outputs. It's important to note, that when any door, or the decklid is closed, the switch state on the DRB III will show OPEN. When any door, or the decklid is open the switch state on the DRB III will show CLOSED. During diagnosis, if a door or the decklid is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the decklid is open and the DRB III displays the switch state as OPEN, it indicates an open ajar circuit. EXTERIOR LIGHTING SYSTEM Headlamp Delay The headlamp time delay operates when the ignition switch is turned OFF while the headlamps are still ON, and the headlamps are then turned OFF within 45 seconds after the ignition is OFF. This will provide a 90-second time delay before turning OFF the headlamps. Part 2C HEATING AND A/C SYSTEMS A single-zone HVAC system is available on all JR series vehicles. Manual Temperature Control HVAC Control The HVAC system maintains incoming air temperature, airflow, fan speed, and fresh air intake for the entire vehicle from the instrument panel mounted A/C - Heater Control. The full range of temperature that the system can produce in any mode for the entire vehicle is available by positioning the blend Control to the desired range. Air Intake When the fresh-air door is open, outside air is drawn into the HVAC housing through the cowl opening at the base of the windshield. When the fresh-air door is closed, recirculated air is drawn in to the HVAC housing from under the instrument panel. Air Distribution The HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single, central mounted outlet delivers air for defrosting the windshield. Two ducts, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and the front seat passenger floor area. A/C-heater Control, Switch Operation Blower Switch The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Mode Switch The rotary Mode Switch has a total of eight positions. The first three, for A/C request, include Recirc/Bi-level, Panel, and Bi-level. The remaining five positions, for Heat request, include Panel, Bi-level, Floor, Floor/Defrost, and Defrost. The Floor/Defrost position and the Defrost position also provided an A/C request. Mode Switch, A/C Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to any of the three A/C request positions, the Floor/Defrost position, or the Defrost position, will result in the A/C - Heater Control sending a signal to the BCM to send a message to the PCM to provide A/C compressor clutch activation. However, the BCM will only provide this request if EVAP function is found acceptable. Mode Switch, Mode Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch will result in the A/C Heater Control sending a signal to the BCM to signal the actuator to move the mode door. A potentiometer, inside the Mode Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1650 Mode Switch, Fresh-air Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to the Recirc position will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to close the fresh-air door. While rotating the mode Switch to any other position results in the A/C - Heater Control sending a signal to the BCM to signal the actuator to open the fresh-air door. When the Blower Switch is OFF, the fresh-air door closes to prevent outside air from entering the passenger compartment. Blend Switch The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Rear Window Defogger Switch The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C - Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. Diagnostic Trouble Codes All HVAC Diagnostic Trouble Codes are stored in the Body Control Module. Stored DTCs indicate that a problem has occurred in the HVAC system, and may still be present. To verify a problem is still present in the HVAC system, use the DRB III to erase all stored BCM DTCs. After erasing the DTC(s), use the DRB III to see if the DTC(s) reappear. If necessary, actuate the A/C - Heater Control switches with the ignition ON and with the engine running while monitoring the DRB III to see if the DTC(s) reappear. INTERIOR LIGHTING Courtesy Lamp Control The body controller has direct control over the majority of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door is ajar. 2. The courtesy lamp switch ON the instrument panel is closed. 3. A Remote Keyless entry unlock message is received. If the interior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 15 minutes or until either the dome lamp switch or door ajar switch changes state. Illuminated Entry Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned ON, the illuminated entry also cancels. MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster (MIC) is divided into 4 sections. Primary gauges (Speedometer and Tachometer), secondary gauges (Fuel Level, Engine Coolant Temperature), PCI bus enabled indicator lamps and hardwired enabled indicator lamps. The gauge mechanisms function in the same way. The main differences are in the face and size of the gauge. The Oil Pressure, Brake Warning, Turn Signal and Fog Lamp indicators are directly wired to the circuits that they are indicators for. These indicators are located in, but not controlled by, the MIC and are not part of any MIC self test or diagnostic. All indicators are replaceable bulbs or LEDs. The PCM sends a gauge position message to the BCM through the PCI bus. The MIC receives this message from the BCM, translates it, and positions the gauges. The BCM also sends messages to the MIC to actuate all PCI controlled indicators. These messages are received when the Ignition Switch is in the RUN or START position. When the ignition Switch is turned to the RUN position, a bulb-check is performed. This consists of activating the PCI bus controlled indicators for approximately 2 to 4 seconds. By holding the TRIP/RESET button in while turning the Ignition Switch to the RUN position, you can activate the MIC Self Test. The Following indicators are controlled by PCI bus messages: Malfunction Indicator Lamp - Charging System Warning Indicator - Engine Coolant Temperature Indicator - Cruise Engaged Indicator - Airbag Warning Indicator - Low Fuel Indicator - ABS Warning Indicator - High Beam Indicator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1651 The following indicators are hardwired and not controlled by PCI bus messages: - Seat Belt Indicator - Oil Pressure Indicator - Brake Warning Indicator - VTSS Indicator - Turn Signal Indicators - Fog Lamp Indicators POWER DOOR LOCK SYSTEM The door lock switches provide a variable amount of voltage through the Multiplexed (MUX) circuit to the BCM. Depending upon that input and various conditions that must be met (i.e. door lock inhibit, etc.), the BCM will determine the action to be taken and activate the proper relay for approximately 250 to 350 msec. If the vehicle is equipped with the vehicle theft security system it will have the central locking feature which locks and unlocks all doors from the cylinder lock switches. These switches are on separate multiplexed circuits to the BCM and have trouble codes relating to each of them. RKE Remote Keyless Entry - This feature allows locking and unlocking of the vehicle door(s) by remote control using a hand-held transmitter (sometimes referred to as a fob) to activate a radio receiver (RKE module). This module now plugs into the body control module which is directly connected to the junction block. With this feature RKE can now be added to a non-equipped vehicle by installing a module. If the vehicle is equipped with the vehicle theft security system, RKE will also arm and disarm that system. A 4-button transmitter is used which provides lock, unlock, decklid release and panic features. Decklid release is only operable while the vehicle is in the park position. The module is capable of retaining up to 4 transmitter codes. Rolling code, which increases security, is also included in this system. If the transmitter goes out of synchronization it is easily put back in by pressing the lock button when the transmitter is within range. An external antenna has been added which plugs into the module to provide greater range. RKE will also turn ON the interior lamps when a valid unlock command is received and will extinguish the interior lamps when a lock command is received and all doors are closed. Door Lock Inhibit - When the key is in the ignition and the driver front door is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic (rolling) Door Locks - This feature can be enabled or disabled by using either the DRB III or the customer programmable method. When enabled, all doors will lock when the vehicle reaches a speed of 15 mph (24 km/h) and all doors are closed. If a door is opened and the vehicle slows to below 15 mph (24 km/h), the locks will operate again once all doors are closed and the speed is above 15 mph (24 km/h). Decklid Release - Decklid release is now a function of the body control module. Trouble codes are provided to assist in the diagnosis of this system. Customer programmable features are: Horn chirp, one or two press decklid release, programming a new transmitter (using a previously programmed transmitter), rolling door locks, unlock on exit, and RKE lamp flash. POWER CONVERTIBLE TOP Top Control The body control module now controls all the functions of the convertible top. The body control module supplies a multiplexed voltage of approximately 90% of ignition voltage to the power top switch. Through a series of resistors the power top switch switches the circuit to ground depending on the position of the switch. The BCM then supplies the ground path for the up or down relay as requested. The power top switch has a 4.7-ohm diagnostic resistor that allows the BCM to detect a possible open circuit. Window Drop Relay Assembly The convertible has a new feature that allows the operator to lower all four windows and lower the top at the same time. This is accomplished by pressing the power top switch to the second detent. Through the multiplexed circuit of the power top switch the BCM will supply the ground for the window drop relay assembly. The window drop relay assembly is comprised of four separate relays that are in series with the power window circuits. The relay assembly is located in the driver door. VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1652 Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1653 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The vehicle theft security system (VTSS) is part of the body control module (BCM), which monitors vehicle doors and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1654 headlamps, courtesy lamps, and the VTSS indicator lamp. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the instrument cluster will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm and the indicator will flash at a slow rate. If the indicator lamp remains steadily lit during the arming process, this can indicate a loss of decklid cylinder lock switch. When something triggers the alarm, the system will signal the headlamps, courtesy lamps, and horn for about 3 minutes, then headlamps for an additional 15 minutes if the offending input is still present. For complaints about the Theft Alarm going OFF on its own use the DRB III and select "Body Computer" then "Input/Output Display" and read the "Last VTSS Cause" status. Tamper Alert - The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch or the RKE. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Tests - NOTE: System self tests can be entered only with the DRB III. NOTE: A Powertrain Control Module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes ON after ignition ON and stays ON, the PCI bus communication with the Powertrain Control Module possibly has been lost. WIPER SYSTEM The wiper system provides the driver with the normal wiper (low and high speeds), intermittent wipe, and wipe after wash. The driver selects the wiper function via the resistive multiplexed stalk switch mounted on the steering column. The BCM uses the input signal from the wiper stalk switch, wiper motor park switch, and the washer switch to control the wiper system. The Body Control Module (BCM) then controls the relays and timing functions to provide the driver selected features. Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 mph (6 km/h), the delay time is doubled providing a range of 1 second to 36 seconds. Park after Ignition OFF Because the wiper relays are powered from the battery the BCM can run the wipers to park after the ignition is turned OFF. Wipe after Wash When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. The wiper system utilizes the BCM to control the ON/OFF and hi/low relays fro low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode, and wiper motor park functions. The BCM uses the vehicle speed input to double the usual delay time below 10 mph (17 km/h). WARNINGS VEHICLE DAMAGE WARNINGS Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1655 When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. ROAD TEST COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition. WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool GLOSSARY OF TERMS ABS Antilock brake system ACM Airbag control module AECM Airbag electronic control module (ACM) ASDM Airbag system diagnostic module (ACM) BCM Body control module CAB Controller antilock brake CMTC Compass/mini-trip computer DAB Driver airbag DLC Data link connector DTC Diagnostic trouble code DR Driver EBL Electric back lite (rear window defogger) HVAC Heater ventilation, air conditioning MIC Mechanical instrument cluster MTC Manual temperature control OBD On board diagnostics ODO Odometer ORC Occupant restraint controller (ACM) PAB Passenger airbag PASS Passenger PCI Programmable Controller Interface (vehicle communication bus) PCM Powertrain control module PDC Power distribution center PWM Pulse width modulated RKE Remote keyless entry SAB Seat airbag SBT Seat belt tensioner SIACM Side impact airbag control module SKIM Sentry key immobilizer module SKIS Sentry key immobilizer system SQUIB Also called initiator (located inside airbag) SRS Supplemental restraint system TCM Transmission control module VFD Vacuum fluorescent display VTSS Vehicle theft security system Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - Use DRB to actuate chime - Body control module chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1658 CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status on DRB III - Seat belt switch shorted - Seat belt switch sense short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Exterior Lights On and Drivers Door Open Test 1 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LIGHTS ON AND DRIVERS DOOR OPEN POSSIBLE CAUSES - Open headlamp switch output - Body control module Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1659 Tests 1 - 3 Tests 4 - 5 SYMPTOM CHIME INOPERATIVE WITH KEY-IN IGNITION AND DRIVER DOOR OPEN POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - BCM incorrect key-in ignition switch status Chime Sounds With Driver Seat Belt Fastened Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1660 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt SW status wrong-open - Seat belt switch open - Ground wire open - Seat belt SW SEN open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1661 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVERS DOOR OPEN AND KEY REMOVED FROM IGNITION POSSIBLE CAUSES - Key-in ignition switch status wrong - Key-in ignition switch status wrong - Key-in ignition SW sense short to ground - Body control module - key-in ignition shorted Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1662 Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1663 Body Control Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1664 Down or Page Up function to display the information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1669 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1670 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1671 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 1672 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 Engine Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Engine Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2001 JR Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1701 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1702 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (PDC) Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1707 Fuel Pump Relay: Diagrams Power Distribution Center (PDC) Fuel Pump Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1708 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the Automatic Shutdown (ASD) relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1712 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1713 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1723 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1724 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1725 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1726 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1730 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1731 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1732 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1733 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1738 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1739 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1740 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1741 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1742 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1746 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1747 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1748 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove. 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1752 Intake Air Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1753 Intake Air Temperature Sensor: Description and Operation Fig. 19 TPS And Inlet Air Temp Sensor INLET AIR TEMPERATURE SENSOR The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1757 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Plastic Manifold .............................................................................................................. .....................................................1.7 Nm (15 in. lbs) MAP Sensor Aluminum Manifold ......................................................................................................... ....................................................3.3 Nm (30 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1761 Manifold Pressure/Vacuum Sensor: Locations The MAP sensor mounts to the driver side of the intake manifold plenum Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1762 Manifold Absolute Pressure Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1763 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 23 MAP Sensor Fig. 24 Generator And MAP Sensor The MAP sensor mounts to the driver side of the intake manifold plenum or. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1764 direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key on is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the CCD bus) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg (Table 1). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Always use the Diagnostic Test Procedures for MAP sensor testing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1765 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove sensor. INSTALLATION 1. The sensor mounts onto intake manifold plenum. Tighten screws to 4.5 Nm (40 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 1770 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1771 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1772 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1773 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications O2 Sensors .......................................................................................................................................... ........................................................27 Nm (20 ft. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The O2S are located at the outlet ends of the catalytic converter Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 1779 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Oxygen Sensor: Connector Views Oxygen Sensor 1/1 Right Bank Up Oxygen Sensor 1/2 Right Bank Down Oxygen Sensor 2/1 Left Bank Up Oxygen Sensor 2/2 Left Bank Down Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 Oxygen Sensor Connector (Component Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Oxygen Sensor: Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 Oxygen Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1804 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 1807 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 1808 Oxygen Sensor: Description and Operation Fig. 26 O2 Sensors The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Separate controlled sensor ground ground circuits are run through the PCM for the upstream O2 sensors. As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor; one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM pulse width modulation the ground side of the heater to regulate the temperature. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 1809 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement Oxygen Sensor: Service and Repair Downstream (1/2, 2/2) Sensor Replacement REMOVAL Fig. 26 O2 Sensors The O2S are located at the outlet ends of the catalytic converter. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Remove the negative battery cable. 2. Raise and support the vehicle. 3. Disconnect the wire connector from the O2S. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 4. Remove the O2S Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION The O2S are located at the outlet ends of the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Install the O2S. Tighten to 28 Nm (20 ft. lbs.) torque. 3. Connect the O2S wire connector. 4. Lower the vehicle. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement > Page 1812 Oxygen Sensor: Service and Repair Upstream (1/1, 2/1) Sensor Replacement REMOVAL The engines uses two heated oxygen sensors, one in each exhaust manifold. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 1. Remove the negative battery cable. 2. Remove the air cleaner box for the rear O2 sensor. 3. Disconnect the heated oxygen sensor electrical connector. 4. Use a Special tool # 8439 to remove oxygen sensor. INSTALLATION The engines uses two heated oxygen sensors, one in each exhaust manifold. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Use a Special tool # 8439 to install oxygen sensor. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 3. Connect the heated oxygen sensor electrical connector. 4. Install the air cleaner box. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Page 1816 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1820 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1821 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1822 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1826 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1827 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1828 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1829 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Vehicle Speed Sensor (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1857 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1858 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1859 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1865 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1866 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1867 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1868 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1873 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1874 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1875 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1876 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1877 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1886 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Deadhead Pressure 880 kpa (130 psi) Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1892 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1893 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1894 Tests 3 - 5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1895 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel Pump Relay - Fuel Pressure Out Of Specs - Restricted Fuel Supply Line - Fuel Pump Inlet Strainer Plugged - Fuel Pump Module - Fuel Pump Capacity (Volume) Out Of Specs - Fuel Pump Relay Fused B+ Circuit - Fuel Pump Relay Output Circuit Open - Fuel Pump Ground Circuit Open/High Resistance Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1896 - Fuel Pump Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 550-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test using a scan tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect inlet air temperature sensor electrical connector (Fig. 7). 3. Disconnect fresh air makeup hose from throttle body air inlet hose (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1904 4. Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. 5. Push in on locking tabs to disengage air inlet hose from air cleaner housing. Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver (Fig. 10). 6. Remove throttle body air inlet hose. 7. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Clean any debris from inside air cleaner housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1905 2. Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. 3. Install throttle body air inlet hose into air cleaner housing. Push in on hose until an audible "click" is heard from locking tabs. 4. Install hose on throttle body. Tighten hose clamp (Fig. 9). 5. Connect fresh air makeup hose (Fig. 8). 6. Connect inlet air temperature sensor electrical sensor (Fig. 7). 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1910 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered (Fig. 2). The firing order is 1-2-3-4-5-6. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1915 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ...................................................................... 0.050 in Tightening Torque ........................................... .......................................................................................................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1923 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................... Champion Platinum Power CHA 3032 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Minimum Cylinder Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1927 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Disconnect and remove all ignition coils from spark plugs. 4. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the -500 psi (Blue) pressure transducer with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 26 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1935 Intake Air Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1936 Intake Air Temperature Sensor: Description and Operation Fig. 19 TPS And Inlet Air Temp Sensor INLET AIR TEMPERATURE SENSOR The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: Customer Interest A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 1948 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: All Technical Service Bulletins A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 1954 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors Body Control Module: Diagrams BCM Connectors Body Control Module C1 Body Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1957 Body Control Module C3 Body Control Module C4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1958 Body Control Module: Diagrams Junction Block/BCM Connector 8W-12-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 1959 8W-12-5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1962 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 Body Control Module: Description and Operation Part 1 of 2 SYSTEM DESCRIPTION The body system on the 2001 JR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled and communicated by the PCI bus, which is described in the Vehicle Communication of this General Information. Always begin by reading the diagnostic trouble codes using the DRB III. Next, look for the symptom in the Diagnostic Information and Procedures of the Table of Contents. This will direct you to the specific tests(s) that must be performed. Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the Airbag module. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. Refer to 2001 JR Powertrain Diagnostics for more information. Erase codes in all modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1965 Body Control Module: Description and Operation Part 2 of 2 Part 2A AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1966 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III, read Airbag DTC's. If the following active codes are present: If neither of the following codes is an active code: Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or if could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1967 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Seat Belt Tensioner (SBT) The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. The JR27 convertible driver and front passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle is connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Side Impact Airbag Control Module (SIACM) Supplemental driver and passenger curtain air-bags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity #5 of the SIACM connector. If cavity #5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1968 DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. Curtain Airbags The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. ORC/SIACM Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Always begin diagnostic with the Table of Contents. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the air-bag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. Part 2B Active Codes The code becomes active as soon as the malfunction is detected or key-in, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit or component. It is impossible to erase an active code. Active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. The exception is the Loss of Ignition Run Only code which is an active code only. A stored code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be active. When a trouble code occurs, the airbag warning indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. It no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1969 AUDIO SYSTEM All radio systems available on the 2001 JR communicate on the PCI Bus. They use the bus for three reasons. The first is to communicate trouble codes, second is to receive dimming information, and third is to receive cabin equalization information. The audio system is available in a 4 speaker base system and a 6 speaker system with an external power amplifier. An in-dash CD Changer is also optional. Depending on the manufacturer of the radio, some systems have a front/rear output system and others have a left/right output system. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. The new in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with you system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Programmable Communication Interface or PCI bus). This network consists of the powertrain control module (PCM), sentry key immobilizer module (SKIM), the Transmission Control Module (TCM), the electro/mechanical instrument cluster (MIC), Compass/mini-trip Computer (CMTC) occupant restraint control (ORC) module, optional Antilock Brakes (ABS), the radio remote CD-player, optional left and right airbag control modules. The (BCM) is operational when battery power is supplied to the module, ignition switch power is needed for ignition switched functions. The body control module provides the following features: A/C switch status/evaporator temperature status BCM diagnostic support Central lock and unlock (VTSS only) Climate Control system support Door ajar switch status Door Lock Inhibit (key in ignition or headlamps/park lamps ON) Electronic Odometer Support Headlamp Time Delay Illuminated Entry with "fade to OFF" Interior lighting with battery save feature Mechanical Instrument Cluster (fuel level, dim data, odometer & warning chime) support Travel information system Power convertible top Power door lock multiplexing control Rear Window Defogger Control Remote Keyless Entry with Panic Mode Remote power deck lid release Rolling door lock control (customer programmable) Sentry key immobilizer support Vehicle Theft Security System Wiper Control (speed sensitive with return to park) The BCM receives information over the PCI Bus from the PCM in order to support certain features. The required information is as follows: Engine RPM - Engine Temperature - Injector on Time and Distance Pulses - Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1970 - Charging System Failure, Engine Temperature Limp-In, VTSS Arming Status - Engine Model - "Check Engine" lamp status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1971 The BCM provides the PCM with information on the A/C switch status and the VTSS status. The JR has several customer programmable features which can be disabled or enabled by the customer. CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1972 Ambient Temperature Sensor The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Powertrain Control Module (PCM), the Programmable Communications Interface (PCI) data bus, and portion of the Compass Mini-Trip Computer (CMTC). If any portion of the ambient temperature sensor circuit fails, the BCM Will self-diagnose the circuit and set a DTC. The CMTC Will lock the display at 54 °C (130 °F) if the sensor is exposed to temperatures above 54 ° (130 °F), or if the sensor is shorted. The CMTC Will lock the display at -40 °C (-40 °F) if the sensor is exposed to temperatures below -40 °C (-40 °F), or if the sensor circuit is open. DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and decklid are in. The DRB III will display the state of the door ajar and the decklid ajar switches in Inputs/Outputs. It's important to note, that when any door, or the decklid is closed, the switch state on the DRB III will show OPEN. When any door, or the decklid is open the switch state on the DRB III will show CLOSED. During diagnosis, if a door or the decklid is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the decklid is open and the DRB III displays the switch state as OPEN, it indicates an open ajar circuit. EXTERIOR LIGHTING SYSTEM Headlamp Delay The headlamp time delay operates when the ignition switch is turned OFF while the headlamps are still ON, and the headlamps are then turned OFF within 45 seconds after the ignition is OFF. This will provide a 90-second time delay before turning OFF the headlamps. Part 2C HEATING AND A/C SYSTEMS A single-zone HVAC system is available on all JR series vehicles. Manual Temperature Control HVAC Control The HVAC system maintains incoming air temperature, airflow, fan speed, and fresh air intake for the entire vehicle from the instrument panel mounted A/C - Heater Control. The full range of temperature that the system can produce in any mode for the entire vehicle is available by positioning the blend Control to the desired range. Air Intake When the fresh-air door is open, outside air is drawn into the HVAC housing through the cowl opening at the base of the windshield. When the fresh-air door is closed, recirculated air is drawn in to the HVAC housing from under the instrument panel. Air Distribution The HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single, central mounted outlet delivers air for defrosting the windshield. Two ducts, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and the front seat passenger floor area. A/C-heater Control, Switch Operation Blower Switch The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Mode Switch The rotary Mode Switch has a total of eight positions. The first three, for A/C request, include Recirc/Bi-level, Panel, and Bi-level. The remaining five positions, for Heat request, include Panel, Bi-level, Floor, Floor/Defrost, and Defrost. The Floor/Defrost position and the Defrost position also provided an A/C request. Mode Switch, A/C Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to any of the three A/C request positions, the Floor/Defrost position, or the Defrost position, will result in the A/C - Heater Control sending a signal to the BCM to send a message to the PCM to provide A/C compressor clutch activation. However, the BCM will only provide this request if EVAP function is found acceptable. Mode Switch, Mode Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch will result in the A/C Heater Control sending a signal to the BCM to signal the actuator to move the mode door. A potentiometer, inside the Mode Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1973 Mode Switch, Fresh-air Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to the Recirc position will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to close the fresh-air door. While rotating the mode Switch to any other position results in the A/C - Heater Control sending a signal to the BCM to signal the actuator to open the fresh-air door. When the Blower Switch is OFF, the fresh-air door closes to prevent outside air from entering the passenger compartment. Blend Switch The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Rear Window Defogger Switch The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C - Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. Diagnostic Trouble Codes All HVAC Diagnostic Trouble Codes are stored in the Body Control Module. Stored DTCs indicate that a problem has occurred in the HVAC system, and may still be present. To verify a problem is still present in the HVAC system, use the DRB III to erase all stored BCM DTCs. After erasing the DTC(s), use the DRB III to see if the DTC(s) reappear. If necessary, actuate the A/C - Heater Control switches with the ignition ON and with the engine running while monitoring the DRB III to see if the DTC(s) reappear. INTERIOR LIGHTING Courtesy Lamp Control The body controller has direct control over the majority of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door is ajar. 2. The courtesy lamp switch ON the instrument panel is closed. 3. A Remote Keyless entry unlock message is received. If the interior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 15 minutes or until either the dome lamp switch or door ajar switch changes state. Illuminated Entry Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned ON, the illuminated entry also cancels. MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster (MIC) is divided into 4 sections. Primary gauges (Speedometer and Tachometer), secondary gauges (Fuel Level, Engine Coolant Temperature), PCI bus enabled indicator lamps and hardwired enabled indicator lamps. The gauge mechanisms function in the same way. The main differences are in the face and size of the gauge. The Oil Pressure, Brake Warning, Turn Signal and Fog Lamp indicators are directly wired to the circuits that they are indicators for. These indicators are located in, but not controlled by, the MIC and are not part of any MIC self test or diagnostic. All indicators are replaceable bulbs or LEDs. The PCM sends a gauge position message to the BCM through the PCI bus. The MIC receives this message from the BCM, translates it, and positions the gauges. The BCM also sends messages to the MIC to actuate all PCI controlled indicators. These messages are received when the Ignition Switch is in the RUN or START position. When the ignition Switch is turned to the RUN position, a bulb-check is performed. This consists of activating the PCI bus controlled indicators for approximately 2 to 4 seconds. By holding the TRIP/RESET button in while turning the Ignition Switch to the RUN position, you can activate the MIC Self Test. The Following indicators are controlled by PCI bus messages: Malfunction Indicator Lamp - Charging System Warning Indicator - Engine Coolant Temperature Indicator - Cruise Engaged Indicator - Airbag Warning Indicator - Low Fuel Indicator - ABS Warning Indicator - High Beam Indicator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1974 The following indicators are hardwired and not controlled by PCI bus messages: Seat Belt Indicator - Oil Pressure Indicator - Brake Warning Indicator - VTSS Indicator - Turn Signal Indicators - Fog Lamp Indicators POWER DOOR LOCK SYSTEM The door lock switches provide a variable amount of voltage through the Multiplexed (MUX) circuit to the BCM. Depending upon that input and various conditions that must be met (i.e. door lock inhibit, etc.), the BCM will determine the action to be taken and activate the proper relay for approximately 250 to 350 msec. If the vehicle is equipped with the vehicle theft security system it will have the central locking feature which locks and unlocks all doors from the cylinder lock switches. These switches are on separate multiplexed circuits to the BCM and have trouble codes relating to each of them. RKE Remote Keyless Entry - This feature allows locking and unlocking of the vehicle door(s) by remote control using a hand-held transmitter (sometimes referred to as a fob) to activate a radio receiver (RKE module). This module now plugs into the body control module which is directly connected to the junction block. With this feature RKE can now be added to a non-equipped vehicle by installing a module. If the vehicle is equipped with the vehicle theft security system, RKE will also arm and disarm that system. A 4-button transmitter is used which provides lock, unlock, decklid release and panic features. Decklid release is only operable while the vehicle is in the park position. The module is capable of retaining up to 4 transmitter codes. Rolling code, which increases security, is also included in this system. If the transmitter goes out of synchronization it is easily put back in by pressing the lock button when the transmitter is within range. An external antenna has been added which plugs into the module to provide greater range. RKE will also turn ON the interior lamps when a valid unlock command is received and will extinguish the interior lamps when a lock command is received and all doors are closed. Door Lock Inhibit - When the key is in the ignition and the driver front door is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic (rolling) Door Locks - This feature can be enabled or disabled by using either the DRB III or the customer programmable method. When enabled, all doors will lock when the vehicle reaches a speed of 15 mph (24 km/h) and all doors are closed. If a door is opened and the vehicle slows to below 15 mph (24 km/h), the locks will operate again once all doors are closed and the speed is above 15 mph (24 km/h). Decklid Release - Decklid release is now a function of the body control module. Trouble codes are provided to assist in the diagnosis of this system. Customer programmable features are: Horn chirp, one or two press decklid release, programming a new transmitter (using a previously programmed transmitter), rolling door locks, unlock on exit, and RKE lamp flash. POWER CONVERTIBLE TOP Top Control The body control module now controls all the functions of the convertible top. The body control module supplies a multiplexed voltage of approximately 90% of ignition voltage to the power top switch. Through a series of resistors the power top switch switches the circuit to ground depending on the position of the switch. The BCM then supplies the ground path for the up or down relay as requested. The power top switch has a 4.7-ohm diagnostic resistor that allows the BCM to detect a possible open circuit. Window Drop Relay Assembly The convertible has a new feature that allows the operator to lower all four windows and lower the top at the same time. This is accomplished by pressing the power top switch to the second detent. Through the multiplexed circuit of the power top switch the BCM will supply the ground for the window drop relay assembly. The window drop relay assembly is comprised of four separate relays that are in series with the power window circuits. The relay assembly is located in the driver door. VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1975 Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1976 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The vehicle theft security system (VTSS) is part of the body control module (BCM), which monitors vehicle doors and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1977 headlamps, courtesy lamps, and the VTSS indicator lamp. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the instrument cluster will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm and the indicator will flash at a slow rate. If the indicator lamp remains steadily lit during the arming process, this can indicate a loss of decklid cylinder lock switch. When something triggers the alarm, the system will signal the headlamps, courtesy lamps, and horn for about 3 minutes, then headlamps for an additional 15 minutes if the offending input is still present. For complaints about the Theft Alarm going OFF on its own use the DRB III and select "Body Computer" then "Input/Output Display" and read the "Last VTSS Cause" status. Tamper Alert - The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch or the RKE. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Tests - NOTE: System self tests can be entered only with the DRB III. NOTE: A Powertrain Control Module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes ON after ignition ON and stays ON, the PCI bus communication with the Powertrain Control Module possibly has been lost. WIPER SYSTEM The wiper system provides the driver with the normal wiper (low and high speeds), intermittent wipe, and wipe after wash. The driver selects the wiper function via the resistive multiplexed stalk switch mounted on the steering column. The BCM uses the input signal from the wiper stalk switch, wiper motor park switch, and the washer switch to control the wiper system. The Body Control Module (BCM) then controls the relays and timing functions to provide the driver selected features. Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 mph (6 km/h), the delay time is doubled providing a range of 1 second to 36 seconds. Park after Ignition OFF Because the wiper relays are powered from the battery the BCM can run the wipers to park after the ignition is turned OFF. Wipe after Wash When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. The wiper system utilizes the BCM to control the ON/OFF and hi/low relays fro low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode, and wiper motor park functions. The BCM uses the vehicle speed input to double the usual delay time below 10 mph (17 km/h). WARNINGS VEHICLE DAMAGE WARNINGS Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 1978 When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. ROAD TEST COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition. WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool GLOSSARY OF TERMS ABS Antilock brake system ACM Airbag control module AECM Airbag electronic control module (ACM) ASDM Airbag system diagnostic module (ACM) BCM Body control module CAB Controller antilock brake CMTC Compass/mini-trip computer DAB Driver airbag DLC Data link connector DTC Diagnostic trouble code DR Driver EBL Electric back lite (rear window defogger) HVAC Heater ventilation, air conditioning MIC Mechanical instrument cluster MTC Manual temperature control OBD On board diagnostics ODO Odometer ORC Occupant restraint controller (ACM) PAB Passenger airbag PASS Passenger PCI Programmable Controller Interface (vehicle communication bus) PCM Powertrain control module PDC Power distribution center PWM Pulse width modulated RKE Remote keyless entry SAB Seat airbag SBT Seat belt tensioner SIACM Side impact airbag control module SKIM Sentry key immobilizer module SKIS Sentry key immobilizer system SQUIB Also called initiator (located inside airbag) SRS Supplemental restraint system TCM Transmission control module VFD Vacuum fluorescent display VTSS Vehicle theft security system Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - Use DRB to actuate chime - Body control module chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1981 CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status on DRB III - Seat belt switch shorted - Seat belt switch sense short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Exterior Lights On and Drivers Door Open Test 1 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LIGHTS ON AND DRIVERS DOOR OPEN POSSIBLE CAUSES - Open headlamp switch output - Body control module Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1982 Tests 1 - 3 Tests 4 - 5 SYMPTOM CHIME INOPERATIVE WITH KEY-IN IGNITION AND DRIVER DOOR OPEN POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - BCM incorrect key-in ignition switch status Chime Sounds With Driver Seat Belt Fastened Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1983 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt SW status wrong-open - Seat belt switch open - Ground wire open - Seat belt SW SEN open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1984 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVERS DOOR OPEN AND KEY REMOVED FROM IGNITION POSSIBLE CAUSES - Key-in ignition switch status wrong - Key-in ignition switch status wrong - Key-in ignition SW sense short to ground - Body control module - key-in ignition shorted Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1985 Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1986 Body Control Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1987 Down or Page Up function to display the information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1992 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1993 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1994 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1995 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1999 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2000 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2001 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2002 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2007 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2008 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2009 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2010 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2011 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Data Link Connector: Connector Views Data Link Connector Data Link Connector Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2040 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2041 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2042 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2043 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 Engine Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2067 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2068 Engine Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2001 JR Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2072 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2073 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2074 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove. 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Fig. 17 Idle Air Control Motor The idle air control motor (IAC) attaches to the throttle body. It is an electric stepper motor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2078 Idle Air Control Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2079 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 17 Idle Air Control Motor The idle air control motor (IAC) attaches to the throttle body. It is an electric stepper motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning). When engine rpm is above idle speed, the IAC is used for the following functions: - Off-idle dashpot - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) Target Idle Target idle is determined by the following inputs: Gear position ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2080 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Fig. 18 Idle Air Control Motor 2. Disconnect the IAC electrical connector. 3. Remove the IAC mounting screws. 4. Remove the IAC. INSTALLATION 1. Install the IAC to the throttle body. 2. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 3. Attach electrical connector to the IAC. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Information Bus: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Information Bus: Electrical Diagrams PCI Bus Communication Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 PCM Communication Wiring Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 8w-18-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 8w-18-3 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2107 Information Bus: Description and Operation VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2108 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2112 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2116 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2117 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Plastic Manifold .............................................................................................................. .....................................................1.7 Nm (15 in. lbs) MAP Sensor Aluminum Manifold ......................................................................................................... ....................................................3.3 Nm (30 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2124 Manifold Pressure/Vacuum Sensor: Locations The MAP sensor mounts to the driver side of the intake manifold plenum Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2125 Manifold Absolute Pressure Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2126 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 23 MAP Sensor Fig. 24 Generator And MAP Sensor The MAP sensor mounts to the driver side of the intake manifold plenum or. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2127 direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key on is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the CCD bus) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg (Table 1). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Always use the Diagnostic Test Procedures for MAP sensor testing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2128 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove sensor. INSTALLATION 1. The sensor mounts onto intake manifold plenum. Tighten screws to 4.5 Nm (40 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 2133 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2134 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2135 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2136 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications O2 Sensors .......................................................................................................................................... ........................................................27 Nm (20 ft. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The O2S are located at the outlet ends of the catalytic converter Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2142 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Oxygen Sensor: Connector Views Oxygen Sensor 1/1 Right Bank Up Oxygen Sensor 1/2 Right Bank Down Oxygen Sensor 2/1 Left Bank Up Oxygen Sensor 2/2 Left Bank Down Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 Oxygen Sensor Connector (Component Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 Oxygen Sensor: Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 Oxygen Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2167 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2170 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2171 Oxygen Sensor: Description and Operation Fig. 26 O2 Sensors The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Separate controlled sensor ground ground circuits are run through the PCM for the upstream O2 sensors. As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor; one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM pulse width modulation the ground side of the heater to regulate the temperature. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2172 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement Oxygen Sensor: Service and Repair Downstream (1/2, 2/2) Sensor Replacement REMOVAL Fig. 26 O2 Sensors The O2S are located at the outlet ends of the catalytic converter. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Remove the negative battery cable. 2. Raise and support the vehicle. 3. Disconnect the wire connector from the O2S. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 4. Remove the O2S Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION The O2S are located at the outlet ends of the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Install the O2S. Tighten to 28 Nm (20 ft. lbs.) torque. 3. Connect the O2S wire connector. 4. Lower the vehicle. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement > Page 2175 Oxygen Sensor: Service and Repair Upstream (1/1, 2/1) Sensor Replacement REMOVAL The engines uses two heated oxygen sensors, one in each exhaust manifold. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 1. Remove the negative battery cable. 2. Remove the air cleaner box for the rear O2 sensor. 3. Disconnect the heated oxygen sensor electrical connector. 4. Use a Special tool # 8439 to remove oxygen sensor. INSTALLATION The engines uses two heated oxygen sensors, one in each exhaust manifold. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Use a Special tool # 8439 to install oxygen sensor. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 3. Connect the heated oxygen sensor electrical connector. 4. Install the air cleaner box. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Page 2179 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: Customer Interest A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 2189 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: All Technical Service Bulletins A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 2195 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors Body Control Module: Diagrams BCM Connectors Body Control Module C1 Body Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 2198 Body Control Module C3 Body Control Module C4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 2199 Body Control Module: Diagrams Junction Block/BCM Connector 8W-12-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 2200 8W-12-5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2203 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 Body Control Module: Description and Operation Part 1 of 2 SYSTEM DESCRIPTION The body system on the 2001 JR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled and communicated by the PCI bus, which is described in the Vehicle Communication of this General Information. Always begin by reading the diagnostic trouble codes using the DRB III. Next, look for the symptom in the Diagnostic Information and Procedures of the Table of Contents. This will direct you to the specific tests(s) that must be performed. Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the Airbag module. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. Refer to 2001 JR Powertrain Diagnostics for more information. Erase codes in all modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2206 Body Control Module: Description and Operation Part 2 of 2 Part 2A AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2207 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III, read Airbag DTC's. If the following active codes are present: If neither of the following codes is an active code: Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or if could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2208 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Seat Belt Tensioner (SBT) The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. The JR27 convertible driver and front passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle is connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Side Impact Airbag Control Module (SIACM) Supplemental driver and passenger curtain air-bags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity #5 of the SIACM connector. If cavity #5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2209 DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. Curtain Airbags The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. ORC/SIACM Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Always begin diagnostic with the Table of Contents. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the air-bag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. Part 2B Active Codes The code becomes active as soon as the malfunction is detected or key-in, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit or component. It is impossible to erase an active code. Active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. The exception is the Loss of Ignition Run Only code which is an active code only. A stored code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be active. When a trouble code occurs, the airbag warning indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. It no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2210 AUDIO SYSTEM All radio systems available on the 2001 JR communicate on the PCI Bus. They use the bus for three reasons. The first is to communicate trouble codes, second is to receive dimming information, and third is to receive cabin equalization information. The audio system is available in a 4 speaker base system and a 6 speaker system with an external power amplifier. An in-dash CD Changer is also optional. Depending on the manufacturer of the radio, some systems have a front/rear output system and others have a left/right output system. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. The new in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with you system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Programmable Communication Interface or PCI bus). This network consists of the powertrain control module (PCM), sentry key immobilizer module (SKIM), the Transmission Control Module (TCM), the electro/mechanical instrument cluster (MIC), Compass/mini-trip Computer (CMTC) occupant restraint control (ORC) module, optional Antilock Brakes (ABS), the radio remote CD-player, optional left and right airbag control modules. The (BCM) is operational when battery power is supplied to the module, ignition switch power is needed for ignition switched functions. The body control module provides the following features: A/C switch status/evaporator temperature status BCM diagnostic support Central lock and unlock (VTSS only) Climate Control system support Door ajar switch status Door Lock Inhibit (key in ignition or headlamps/park lamps ON) Electronic Odometer Support Headlamp Time Delay Illuminated Entry with "fade to OFF" Interior lighting with battery save feature Mechanical Instrument Cluster (fuel level, dim data, odometer & warning chime) support Travel information system Power convertible top Power door lock multiplexing control Rear Window Defogger Control Remote Keyless Entry with Panic Mode Remote power deck lid release Rolling door lock control (customer programmable) Sentry key immobilizer support Vehicle Theft Security System Wiper Control (speed sensitive with return to park) The BCM receives information over the PCI Bus from the PCM in order to support certain features. The required information is as follows: Engine RPM - Engine Temperature - Injector on Time and Distance Pulses - Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2211 - Charging System Failure, Engine Temperature Limp-In, VTSS Arming Status - Engine Model - "Check Engine" lamp status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2212 The BCM provides the PCM with information on the A/C switch status and the VTSS status. The JR has several customer programmable features which can be disabled or enabled by the customer. CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2213 Ambient Temperature Sensor The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Powertrain Control Module (PCM), the Programmable Communications Interface (PCI) data bus, and portion of the Compass Mini-Trip Computer (CMTC). If any portion of the ambient temperature sensor circuit fails, the BCM Will self-diagnose the circuit and set a DTC. The CMTC Will lock the display at 54 °C (130 °F) if the sensor is exposed to temperatures above 54 ° (130 °F), or if the sensor is shorted. The CMTC Will lock the display at -40 °C (-40 °F) if the sensor is exposed to temperatures below -40 °C (-40 °F), or if the sensor circuit is open. DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and decklid are in. The DRB III will display the state of the door ajar and the decklid ajar switches in Inputs/Outputs. It's important to note, that when any door, or the decklid is closed, the switch state on the DRB III will show OPEN. When any door, or the decklid is open the switch state on the DRB III will show CLOSED. During diagnosis, if a door or the decklid is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the decklid is open and the DRB III displays the switch state as OPEN, it indicates an open ajar circuit. EXTERIOR LIGHTING SYSTEM Headlamp Delay The headlamp time delay operates when the ignition switch is turned OFF while the headlamps are still ON, and the headlamps are then turned OFF within 45 seconds after the ignition is OFF. This will provide a 90-second time delay before turning OFF the headlamps. Part 2C HEATING AND A/C SYSTEMS A single-zone HVAC system is available on all JR series vehicles. Manual Temperature Control HVAC Control The HVAC system maintains incoming air temperature, airflow, fan speed, and fresh air intake for the entire vehicle from the instrument panel mounted A/C - Heater Control. The full range of temperature that the system can produce in any mode for the entire vehicle is available by positioning the blend Control to the desired range. Air Intake When the fresh-air door is open, outside air is drawn into the HVAC housing through the cowl opening at the base of the windshield. When the fresh-air door is closed, recirculated air is drawn in to the HVAC housing from under the instrument panel. Air Distribution The HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single, central mounted outlet delivers air for defrosting the windshield. Two ducts, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and the front seat passenger floor area. A/C-heater Control, Switch Operation Blower Switch The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Mode Switch The rotary Mode Switch has a total of eight positions. The first three, for A/C request, include Recirc/Bi-level, Panel, and Bi-level. The remaining five positions, for Heat request, include Panel, Bi-level, Floor, Floor/Defrost, and Defrost. The Floor/Defrost position and the Defrost position also provided an A/C request. Mode Switch, A/C Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to any of the three A/C request positions, the Floor/Defrost position, or the Defrost position, will result in the A/C - Heater Control sending a signal to the BCM to send a message to the PCM to provide A/C compressor clutch activation. However, the BCM will only provide this request if EVAP function is found acceptable. Mode Switch, Mode Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch will result in the A/C Heater Control sending a signal to the BCM to signal the actuator to move the mode door. A potentiometer, inside the Mode Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2214 Mode Switch, Fresh-air Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to the Recirc position will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to close the fresh-air door. While rotating the mode Switch to any other position results in the A/C - Heater Control sending a signal to the BCM to signal the actuator to open the fresh-air door. When the Blower Switch is OFF, the fresh-air door closes to prevent outside air from entering the passenger compartment. Blend Switch The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Rear Window Defogger Switch The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C - Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. Diagnostic Trouble Codes All HVAC Diagnostic Trouble Codes are stored in the Body Control Module. Stored DTCs indicate that a problem has occurred in the HVAC system, and may still be present. To verify a problem is still present in the HVAC system, use the DRB III to erase all stored BCM DTCs. After erasing the DTC(s), use the DRB III to see if the DTC(s) reappear. If necessary, actuate the A/C - Heater Control switches with the ignition ON and with the engine running while monitoring the DRB III to see if the DTC(s) reappear. INTERIOR LIGHTING Courtesy Lamp Control The body controller has direct control over the majority of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door is ajar. 2. The courtesy lamp switch ON the instrument panel is closed. 3. A Remote Keyless entry unlock message is received. If the interior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 15 minutes or until either the dome lamp switch or door ajar switch changes state. Illuminated Entry Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned ON, the illuminated entry also cancels. MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster (MIC) is divided into 4 sections. Primary gauges (Speedometer and Tachometer), secondary gauges (Fuel Level, Engine Coolant Temperature), PCI bus enabled indicator lamps and hardwired enabled indicator lamps. The gauge mechanisms function in the same way. The main differences are in the face and size of the gauge. The Oil Pressure, Brake Warning, Turn Signal and Fog Lamp indicators are directly wired to the circuits that they are indicators for. These indicators are located in, but not controlled by, the MIC and are not part of any MIC self test or diagnostic. All indicators are replaceable bulbs or LEDs. The PCM sends a gauge position message to the BCM through the PCI bus. The MIC receives this message from the BCM, translates it, and positions the gauges. The BCM also sends messages to the MIC to actuate all PCI controlled indicators. These messages are received when the Ignition Switch is in the RUN or START position. When the ignition Switch is turned to the RUN position, a bulb-check is performed. This consists of activating the PCI bus controlled indicators for approximately 2 to 4 seconds. By holding the TRIP/RESET button in while turning the Ignition Switch to the RUN position, you can activate the MIC Self Test. The Following indicators are controlled by PCI bus messages: Malfunction Indicator Lamp - Charging System Warning Indicator - Engine Coolant Temperature Indicator - Cruise Engaged Indicator - Airbag Warning Indicator - Low Fuel Indicator - ABS Warning Indicator - High Beam Indicator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2215 The following indicators are hardwired and not controlled by PCI bus messages: - Seat Belt Indicator - Oil Pressure Indicator - Brake Warning Indicator - VTSS Indicator - Turn Signal Indicators - Fog Lamp Indicators POWER DOOR LOCK SYSTEM The door lock switches provide a variable amount of voltage through the Multiplexed (MUX) circuit to the BCM. Depending upon that input and various conditions that must be met (i.e. door lock inhibit, etc.), the BCM will determine the action to be taken and activate the proper relay for approximately 250 to 350 msec. If the vehicle is equipped with the vehicle theft security system it will have the central locking feature which locks and unlocks all doors from the cylinder lock switches. These switches are on separate multiplexed circuits to the BCM and have trouble codes relating to each of them. RKE Remote Keyless Entry - This feature allows locking and unlocking of the vehicle door(s) by remote control using a hand-held transmitter (sometimes referred to as a fob) to activate a radio receiver (RKE module). This module now plugs into the body control module which is directly connected to the junction block. With this feature RKE can now be added to a non-equipped vehicle by installing a module. If the vehicle is equipped with the vehicle theft security system, RKE will also arm and disarm that system. A 4-button transmitter is used which provides lock, unlock, decklid release and panic features. Decklid release is only operable while the vehicle is in the park position. The module is capable of retaining up to 4 transmitter codes. Rolling code, which increases security, is also included in this system. If the transmitter goes out of synchronization it is easily put back in by pressing the lock button when the transmitter is within range. An external antenna has been added which plugs into the module to provide greater range. RKE will also turn ON the interior lamps when a valid unlock command is received and will extinguish the interior lamps when a lock command is received and all doors are closed. Door Lock Inhibit - When the key is in the ignition and the driver front door is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic (rolling) Door Locks - This feature can be enabled or disabled by using either the DRB III or the customer programmable method. When enabled, all doors will lock when the vehicle reaches a speed of 15 mph (24 km/h) and all doors are closed. If a door is opened and the vehicle slows to below 15 mph (24 km/h), the locks will operate again once all doors are closed and the speed is above 15 mph (24 km/h). Decklid Release - Decklid release is now a function of the body control module. Trouble codes are provided to assist in the diagnosis of this system. Customer programmable features are: Horn chirp, one or two press decklid release, programming a new transmitter (using a previously programmed transmitter), rolling door locks, unlock on exit, and RKE lamp flash. POWER CONVERTIBLE TOP Top Control The body control module now controls all the functions of the convertible top. The body control module supplies a multiplexed voltage of approximately 90% of ignition voltage to the power top switch. Through a series of resistors the power top switch switches the circuit to ground depending on the position of the switch. The BCM then supplies the ground path for the up or down relay as requested. The power top switch has a 4.7-ohm diagnostic resistor that allows the BCM to detect a possible open circuit. Window Drop Relay Assembly The convertible has a new feature that allows the operator to lower all four windows and lower the top at the same time. This is accomplished by pressing the power top switch to the second detent. Through the multiplexed circuit of the power top switch the BCM will supply the ground for the window drop relay assembly. The window drop relay assembly is comprised of four separate relays that are in series with the power window circuits. The relay assembly is located in the driver door. VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2216 Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2217 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The vehicle theft security system (VTSS) is part of the body control module (BCM), which monitors vehicle doors and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2218 headlamps, courtesy lamps, and the VTSS indicator lamp. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the instrument cluster will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm and the indicator will flash at a slow rate. If the indicator lamp remains steadily lit during the arming process, this can indicate a loss of decklid cylinder lock switch. When something triggers the alarm, the system will signal the headlamps, courtesy lamps, and horn for about 3 minutes, then headlamps for an additional 15 minutes if the offending input is still present. For complaints about the Theft Alarm going OFF on its own use the DRB III and select "Body Computer" then "Input/Output Display" and read the "Last VTSS Cause" status. Tamper Alert - The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch or the RKE. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Tests - NOTE: System self tests can be entered only with the DRB III. NOTE: A Powertrain Control Module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes ON after ignition ON and stays ON, the PCI bus communication with the Powertrain Control Module possibly has been lost. WIPER SYSTEM The wiper system provides the driver with the normal wiper (low and high speeds), intermittent wipe, and wipe after wash. The driver selects the wiper function via the resistive multiplexed stalk switch mounted on the steering column. The BCM uses the input signal from the wiper stalk switch, wiper motor park switch, and the washer switch to control the wiper system. The Body Control Module (BCM) then controls the relays and timing functions to provide the driver selected features. Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 mph (6 km/h), the delay time is doubled providing a range of 1 second to 36 seconds. Park after Ignition OFF Because the wiper relays are powered from the battery the BCM can run the wipers to park after the ignition is turned OFF. Wipe after Wash When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. The wiper system utilizes the BCM to control the ON/OFF and hi/low relays fro low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode, and wiper motor park functions. The BCM uses the vehicle speed input to double the usual delay time below 10 mph (17 km/h). WARNINGS VEHICLE DAMAGE WARNINGS Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 2219 When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. ROAD TEST COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition. WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool GLOSSARY OF TERMS ABS Antilock brake system ACM Airbag control module AECM Airbag electronic control module (ACM) ASDM Airbag system diagnostic module (ACM) BCM Body control module CAB Controller antilock brake CMTC Compass/mini-trip computer DAB Driver airbag DLC Data link connector DTC Diagnostic trouble code DR Driver EBL Electric back lite (rear window defogger) HVAC Heater ventilation, air conditioning MIC Mechanical instrument cluster MTC Manual temperature control OBD On board diagnostics ODO Odometer ORC Occupant restraint controller (ACM) PAB Passenger airbag PASS Passenger PCI Programmable Controller Interface (vehicle communication bus) PCM Powertrain control module PDC Power distribution center PWM Pulse width modulated RKE Remote keyless entry SAB Seat airbag SBT Seat belt tensioner SIACM Side impact airbag control module SKIM Sentry key immobilizer module SKIS Sentry key immobilizer system SQUIB Also called initiator (located inside airbag) SRS Supplemental restraint system TCM Transmission control module VFD Vacuum fluorescent display VTSS Vehicle theft security system Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - Use DRB to actuate chime - Body control module chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2222 CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status on DRB III - Seat belt switch shorted - Seat belt switch sense short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Exterior Lights On and Drivers Door Open Test 1 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LIGHTS ON AND DRIVERS DOOR OPEN POSSIBLE CAUSES - Open headlamp switch output - Body control module Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2223 Tests 1 - 3 Tests 4 - 5 SYMPTOM CHIME INOPERATIVE WITH KEY-IN IGNITION AND DRIVER DOOR OPEN POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - BCM incorrect key-in ignition switch status Chime Sounds With Driver Seat Belt Fastened Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2224 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt SW status wrong-open - Seat belt switch open - Ground wire open - Seat belt SW SEN open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2225 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVERS DOOR OPEN AND KEY REMOVED FROM IGNITION POSSIBLE CAUSES - Key-in ignition switch status wrong - Key-in ignition switch status wrong - Key-in ignition SW sense short to ground - Body control module - key-in ignition shorted Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2226 Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2227 Body Control Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2228 Down or Page Up function to display the information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2233 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2234 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2235 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2236 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 Engine Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Powertrain Control Module C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Powertrain Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Engine Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2001 JR Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2265 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2266 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2275 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2276 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2277 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2278 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant emperature Sensor 168 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2282 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2283 Engine Coolant Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2284 Coolant Temperature Sensor/Switch (For Computer): Description and Operation REMOVAL The Engine Coolant Temperature (ECT) Sensor threads into the coolant outlet connector. The ECT Sensor is a negative thermal coefficient sensor. OPERATION The ECT sensor provides an input to the PCM. As temperature increases, resistance of the sensor decreases. As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air fuel mixture, timing, and radiator fan on/off times. The PCM uses ECT sensor input to send messages over the PCI bus to various modules for other functions such as temperature gauge and AC operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2285 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. With engine cold, partially drain cooling system below level of ECT sensor. 2. Disconnect ECT sensor electrical connector or. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Torque sensor to 19 Nm (168 inch lbs.). 2. Reconnect ECT sensor electrical sensor. 3. Fill cooling system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2290 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2291 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2292 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2293 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2294 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2298 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2299 Fuel Level Sensor: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2300 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector. 4. Push level sensor signal and ground terminals out of the connector. Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove. 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2304 Intake Air Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2305 Intake Air Temperature Sensor: Description and Operation Fig. 19 TPS And Inlet Air Temp Sensor INLET AIR TEMPERATURE SENSOR The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Inlet/Intake Air Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: Injector pulse width - Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2309 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Plastic Manifold .............................................................................................................. .....................................................1.7 Nm (15 in. lbs) MAP Sensor Aluminum Manifold ......................................................................................................... ....................................................3.3 Nm (30 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2313 Manifold Pressure/Vacuum Sensor: Locations The MAP sensor mounts to the driver side of the intake manifold plenum Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2314 Manifold Absolute Pressure Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2315 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 23 MAP Sensor Fig. 24 Generator And MAP Sensor The MAP sensor mounts to the driver side of the intake manifold plenum or. The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi the voltage changes 4.0V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2316 direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key ON. The difference between current and what it was at key on is manifold vacuum. During key ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the CCD bus) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone. When silicone is exposed to stress its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg (Table 1). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops 0.10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Always use the Diagnostic Test Procedures for MAP sensor testing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2317 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor. 3. Remove sensor. INSTALLATION 1. The sensor mounts onto intake manifold plenum. Tighten screws to 4.5 Nm (40 in. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations Oil Pressure Sensor: Component Locations Note: Chrysler does not provide a image location of the Oil Pressure Switch/Sensor for this specified year. Image provided for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Component Locations > Page 2322 Oil Pressure Sensor: Connector Locations Note: Chrysler does not provide a location of the Oil Pressure Switch/Sensor for this specified year. Image provided from 2007 model for reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2323 Oil Pressure Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2324 Oil Pressure Sensor: Description and Operation DESCRIPTION The engine oil pressure switch is located on the right side of the engine block. The switch screws into the engine main oil gallery. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2325 Oil Pressure Sensor: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove heat shield that covers oil pressure switch. 3. Disconnect oil pressure switch electrical connector. 4. Position an oil collecting container under switch location. 5. Remove switch by unscrewing from the engine block. INSTALLATION 1. Apply Mopar Thread Sealant to the switch threads. 2. Install oil pressure switch. 3. Connect electrical connector. 4. Install oil pressure switch heat shield. 5. Lower vehicle. 6. Start engine and check for leaks. 7. Check engine oil level and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications O2 Sensors .......................................................................................................................................... ........................................................27 Nm (20 ft. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System The O2S are located at the outlet ends of the catalytic converter Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2331 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 Oxygen Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 Oxygen Sensor: Connector Views Oxygen Sensor 1/1 Right Bank Up Oxygen Sensor 1/2 Right Bank Down Oxygen Sensor 2/1 Left Bank Up Oxygen Sensor 2/2 Left Bank Down Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 Oxygen Sensor Connector (Component Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 Oxygen Sensor: Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Oxygen Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2356 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 2359 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2360 Oxygen Sensor: Description and Operation Fig. 26 O2 Sensors The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Separate controlled sensor ground ground circuits are run through the PCM for the upstream O2 sensors. As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor; one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM pulse width modulation the ground side of the heater to regulate the temperature. Upstream Oxygen Sensor The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 2361 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Downstream Oxygen Sensor The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream O2 goal voltage (switching point). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement Oxygen Sensor: Service and Repair Downstream (1/2, 2/2) Sensor Replacement REMOVAL Fig. 26 O2 Sensors The O2S are located at the outlet ends of the catalytic converter. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Remove the negative battery cable. 2. Raise and support the vehicle. 3. Disconnect the wire connector from the O2S. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 4. Remove the O2S Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION The O2S are located at the outlet ends of the catalytic converter. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 2. Install the O2S. Tighten to 28 Nm (20 ft. lbs.) torque. 3. Connect the O2S wire connector. 4. Lower the vehicle. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream (1/2, 2/2) Sensor Replacement > Page 2364 Oxygen Sensor: Service and Repair Upstream (1/1, 2/1) Sensor Replacement REMOVAL The engines uses two heated oxygen sensors, one in each exhaust manifold. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 1. Remove the negative battery cable. 2. Remove the air cleaner box for the rear O2 sensor. 3. Disconnect the heated oxygen sensor electrical connector. 4. Use a Special tool # 8439 to remove oxygen sensor. INSTALLATION The engines uses two heated oxygen sensors, one in each exhaust manifold. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Use a Special tool # 8439 to install oxygen sensor. Tighten the sensor to 28 Nm (20 ft. lbs.) torque. 3. Connect the heated oxygen sensor electrical connector. 4. Install the air cleaner box. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Page 2368 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2372 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2373 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2374 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2378 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2379 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2380 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2381 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Vehicle Speed Sensor (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2408 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2409 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2410 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2414 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2415 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2416 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2417 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2424 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2425 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2426 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 Vehicle Speed Sensor (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic Converter to Exhaust 250 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Front Catalytic Converter: Service and Repair Front FRONT REMOVAL 1. Disconnect negative battery cable. 2. Disconnect upstream oxygen sensor connector. 3. Remove 3 converter attaching nuts that are visible from the engine compartment. 4. Raise vehicle on hoist. 5. Remove exhaust cross-under pipe. 6. Remove remaining bolt attaching converter to exhaust manifold. 7. Remove catalytic converter. 8. Remove and discard gasket. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a horoscope or equivalent. Remove both oxygen sensors and insert borescope. If horoscope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Front > Page 2447 NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to Appropriate Diagnostic Information for test procedures. INSTALLATION 1. Clean manifold to converter sealing surfaces. 2. Position new gasket on converter inlet flange. 3. Ensure exhaust manifold heat shield is in position, and loosely install converter with lower attaching bolt to exhaust manifold. 4. Lower vehicle. 5. Install 3 nuts attaching converter to manifold. Torque nuts to 28 Nm (250 inch lbs.). 6. Reconnect upstream oxygen sensor. 7. Raise vehicle. 8. Torque remaining attaching bolt to 28 Nm (250 inch lbs.). 9. Install cross-under pipe. 10. Lower vehicle. 11. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Front > Page 2448 Catalytic Converter: Service and Repair Rear CATALYTIC CONVERTER REAR REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle on hoist. 3. Remove entire exhaust system from vehicle 4. Remove exhaust cross-under pipe. 5. Disconnect upstream oxygen sensor. 6. Remove nuts attaching converter to exhaust manifold. 7. Remove exhaust manifold heat shield. 8. Remove catalytic converter. 9. Remove and discard gasket. INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. Check catalytic converter for a flow restriction. Refer to Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a horoscope or equivalent. Remove both oxygen sensors and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to Appropriate Diagnostic Information for test procedures. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Front > Page 2449 1. Clean manifold to converter sealing surfaces. 2. Position new gasket on converter inlet flange. 3. Install converter to exhaust manifold. 4. Install exhaust manifold heat shield into position. 5. Install nuts attaching converter to manifold. Torque nuts to 28 Nm (250 inch lbs.). 6. Connect upstream oxygen sensor. 7. Install cross-under pipe. 8. Install exhaust system on vehicle. 9. Lower vehicle. 10. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2454 Canister Purge Solenoid: Diagrams Evaporative Purge Solenoid Evaporative Purge Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2455 Canister Purge Solenoid: Description and Operation EVAP/PURGE SOLENOID During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2456 Canister Purge Solenoid: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. 3. Disconnect the electrical connector. 4. Disconnect the vacuum hoses. Fig. 2 Purge Solenoid 5. Remove purge solenoid from the bracket. INSTALLATION 1. Install purge solenoid onto bracket. 2. Connect the vacuum hoses. 3. Connect the electrical connector. 4. Install the air cleaner box. 5. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2460 Evaporative Emission Control Canister: Description and Operation EVAP/PURGE SOLENOID During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Fig. 10 EVAP Canister VAPOR CANISTER The canister attaches to the bracket. The vacuum and vapor tubes connect to the top of the canister. It is a charcoal canister. All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through the proportional purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. Purge Free Cells Purge-free memory cells are used to identify the fuel vapor content of the evaporative canister. Since the evaporative canister is not purged 100% of the time, the PCM stores information about the evaporative canister's vapor content in a memory cell. The purge-free cells are constructed similar to certain purge-normal cells. The purge-free cells can be monitored by the DRB III Scan Tool. The only difference between the purge-free cells and normal adaptive cells is that in purge-free, the purge is completely turned off. This gives the PCM the ability to compare purge and purge-free operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > EVAP/Purge Solenoid Replacement Evaporative Emission Control Canister: Service and Repair EVAP/Purge Solenoid Replacement REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. 3. Disconnect the electrical connector. 4. Disconnect the vacuum hoses. Fig. 2 Purge Solenoid 5. Remove purge solenoid from the bracket. INSTALLATION 1. Install purge solenoid onto bracket. 2. Connect the vacuum hoses. 3. Connect the electrical connector. 4. Install the air cleaner box. 5. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > EVAP/Purge Solenoid Replacement > Page 2463 Evaporative Emission Control Canister: Service and Repair Vapor Canister Replacement REMOVAL 1. Disconnect the negative battery cable. Fig. 11 Fuel Tank And EVAP System 2. Remove fuel tank, refer to the Fuel Delivery. 3. Remove the LDP Pump from the EVAP canister. 4. Disconnect the hoses from the EVAP canister. Fig. 12 EVAP Canister Bracket Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > EVAP/Purge Solenoid Replacement > Page 2464 Fig. 13 EVAP Canister Pins 5. Remove plastic fastener from the bracket of the EVAP canister and 6. Remove EVAP canister from bracket. INSTALLATION 1. Install LDP to EVAP Canister. 2. Install EVAP canister to Bracket. 3. Install the plastic fastener to EVAP canister bracket. 4. Connect hoses. 5. Install fuel tank refer to the Fuel Delivery. 6. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations Leak Detection Pump: Locations Fig. 4 LDP Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2468 Leak Detection Pump (Except Built-Up_Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2469 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2470 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2471 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2472 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2473 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2474 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2475 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2476 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2477 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2478 Leak Detection Pump: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Fig. 3 Fuel Tank And EVAP System Fig. 4 LDP Location 2. Remove fuel tank, refer to the Fuel Delivery and. 3. Disconnect the hoses from the EVAP canister. 4. Remove LDP from EVAP canister. INSTALLATION 1. Install LDP to EVAP Canister. 2. Connect hoses. 3. Install fuel tank refer to the Fuel Delivery. 4. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 2483 EGR Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube Plastic Manifold ................................................................................................................. .....................................................5.7 Nm (50 in. lbs) EGR Tube Aluminum Manifold ............................................................................................................ ................................................11.9 Nm (105 in. lbs) EGR Tube to EGR valve ....................................................................................................................................................11.3 Nm (8.5 ft. lbs, 99.9 in. lbs) EGR Tube to Intake Manifold ............................................................................................................................................11.3 Nm (8.5 ft. lbs, 99.9 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2487 EGR Tube: Locations The EGR tube attaches to the intake manifold plenum on both sides of the throttle body and the EGR valve. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2488 EGR Tube: Service and Repair REMOVAL Upper Tube Fig. 5 EGR Tube The EGR tube attaches to the intake manifold plenum on both sides of the throttle body and the EGR valve. 1. Disconnect negative battery cable. 2. Remove air cleaner box. 3. Remove throttle cable shield. Fig. 6 PCV Valve 4. Remove EGR tube mounting screws at intake manifold plenum. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2489 Fig. 7 Lower EGR Tube Bolts 5. Remove EGR tube mounting screws at EGR valve. 6. Remove EGR upper tube. 7. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve. Note that any loose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum. Lower Tube 1. Disconnect negative battery cable. 2. Remove air cleaner box. 3. Remove the throttle cable shield. 4. Loosen the 4 bolts for the upper EGR tube at the intake manifold. 5. Remove the 2 bolts for the upper EGR tube to EGR valve. 6. Loosen the 2 bolts for the EGR valve to cylinder head. 7. Raise vehicle and support. Fig. 8 Lower Tube To Exhaust Manifold 8. Remove the 2 bolts and gasket for the lower EGR tube to exhaust manifold. 9. Lower vehicle. 10. Remove the 2 bolts for the EGR valve to cylinder head. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2490 Fig. 9 Lower Tube And EGR Valve 11. Remove assembly. Fig. 10 Lower Tube To EGR Valve Bolts 12. Remove the 2 bolts to the lower EGR tube to EGR valve. INSTALLATION Upper Tube Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2491 Fig. 11 EGR Tube The EGR tube attaches to the intake manifold plenum on both sides of the throttle body and the EGR valve. 1. Inspect rubber silicone seals on intake manifold end of EGR tube. 2. Install upper tube into the intake manifold, being careful that the silicone rubber seals are correctly installed and undamaged. 3. Install new gasket between the EGR valve and tube and install bolts. 4. Tighten the EGR upper tube to intake manifold plenum screws to 11 Nm (95 in. lbs.) torque. 5. Tighten the EGR upper tube to EGR valve bolts to 11 Nm (95 in. lbs.) torque. 6. Install the throttle cable shield. 7. Install air cleaner box. 8. Connect negative battery cable. Lower Tube Fig. 10 Lower Tube To EGR Valve Bolts 1. Install the 2 bolts to the lower EGR tube to EGR valve. Tighten the inboard screw to torque and snug the outboard screw. Locate the tube in the approximate location needed for assembly. This will allow the movement of the tube into position when install on the vehicle. Tighten the EGR tube inboard screw to 11 Nm (95 in. lbs.) torque. 2. Install new gasket for the EGR valve to cylinder head and loosely install bolts. 3. Install assembly. 4. Loose install the 2 bolts for the EGR valve to cylinder head to cylinder head. 5. Loose install the 2 bolts and gasket for the upper EGR Tube to EGR valve. 6. Raise vehicle and support. 7. Rotate tube into position. 8. Install new gasket between the exhaust manifold and tube and loosely install bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2492 9. Tighten the EGR tube to exhaust manifold bolts to 31 Nm (275 in. lbs.) torque. 10. Lower vehicle. 11. Tighten the EGR valve to cylinder head bolts to 23 Nm (203 in. lbs.) torque. 12. Tighten the EGR tube outboard screw to 11 Nm (95 in. lbs.) torque. 13. Tighten the upper EGR tube screws to EGR valve to 11 Nm (95 in. lbs.) torque. 14. Tighten the upper EGR tube to intake manifold to 11 Nm (95 in. lbs.) torque. 15. Connect the electrical connector to the EGR valve. 16. Install air cleaner box. 17. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR valve to cylinder head ...............................................................................................................................................22.9 Nm (16.8 ft. lbs, 202 in. lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2496 EGR Valve: Description and Operation The EGR valve consists of three major components. First there is the pintle, valve seat, and housing which contains and regulates the gas flow. Second there is the armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects to the two connectors in the connector assembly. The third major component which senses pintle position and is connected to the three connectors in the electrical connector. Refer to Monitored Systems - EGR Monitor for more information. The engines use Exhaust Gas Recirculation (EGR) systems. The EGR system reduces oxides of nitrogen (NOx) in engine exhaust and helps prevent detonation (engine knock). Under normal operating conditions, engine cylinder temperature can reach more than 3000 °F. Formation of NOx increases proportionally with combustion temperature. To reduce the emission of these oxides, the cylinder temperature must be lowered. The system allows a predetermined amount of hot exhaust gas to recirculate and dilute the incoming air/fuel mixture. The diluted air/fuel mixture reduces peak flame temperature during combustion. Fig. 12 EGR Valve And Transducer - Typical The electric EGR transducer contains an electrically operated solenoid and a back-pressure transducer. The Powertrain Control Module (PCM) operates the solenoid. The PCM determines when to energize the solenoid. Exhaust system back- pressure controls the transducer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2497 When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. A failed or malfunctioning EGR system can cause engine spark knock, sags or hesitation, rough idle, engine stalling and increased emissions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2498 EGR Valve: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove air cleaner box. 3. Remove the throttle cable shield. Fig. 6 PCV Valve 4. Loosen the 4 bolts for the upper EGR tube at the intake manifold. Fig. 7 Lower EGR Tube Bolts 5. Remove the 2 bolts for the upper EGR tube to EGR valve. 6. Loosen the 2 bolts for the EGR valve to cylinder head. 7. Raise vehicle and support. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2499 Fig. 8 Lower Tube To Exhaust Manifold 8. Remove the 2 bolts and gasket for the lower EGR tube to exhaust manifold. 9. Lower vehicle. 10. Remove the 2 bolts for the EGR valve to cylinder head. Fig. 9 Lower Tube And EGR Valve 11. Remove assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2500 Fig. 10 Lower Tube To EGR Valve Bolts 12. Remove the 2 bolts to the lower EGR tube to EGR valve. INSTALLATION 1. Install the 2 bolts to the lower EGR tube to EGR valve. Tighten the inboard screw to torque and snug the outboard screw. Locate the tube in the approximate location needed for assembly. This will allow the movement of the tube into position when install on the vehicle. Tighten the EGR tube inboard screw to 11 Nm (95 in. lbs.) torque. 2. Install new gasket for the EGR valve to cylinder head and loosely install bolts. 3. Install assembly. 4. Loose install the 2 bolts for the EGR valve to cylinder head to cylinder head. 5. Loose install the 2 bolts and gasket for the upper EGR Tube to EGR valve. 6. Raise vehicle and support. 7. Rotate tube into position. 8. Install new gasket between the exhaust manifold and tube and loosely install bolts. 9. Tighten the EGR tube to exhaust manifold bolts to 31 Nm (275 in. lbs.) torque. 10. Lower vehicle. 11. Tighten the EGR valve to cylinder head bolts to 23 Nm (203 in. lbs.) torque. 12. Tighten the EGR tube outboard screw to 11 Nm (95 in. lbs.) torque. 13. Tighten the upper EGR tube screws to EGR valve to 11 Nm (95 in. lbs.) torque. 14. Tighten the upper EGR tube to intake manifold to 11 Nm (95 in. lbs.) torque. 15. Connect the electrical connector to the EGR valve. 16. Install air cleaner box. 17. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Heater > Component Information > Diagrams PCV Heater Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Fig. 6 Positive Crankcase Valve Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2508 Positive Crankcase Ventilation Valve: Description and Operation Fig. 6 Positive Crankcase Valve The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 7 Engine OFF Or Engine Backfire No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. Fig. 8 High Intake Manifold Vacuum Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2509 Fig. 9 Moderate Intake Manifold Vacuum Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Deadhead Pressure 880 kpa (130 psi) Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure > Page 2515 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2516 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2517 Tests 3 - 5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2518 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel Pump Relay - Fuel Pressure Out Of Specs - Restricted Fuel Supply Line - Fuel Pump Inlet Strainer Plugged - Fuel Pump Module - Fuel Pump Capacity (Volume) Out Of Specs - Fuel Pump Relay Fused B+ Circuit - Fuel Pump Relay Output Circuit Open - Fuel Pump Ground Circuit Open/High Resistance Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2519 - Fuel Pump Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 2523 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed 550-1300 rpm Idle speed range achieved by performing the Minimum Air Flow Idle Speed Test using a scan tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL Fig. 1 Throttle Cable Release 1. Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam (Fig. 1). Fig. 2 Cable Clip 2. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 2530 Fig. 3 Accelerator Pedal 3. Remove nuts from accelerator pedal attaching studs. Remove assembly from vehicle (Fig. 3). INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in. lbs.) torque (Fig. 3). 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft (Fig. 2). 3. From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect inlet air temperature sensor electrical connector (Fig. 7). 3. Disconnect fresh air makeup hose from throttle body air inlet hose (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2535 4. Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. 5. Push in on locking tabs to disengage air inlet hose from air cleaner housing. Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver (Fig. 10). 6. Remove throttle body air inlet hose. 7. Remove air cleaner element from air cleaner housing. INSTALLATION 1. Clean any debris from inside air cleaner housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2536 2. Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. 3. Install throttle body air inlet hose into air cleaner housing. Push in on hose until an audible "click" is heard from locking tabs. 4. Install hose on throttle body. Tighten hose clamp (Fig. 9). 5. Connect fresh air makeup hose (Fig. 8). 6. Connect inlet air temperature sensor electrical sensor (Fig. 7). 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Rating Fuel Rating Fuel Unleaded fuel having a minimum octane rating of 87. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Page 2540 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations Fuel Filler Cap: Locations The plastic fuel fill cap is threaded one quarter turn onto the end of the fuel filler tube. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations > Page 2544 Fuel Filler Cap: Service Precautions CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations > Page 2545 Fuel Filler Cap: Description and Operation The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to retain vapors and fuel in the fuel tank. The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal operating conditions. The relief valve is calibrated to open when a pressure of 17 kPa (2.5 psi) or vacuum of 2 kPa (0.6 in. Hg) occurs in the fuel tank. When the pressure or vacuum is relieved, the valve returns to the normally closed position. CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2550 Fuel Pressure Release: Service and Repair 1. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. 5. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 6. Return fuel pump relay to PDC. 7. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB III scan tool must be used to erase a DTC. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Resistance 10 - 16 Ohms At 68 degrees F (20 degrees C) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2554 Fuel Injector: Locations Fig. 11 Fuel Injector Location Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 11). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2555 Fuel Injector: Diagrams Fuel Injector No.1 Fuel Injector No.2 Fuel Injector No.3 Fuel Injector No.4 Fuel Injector No.5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2556 Fuel Injector No.6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2557 Fuel Injector: Description and Operation Fig. 11 Fuel Injector Location Typical The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 11). Fig. 12 Fuel Injector Typical The fuel injectors are 12 volt electrical solenoids (Fig. 12). The injector contains a pintle that closes OFF an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. The PCM provides battery voltage to each injector through the ASD relay. Injector operation is controlled by a ground path provided for each injector by the PCM. Injector on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously discussed to obtain the optimum injector pulse width for each operating condition. The pulse width is controlled by the duration of the ground path provided. Fuel injectors are fired one crankshaft revolution before TDC compression. When cylinder # 4 is at TDC compression the injector for cylinder # 1 will be energized. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2558 Fuel Injector: Service and Repair REMOVAL 1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure. 2. Disconnect negative cable to battery. 3. Remove intake manifold plenum. Refer to the Engine for information. 4. Remove intake manifold plenum mounting bolts. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine. 5. Disconnect fuel supply tube quick connect fittings at the rear of intake manifold. Refer to Quick Connect Fittings in the Fuel Delivery. 6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder 7. Remove electrical connectors from the fuel injectors. 8. Remove fuel rail mounting bolts. 9. Lift fuel rail straight up off of the cylinder head. 10. Remove retaining clips from fuel injectors at fuel rail. 11. Remove fuel injectors. INSTALLATION 1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil. 2. Install retaining clips on fuel injectors. 3. Push injectors into fuel injector rail until clips are in the correct position. 4. Position fuel rail over cylinder head, and push rail into place. Tighten fuel rail mounting bolts to 12 Nm (106.2 in. lbs.) torque. 5. Connect fuel supply tube quick connect fittings at the rear of the fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery. 6. Connect electrical connectors to fuel injectors. 7. Install intake manifold plenum. Refer to the Engine for information. 8. Connect negative cable to battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING: - RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. - THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Quick Connect Fitting Service REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. 1. Perform Fuel Pressure Release Procedure. Refer to the fuel pressure release procedure 2. Disconnect negative cable from battery or auxiliary jumper terminal. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. 1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. Fig. 20 Plastic Quick-Connect Fitting/Fuel Tube Connection 4. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Fig. 20). Do not rely upon the audible click to confirm a secure connection. 5. Connect negative cable to battery or auxiliary jumper terminal. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for several minutes, until the test is' stopped, or until the ignition switch is turned to the OFF position. 6. Use the DRB III scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service > Page 2564 Fuel Line Coupler: Service and Repair Two-Tab Type Fitting Service TWO-TAB TYPE FITTING Fig. 21 Typical Two-Tab Type Quick-Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting (Fig. 21). These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. DISCONNECTION / CONNECTION 1. Perform fuel pressure release procedure. Refer to fuel system pressure release procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 21) against sides of quick connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick connect fitting connector body. 5. Inspect quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal. 10. Use the DRB III scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Service > Page 2565 Fuel Line Coupler: Service and Repair Plastic Retainer Ring Type Fitting Service PLASTIC RETAINER RING TYPE FITTING Fig. 22 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 22) usually black in color. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. DISCONNECTION / CONNECTION 1. Perform fuel pressure release procedure. Refer to the fuel pressure release procedure 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 22). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. 5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery or auxiliary jumper terminal 11. Use the DRB III scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2569 Fuel Pressure Regulator: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2570 Fuel Pressure Regulator: Description and Operation A combination fuel filter and fuel pressure regulator is used on all gas powered engines. It is located on the top of the fuel pump module. Fig. 5 Side View - Filter/Regulator It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 5) is also part of the assembly. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 400 kpa ±34 kPa (58 psi ±5 psi.) at the fuel injectors. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator (Fig. 5). The fuel pump module contains a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. If fuel pressure at the pressure regulator exceeds approximately 58 psi, an internal diaphragm closes and excess fuel pressure is routed back into the tank through the pressure regulator. A separate fuel return line is not used with any gas powered engine. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2571 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. 1. Refer to Fuel System Pressure Release in the Fuel Delivery System. The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Fuel pump module removal is not necessary. 2. Raise vehicle on hoist. 3. Remove fuel tank. 4. Disconnect fuel supply line at the Filter/Regulator nipple (refer to Quick Connect Fittings). Fig. 6 Locking Spring Tab 5. Depress locking spring tab on side of Fuel/Regulator (Fig. 6) and rotate 90° counter-clockwise and pull out. NOTE: Make sure that the upper and lower O-rings are on the Filter/Regulator assembly. INSTALLATION Lightly lubricate the O-rings with engine Oil. 1. Insert Filter/Regulator into the opening in the fuel pump module, align the two hold down tabs with the flange. Fig. 7 Spring Tab In Locating Slot 2. While applying downward pressure, rotate the Filter/Regulator clockwise until the the spring tab engages the locating slot (Fig. 7). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2572 3. Install the fuel tank. 4. Connect the fuel line to the Filter/Regulator. 5. Lower vehicle from hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel Pressure Fuel Pressure Deadhead Pressure 880 kpa (130 psi) Regulated Pressure 400 +/- 34 kpa (58 +/- 5 psi) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure > Page 2578 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2579 Fuel Pressure: Testing and Inspection Tests 1 - 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2580 Tests 3 - 5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2581 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel Pump Relay - Fuel Pressure Out Of Specs - Restricted Fuel Supply Line - Fuel Pump Inlet Strainer Plugged - Fuel Pump Module - Fuel Pump Capacity (Volume) Out Of Specs - Fuel Pump Relay Fused B+ Circuit - Fuel Pump Relay Output Circuit Open - Fuel Pump Ground Circuit Open/High Resistance Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2582 - Fuel Pump Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (PDC) Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2586 Fuel Pump Relay: Diagrams Power Distribution Center (PDC) Fuel Pump Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2587 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the Automatic Shutdown (ASD) relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation Fig. 8 Fuel Pump Module FUEL PUMP MODULE The fuel pump module contains the fuel pump, fuel reservoir, level sensor, inlet strainer, and fuel pressure regulator/filter (Fig. 8). The Chrysler fuel pump module is an in-tank unit with an integral fuel level sensor and pressure regulator. The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized. Serviceable components on the module include: Inlet strainer - Fuel level sensor - Fuel Filter/Pressure regulator The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains two check valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. The second valve, in the pump outlet, maintains pump pressure during engine OFF conditions. The fuel system use a positive displacement, gerotor; with a permanent magnet electric motor. This fuel system does not contain the traditional fuel return lines. The regulator contains a calibrated spring which forces a diaphragm against the fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank. The maximum deadhead pressure is approximately 880 kpa (130 psi). The regulator adjusts fuel system pressure to approximately 400 kpa ±34 kPa (58 psi ±5 psi). The inlet strainer, level sensor and fuel pressure regulator/filter are the only serviceable items. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 2591 Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Fig. 18 Inlet Strainer 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 18). Fig. 19 Inlet Strainer Removed 3. Remove strainer O-ring from the fuel pump reservoir body (Fig. 19). 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions Fuel Rail: Service Precautions WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 2595 Fuel Rail: Service and Repair REMOVAL WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure. 2. Disconnect the negative battery cable. 3. Remove intake manifold plenum. Refer to the Engine for information. 4. Remove intake manifold plenum mounting bolts. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine. 5. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery. Fig. 12 Injector Electrical Connectors 6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder (Fig. 12). 7. Remove mounting bolts on both sides of fuel rail. 8. Lift fuel rail straight up off of cylinder head. 9. Remove retaining clips from fuel injectors at fuel rail. 10. Remove fuel injector from fuel rail. INSTALLATION 1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil. 2. Install retaining clips on fuel injectors. 3. Push injectors into fuel injector rail until clips are in the correct position. 4. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 11 Nm (100 in. lbs.) torque. 5. Connect the fuel supply tube quick connect fitting to the fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery. 6. Connect the electrical connectors to the fuel injectors. 7. Install intake manifold plenum. Refer to the Engine for information. 8. Connect negative cable to battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > NHTSA00V320002 > Oct > 00 > Recall 00V320002: Defective Fuel Return Hose Fuel Return Line: Recalls Recall 00V320002: Defective Fuel Return Hose The outer layer only of this 3-layer fuel return hose does not contain the desired ozone protection due to a processing error. This hose is considered to be inadequate. Dealers will replace the fuel return hose. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > NHTSA00V320002 > Oct > 00 > Recall 00V320002: Defective Fuel Return Hose Fuel Return Line: All Technical Service Bulletins Recall 00V320002: Defective Fuel Return Hose The outer layer only of this 3-layer fuel return hose does not contain the desired ozone protection due to a processing error. This hose is considered to be inadequate. Dealers will replace the fuel return hose. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications Fuel Filler Hose: Specifications Filler Tube Ground Strap ..................................................................................................................... .....................................................7.5 Nm (66 in. lbs) Filler Tube Screws ............................................................................................................................... .....................................................1.9 Nm (16 in. lbs) Fuel Filler Tube Clamp ........................................................................................................................ ..................................................3.6 Nm (31.8 in. lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2616 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2617 Fuel Gauge Sender: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 1). Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2618 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector (Fig. 3). 4. Push level sensor signal and ground terminals out of the connector (Fig. 3). Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove (Fig. 4). 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Service and Repair Fuel Tank Vent: Service and Repair REMOVAL 1. Perform fuel system pressure release. 2. Disconnect negative cable from battery. 3. Drain fuel tank. 4. Raise and support vehicle on host. 5. Lower fuel tank. 6. Remove vent hose from top of tank. 7. Remove vent hose from fuel filler neck. INSTALLATION 1. Install vent hose and tighten clamp. 2. Install fuel tank. 3. Install vent hose to fuel filler neck and tighten clamp. 4. Lower vehicle. 5. Fill fuel tank and check for leaks. 6. Connect negative cable to battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Fig. 17 Idle Air Control Motor The idle air control motor (IAC) attaches to the throttle body. It is an electric stepper motor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2625 Idle Air Control Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2626 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 17 Idle Air Control Motor The idle air control motor (IAC) attaches to the throttle body. It is an electric stepper motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning). When engine rpm is above idle speed, the IAC is used for the following functions: - Off-idle dashpot - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) Target Idle Target idle is determined by the following inputs: Gear position ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2627 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Fig. 18 Idle Air Control Motor 2. Disconnect the IAC electrical connector. 3. Remove the IAC mounting screws. 4. Remove the IAC. INSTALLATION 1. Install the IAC to the throttle body. 2. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 3. Attach electrical connector to the IAC. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2631 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2632 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (PDC) Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2637 Fuel Pump Relay: Diagrams Power Distribution Center (PDC) Fuel Pump Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2638 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the Automatic Shutdown (ASD) relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path OFF when the ignition switch is in the OFF position. When the ignition switch is in the ON position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Power Distribution Center (PDC) Automatic Shut Down (ASD) Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2642 Main Relay (Computer/Fuel System): Diagrams Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2643 8w-10-4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation All vehicles have rollover valve(s) on top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. The rollover valves on the fuel tank are not serviceable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2651 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2652 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2653 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations The throttle body is located on the intake manifold. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2657 Throttle Body: Description and Operation Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2658 Throttle Body: Service and Repair REMOVAL 1. Disconnect negative cable from battery Fig. 31 TPS And Inlet Air Temp Sensor 2. Disconnect electrical connectors from throttle body (Fig. 31). 3. Remove the air cleaner box. Fig. 32 Throttle Shield 4. Remove the throttle cable shield (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2659 Fig. 33 Throttle Cables 5. Hold throttle lever in wide open position. Remove throttle cable and speed control cables from throttle arm (Fig. 33). 6. Remove throttle cable bracket. Fig. 34 Throttle Body Support Bracket 7. Remove the throttle body support bracket from the bottom of the throttle body (Fig. 34). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 2660 Fig. 35 Throttle Body 8. Remove 3 throttle body bolts (Fig. 35). 9. Remove throttle body. 10. Clean mating surfaces. INSTALLATION 1. Loose install 2 throttle body bolts (Fig. 35). 2. Install the throttle cable bracket. 3. Install the third throttle body bolt and the throttle body support bracket to the bottom of the throttle body (Fig. 34). Tighten the lower support bracket bolts to 27.1 Nm (20 ft. lbs.) torque. 4. Tighten throttle body bolts to 11.9 Nm (105 in. lbs.) torque. 5. Hold throttle lever in wide open throttle position. Install throttle cable and speed control cable (Fig. 33). 6. Install the throttle cable shield (Fig. 32). 7. Connect electrical connectors to throttle body (Fig. 31). 8. Install air cleaner box. 9. Connect negative cable to battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Throttle Cable Bracket Plastic Manifold ...................................................................................................................................................5.7 Nm (50 in. lbs) Throttle Cable Bracket Aluminum Manifold .........................................................................................................................................11.9 Nm (105 in. lbs) The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpm) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 2664 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. Fig. 37 Throttle Cable 2. Remove the throttle cable from the throttle body cam (Fig. 37). 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. Fig. 38 Retainer Clip 4. Remove retainer clip from throttle cable and grommet at dash panel (Fig. 38). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. 6. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously. Then gently pull the throttle cable from throttle bracket. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal lever. 4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet (Fig. 38). 5. From the engine compartment, rotate the throttle lever wide open and install the throttle cable (Fig. 37). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The throttle position sensor mounts to the side of the throttle body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2668 Throttle Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2669 Throttle Position Sensor: Description and Operation The throttle position sensor mounts to the side of the throttle body. The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor (potentiometer) that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2670 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the negative battery cable. 2. Remove the throttle body. Fig. 40 Idle Air Control Module And Throttle Position Sensor 3. Remove the TPS mounting screws. 4. Remove the TPS. INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. The TPS has slight tension when rotated into position. If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. Tighten mounting screws to 5.1 Nm (45 in. lbs.) torque. 2. After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install the throttle body. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Description and Operation Variable Induction Control Valve: Description and Operation MANIFOLD TUNE VALVE Fig. 20 Manifold Tuning Valve The valve opens a crossover passage in that connects both sides of the intake manifold plenum (Fig. 20). It is an electric motor. The PCM controls the MTV solenoid. The manifold tuning valve optimizes acoustical tuning of the intake system during wide open throttle operation throughout the RPM range to increase torque. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Description and Operation > Page 2675 Variable Induction Control Valve: Service and Repair REMOVAL 1. Disconnect negative battery cable. Fig. 21 Manifold Tuning Valve 2. Disconnect electrical connector (Fig. 21). Fig. 22 Manifold Tuning Valve Removal/Installation 3. Remove manifold tuning valve mounting screws. Remove tuning valve (Fig. 22). INSTALLATION 1. Install tuning valve. Tighten mounting screws to 11.9 Nm (105 in. lbs.) torque. 2. Install electrical connector. 3. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front to rear, with the right bank odd numbered, and the left bank even numbered (Fig. 2). The firing order is 1-2-3-4-5-6. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2681 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2690 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2691 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2692 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2693 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2698 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2699 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2700 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2701 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2702 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations Ignition Coil: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 2706 Ignition Coil: Diagrams Coil On Plug No.1 Coil On Plug No.2 Coil On Plug No.3 Coil On Plug No.4 Coil On Plug No.5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 2707 Coil On Plug No.6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 2711 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Fig.3 CAM Sensor Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2717 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2718 Camshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2719 Camshaft Position Sensor: Description and Operation Fig.3 CAM Sensor Location The Camshaft Position Sensor (CMP) is mounted at the front of the cylinder head. The CMP sensor contains a hall effect device that provide cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope or DRB III PEP Module can display the square wave patterns of each timing event. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2720 Camshaft Position Sensor: Service and Repair REMOVAL The camshaft position sensor is mounted in the front of the head. 1. Disconnect electrical connector from sensor. 2. Remove camshaft position sensor screw. Fig.3 CAM Sensor Location (2.7L) 3. Without pulling on the connector, pull the sensor out of the chain case cover. INSTALLATION The camshaft position sensor is mounted in the front of the head. 1. Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque 2. Attach electrical connector to sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Fig.5 2.7L This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2725 Fig. 15 Engine Connectors 2.7L Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2726 Crankshaft Position Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2727 Crankshaft Position Sensor: Description and Operation Fig. 5 This crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. The Crankshaft Position (CKP) sensor is a Hall-effect sensor. The PCM sends approximately 8 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit of the PCM. The input to the PCM occurs on a 5 volt output reference circuit. The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses. From the width of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse width. The faster the engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor notifies the PCM that 2 cylinders are on Top Dead Center. Based on this, the PCM will energize one of these 2 cylinder's injectors and ignition coil. The camshaft position sensor identifies which cylinder of the 2 is on Top Dead Center and on the compression stroke. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2728 Fig. 7 Crankshaft Position Sensor Fig. 8 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29 °, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2729 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air cleaner box. Fig. 10 Crankshaft Sensor 3. Disconnect the electrical connector from Crankshaft position sensor. 4. Remove bolt. 5. Remove sensor. INSTALLATION 1. Install crankshaft sensor. 2. Tighten bolt. 3. Install air cleaner box. 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2738 Knock Sensor: Diagrams Knock Sensor Knock Sensor Connector (KS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ...................................................................... 0.050 in Tightening Torque ........................................... .......................................................................................................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2742 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................... Champion Platinum Power CHA 3032 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 294). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 295). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 2749 7. Remove solenoid/pressure switch assembly and gasket (Fig. 296). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 296). 2. Install and torque three (3) bolts (Fig. 295) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 294) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Solenoid And Solenoid Valves - Overall View Solenoid And Solenoid Valve Views A - D Name Symbol Solenoid And Pressure Switch Assembly D Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID Shift Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Shift Indicator ....................................................................................................................................... ...................................................... VF Display Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID > Page 2761 Shift Indicator: Service and Repair REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of transmission range indicator bezel from floor console. 3. Pull upward carefully on transmission range indicator bezel and disengage tabs from rear floor console bezel. 4. Disconnect wire connector to lamp assembly. 5. Remove transmission range indicator bezel and lamp assembly from vehicle. INSTALLATION 1. Position transmission range indicator bezel and lamp assembly to vehicle. 2. Connect wire connector to lamp assembly. 3. Engage tabs on transmission range indicator bezel to slots in rear floor console bezel. 4. Push downward on transmission range indicator bezel to engage to bezel to floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2767 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 2768 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 2777 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2782 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2783 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2784 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 2790 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 2796 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2801 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2802 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2803 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 2808 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 2814 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 2820 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2825 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2826 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 2827 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 2828 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 2829 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 2830 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 2839 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 2840 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2844 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2845 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2846 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2847 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 2851 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 2854 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 2855 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 2856 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 2859 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-01 > Nov > 01 > Engine - Idle Roughness PROM - Programmable Read Only Memory: Customer Interest Engine - Idle Roughness NUMBER: 18-028-01 GROUP: Vehicle Performance DATE: Nov. 23, 2001 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL DECEMBER 10, 2001. THE MDS2 MUST BE OPERATING WITH CIS CD2097 OR HIGHER. SUBJECT: Engine Idle Roughness OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE (SALES CODE EES). SYMPTOM/CONDITION: ^ Rough idle following a cold start. More prevalent in ambient temperatures of 10°C. to 21°C. (50°F. to 70°F.). ^ Engine speed flares or rough idle while slowing to a stop. May be attributed to an accessory load (power steering, A/C, or generator). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-028-01 > Nov > 01 > Engine - Idle Roughness > Page 2868 2. Type the necessary information on the "authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-007-01 > Feb > 01 > A/T - Surge/Sag/Shift Bump PROM - Programmable Read Only Memory: Customer Interest A/T - Surge/Sag/Shift Bump NUMBER: 18-007-01 GROUP: Vehicle Performance DATE: Feb. 23, 2001 SUBJECT: Transaxle Shift Quality Improvements OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2001 (JR) Sebring/Stratus Sedan/Sebring Convertible 2001 (LH) Intrepid/Concorde/LHS/300M 2001 (PT) PT Cruiser NOTE: THIS INFORMATION APPLIES TO MODELS BUILT PRIOR TO THE FOLLOWING: JR - DEC. 7, 2000 (MDH1207XX)/LH - DEC. 12, 2000 (MDH1212XX)/PT - FEB. 8, 2001 (MDHO2O8XX). SYMPTOM/CONDITION: Shift schedule improvements have been incorporated to address the following: ^ JR/PT - Some vehicles may exhibit tachometer jumpiness or surge with or without cruise control. It may be most noticeable with the cruise control engaged. This repair includes throttle rate changes to reduce torque converter clutch control busyness. This change will reduce clutch control on/off cycling due to minor throttle rate changes. ^ LH - Some vehicles may exhibit soft (sag) 3-1 or 2-1 kickdowns during low speed high throttle conditions. This repair improves low speed, 24 to 32 kph (15 to 20 mph), high throttle 3-1 or 2-1 kickdown. This provides a smoother and crisper shift. ^ LH - Some vehicles may exhibit 2-1 coastdown bump. This repair improves the 2-1 coastdown shift between 3 to 10 kph (2 to 6 mph). This provides a smoother coastdown shift at low speed. DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2078 OR HIGHER. 1. Flash the TCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-007-01 > Feb > 01 > A/T - Surge/Sag/Shift Bump > Page 2873 NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the TCM and cover it with the clear plastic overlay. Type the necessary information on the Authorized Modification Label p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2879 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2880 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2881 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2882 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2883 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2884 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2885 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2886 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2887 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2888 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2889 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2890 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2891 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2892 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2893 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2894 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2895 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2896 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2897 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-01 > Nov > 01 > Engine - Idle Roughness PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Idle Roughness NUMBER: 18-028-01 GROUP: Vehicle Performance DATE: Nov. 23, 2001 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL DECEMBER 10, 2001. THE MDS2 MUST BE OPERATING WITH CIS CD2097 OR HIGHER. SUBJECT: Engine Idle Roughness OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE (SALES CODE EES). SYMPTOM/CONDITION: ^ Rough idle following a cold start. More prevalent in ambient temperatures of 10°C. to 21°C. (50°F. to 70°F.). ^ Engine speed flares or rough idle while slowing to a stop. May be attributed to an accessory load (power steering, A/C, or generator). DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-028-01 > Nov > 01 > Engine - Idle Roughness > Page 2902 2. Type the necessary information on the "authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Type the necessary information on the "Authorized Modification Label" p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-007-01 > Feb > 01 > A/T - Surge/Sag/Shift Bump PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Surge/Sag/Shift Bump NUMBER: 18-007-01 GROUP: Vehicle Performance DATE: Feb. 23, 2001 SUBJECT: Transaxle Shift Quality Improvements OVERVIEW: This bulletin involves reprogramming the Transmission Control Module (TCM). MODELS: 2001 (JR) Sebring/Stratus Sedan/Sebring Convertible 2001 (LH) Intrepid/Concorde/LHS/300M 2001 (PT) PT Cruiser NOTE: THIS INFORMATION APPLIES TO MODELS BUILT PRIOR TO THE FOLLOWING: JR - DEC. 7, 2000 (MDH1207XX)/LH - DEC. 12, 2000 (MDH1212XX)/PT - FEB. 8, 2001 (MDHO2O8XX). SYMPTOM/CONDITION: Shift schedule improvements have been incorporated to address the following: ^ JR/PT - Some vehicles may exhibit tachometer jumpiness or surge with or without cruise control. It may be most noticeable with the cruise control engaged. This repair includes throttle rate changes to reduce torque converter clutch control busyness. This change will reduce clutch control on/off cycling due to minor throttle rate changes. ^ LH - Some vehicles may exhibit soft (sag) 3-1 or 2-1 kickdowns during low speed high throttle conditions. This repair improves low speed, 24 to 32 kph (15 to 20 mph), high throttle 3-1 or 2-1 kickdown. This provides a smoother and crisper shift. ^ LH - Some vehicles may exhibit 2-1 coastdown bump. This repair improves the 2-1 coastdown shift between 3 to 10 kph (2 to 6 mph). This provides a smoother coastdown shift at low speed. DIAGNOSIS: If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) are described by the customer, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2078 OR HIGHER. 1. Flash the TCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-007-01 > Feb > 01 > A/T - Surge/Sag/Shift Bump > Page 2907 NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the TCM and cover it with the clear plastic overlay. Type the necessary information on the Authorized Modification Label p/n 04275086 (Fig. 2) and attach the label near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2913 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2914 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2915 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2916 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2917 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2918 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2919 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2920 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2921 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2922 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2923 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2924 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2925 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2926 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2927 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2928 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2929 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2930 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 2931 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 294). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 295). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 2938 7. Remove solenoid/pressure switch assembly and gasket (Fig. 296). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 296). 2. Install and torque three (3) bolts (Fig. 295) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 294) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Solenoid And Solenoid Valves - Overall View Solenoid And Solenoid Valve Views A - D Name Symbol Solenoid And Pressure Switch Assembly D Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 294). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 295). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 2950 7. Remove solenoid/pressure switch assembly and gasket (Fig. 296). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 296). 2. Install and torque three (3) bolts (Fig. 295) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 294) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Solenoid And Solenoid Valves - Overall View Solenoid And Solenoid Valve Views A - D Name Symbol Solenoid And Pressure Switch Assembly D Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation Accumulator: Description and Operation DESCRIPTION The 41te underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumulator. An accumulator typically consists of a piston, seals, return spring(s), and a cover or plug. The overdrive and underdrive accumulators are located within the transaxle case, and are retained by the valve body (Fig. 155). The low reverse accumulator (Fig. 156) is also located within the transaxle case, but the assembly is retained by a cover and a snap-ring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > Page 2960 The 2/4 accumulator is located in the valve body. It is retained by a cover and retaining screws (Fig. 157). OPERATION The function of an accumulator is to cushion the application of a frictional clutch element. When pressurized fluid is applied to a clutch circuit, the application force is dampened by fluid collecting in the respective accumulator chamber against the piston and spring(s). The intended result is a smooth, firm clutch application. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Low/Rev Clutch (Select Reaction Plate 0.035 - 0.058 in Two/Four Clutch (No Selection) 0.030 - 0.104 in Reverse Clutch (Select Snap Ring) 0.035 - 0.054 in Overdrive Clutch (No Selection) 0.042 - 0.128 in Underdrive Clutch (Select Pressure Plate) 0.037 - 0.059 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Driving Clutches Clutch: Description and Operation Driving Clutches DRIVING CLUTCHES DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 158). The input clutch assembly also contains: Input shaft - Input hub - Clutch retainer - Underdrive piston - Overdrive/reverse piston - Overdrive hub - Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the rear sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and overdrive gears by pressurized fluid against the overdrive/reverse piston. When the overdrive clutch is applied, the overdrive hub drives the front planet carrier. REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the front sun gear assembly is driven. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Driving Clutches > Page 2966 Clutch: Description and Operation Low/Reverse Clutch HOLDING CLUTCHES DESCRIPTION Two hydraulically applied multi-disc clutches are used to hold planetary geartrain components stationary while the input clutches drive others. The 2/4 and Low/Reverse clutches are considered holding clutches and are contained at the rear of the transaxle case. (Fig. 198). OPERATION NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. 2/4 CLUTCH The 2/4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2/4 clutch piston. When the 2/4 clutch is applied, the front sun gear assembly is held or grounded to the transaxle case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gears by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the front planet carrier/rear annulus assembly is held or grounded to the transaxle case. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2967 Clutch: Service and Repair INPUT CLUTCH ASSEMBLY DISASSEMBLY 1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391). 2. Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 199). 3. Remove reverse clutch snap ring (Fig. 200). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2968 4. Pry up and remove reverse clutch reaction plate (Fig. 201) (Fig. 202). 5. Remove the reverse clutch pack (two fibers/one steel) (Fig. 203). NOTE: Tag reverse clutch pack for reassembly identification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2969 6. Remove the OD/Reverse reaction plate snap ring (Fig. 204). 7. Remove OD/Reverse reaction plate (Fig. 205). 8. Remove OD/Reverse reaction plate wave snap ring (Fig. 206). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2970 9. Remove OD shaft/hub and OD clutch pack (Fig. 207) (Fig. 208). NOTE: Tag overdrive clutch pack for reassembly identification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2971 10. Remove and inspect #3 & #4 thrust washers (Fig. 209). 11. Remove the underdrive shaft assembly (Fig. 210). 12. Remove the #2 needle bearing (Fig. 211). 13. Remove the OD/UD reaction plate tapered snap ring (Fig. 212). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2972 NOTE: The OD/UD clutch reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. 14. Remove the OD/UD reaction plate (Fig. 213). 15. Remove the first UD clutch disc (Fig. 214). 16. Remove the UD clutch flat snap ring (Fig. 215). NOTE: Tag underdrive clutch pack for reassembly identification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2973 17. Remove the UD clutch pack (Fig. 216). CAUTION: Compress return spring just enough to remove or install snap ring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2974 18. Using Tool 5059A and an arbor press, compress UD clutch piston enough to remove snap ring (Fig. 217) (Fig. 218). 19. Remove spring retainer (Fig. 218). 20. Remove UD clutch piston (Fig. 219). 21. Remove input hub tapered snap ring (Fig. 220). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2975 22. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer (Fig. 221) (Fig. 222). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2976 23. Separate clutch retainer from OD/Reverse piston (Fig. 223). 24. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring (Fig. 224) (Fig. 225). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2977 25. Remove input shaft to input clutch hub snap ring (Fig. 226). 26. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub (Fig. 227). ASSEMBLY Use petrolatum on all seals to ease assembly of components. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2978 1. Using an arbor press, install input shaft to input shaft hub (Fig. 228). 2. Install input shaft snap ring (Fig. 229). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2979 3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. 230) (Fig. 231). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2980 4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 232). 5. Install the input hub/shaft assy. to the OD/Reverse piston/clutch retainer assy. (Fig. 233). 6. Install input hub tapered snap ring (Fig. 234). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2981 7. Install UD clutch piston (Fig. 235). 8. Install UD piston return spring and Tool 5067 as shown in (Fig. 236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2982 9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. (Fig. 237) (Fig. 238)Compress just enough to install snap ring. CAUTION: Compress return spring just enough to install snap ring. 10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig. 239). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2983 11. Install the UD clutch flat snap ring (Fig. 240). 12. Install the last UD clutch disc (Fig. 241). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2984 13. Install the OD/UD clutch reaction plate and snap ring (Fig. 242) (Fig. 243). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around. 14. Seat tapered snap ring to ensure proper installation (Fig. 244). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2985 15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig. 245). 16. Set up dial indicator on the UD clutch pack as shown in (Fig. 246) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2986 17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 247). When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010. CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack. 18. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart. 19. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.941.50 mm (0.037 - 0.059 inch). 20. If necessary, select the proper reaction plate to achieve specifications: 21. Install the OD clutch pack (four frictions/three steels) (Fig. 248). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2987 22. Install OD reaction plate waved snap ring (Fig. 249). 23. Install the OD/Reverse reaction plate with large step down (towards OD clutch pack) (Fig. 250). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2988 24. Install OD reaction plate flat snap ring (Fig. 251). 25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse reaction plate as shown in (Fig. 252). 26. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart. 27. Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is 1.07 3.25 mm (0.042 - 0.128 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2989 28. Install reverse clutch pack (two frictions/one steel) (Fig. 253). 29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 254). 30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig. 255). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2990 31. Pry up reverse reaction plate to seat against snap ring (Fig. 256). 32. Set up a dial indicator on the reverse clutch pack as shown in (Fig. 257). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2991 33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig. 258). When releasing pressure, indicator should advance 0.005 - 0.010 as clutch pack relaxes. 34. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four 4. places, 90° apart. REVERSE CLUTCH SNAP RING THICKNESS 35. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89 - 1.37 mm (0.036 - 0.054 inch). Select the proper reverse clutch snap ring to achieve specifications: 36. To complete the assembly, reverse clutch and overdrive clutch must be removed. 37. Install the #2 needle bearing (Fig. 259). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2992 38. Install the underdrive shaft assembly (Fig. 260). 39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig. 261). 40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig. 262). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 2993 41. Install the overdrive shaft assembly (Fig. 263). 42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 2997 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 2998 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications Differential: Specifications Bolt, Differential Cover-to-Case 165 in.lb Bolt, Differential Ring Gear-to-Case 70 ft.lb Bolt, Differential Bearing Retainer-to-Case 21 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3002 Differential: Description and Operation FINAL DRIVE DESCRIPTION The 41TE differential is a conventional open design. It consists of a ring gear and a differential case. The differential case consists of pinion and side gears, and a pinion shaft. The differential case is supported in the transaxle by tapered roller bearings (Fig. 159). OPERATION The differential assembly is driven by the transfer shaft, by way of the differential ring gear. The ring gear drives the differential case, and the case drives the driveshafts through the differential gears. The differential pinion and side gears are supported in the case by thrust washers and a pinion shaft. Differential pinion and side gears make it possible for front tires to rotate at different speeds while cornering. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3003 Differential: Adjustments DIFFERENTIAL BEARING PRELOAD MEASUREMENT AND ADJUSTMENT NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear removed. DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM 1. Position the transaxle assembly vertically on the support stand, differential bearing retainer side up. 2. Install Tool L-4436A into the differential and onto the pinion mate shaft (Fig. 176). 3. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated. 4. Using Tool L-4436A and an inch-pound torque wrench, check the turning torque of the differential (Fig. 177). The turning torque should be between 5 and 18 inch lbs. 5. If the turning torque is within specifications, remove tools. Setup is complete. 6. If turning torque is not within specifications proceed with the following steps. a. Remove differential bearing retainer from the transaxle case. b. Remove the bearing cup from the differential bearing retainer using Tool 6062A. c. Remove the existing shim from under the cup. d. Measure the existing shim. e. If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5 to 18 inch lbs. turning torque is obtained. Oil Baffle is not required to be installed when making shim selection. f. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3004 cup. g. Install the differential bearing retainer using Tool 5052 and C-4171. Seal the retainer to the housing with Mopar Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.). 7. Using Tool L-4436A and an inch-pound torque wrench, recheck the turning torque of the differential (Fig. 177). The turning torque should be between 5 and 18 inch lbs. Shim thickness need be determined only if any of the following parts are replaced: Transaxle case - Differential carrier - Differential bearing retainer - Extension housing - Differential bearing cups and cones DIFFERENTIAL BEARING SHIM CHART PRELOAD ADJUSTMENT W/0 SHIM 1. Remove the bearing cup from the differential bearing retainer using Miller special Tool 6062A. 2. Remove existing shim from under bearing cup. 3. Reinstall the bearing cup into the retainer using Miller Special Tool 6061, and C-4171. NOTE: Oil baffle is not required when making the shim calculation. 4. Install the bearing retainer into the case. Torque bolts to 28 Nm (250 inch lbs.). 5. Position the transaxle assembly vertically on the support stand and install Miller Special Tool L-4436-A into the bearing retainer. 6. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated. 7. Attach a dial indicator to the case and zero the dial. Place the tip on the end of Special Tool L-4436-A. 8. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play. CAUTION: Do not damage the transaxle case and/or differential retainer sealing surface. 9. Using the end play measurement that was determined, add 0.18 mm (0.007 inch). This should give you between 5 and 18 inch pounds of bearing preload. Refer to the Differential Bearing Shim Chart to determine which shim to use. 10. Remove the differential bearing retainer. Remove the bearing cup. 11. Install the oil baffle. Install the proper shim combination under the bearing cup. 12. Install the differential bearing retainer. Seal the retainer to the housing with Mopar Silicone Rubber Adhesive Sealant. Torque bolts to 28 Nm (250 inch lbs.). 13. Using Miller Special Tool L-4436-A and an inch-pound torque wrench, check the turning torque of the differential (Fig. 177). The turning torque Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3005 should be between 5 - 18 inch lbs. NOTE: If turning torque is too high install a 0.05 mm (0.002 inch) thicker shim. If the turning torque is too low, install a 0.05mm (0.002 inch) thinner shim. Repeat until 5 - 18 inch lbs. of turning torque is obtained. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3006 Differential: Service and Repair DISASSEMBLY NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. The transfer shaft should be removed for differential repair and bearing turning torque checking. 1. Remove the differential cover and bolts (Fig. 160) (Fig. 161). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3007 2. Remove the differential bearing retainer and bolts (Fig. 162) (Fig. 163). 3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle. WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING. 4. Remove differential assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3008 5. Set up dial indicator set C-3339 and tool C-4996 as shown in (Fig. 164) (Fig. 165) to measure side gear end play. Side gear end play must be within 0.001 - 0.013 inch. 6. Use Miller Special Tool 5048, 6048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3009 7. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side (Fig. 166) (Fig. 167) (Fig. 168). 8. Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing/adapter plate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3010 9. Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig. 169) (Fig. 170). DIFFERENTIAL SERVICE TOOLS ASSEMBLY NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. NOTE: Use Mopar Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3011 1. Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Fig. 171). 2. Using Miller Special Tool 5052 and C-4171, install differential bearing to differential (bearing retainer side). 3. Using Miller Special Tool 6061 and C-4171, install differential bearing race to bearing retainer (Fig. 172). 4. Using Miller Special Tool L 4520 and C-4171, install differential bearing cup to extension housing. 5. Measure and adjust differential bearing preload. 6. Install differential assembly to case. Install extension housing/adapter plate and bearing retainer. 7. Install bearing retainer with a bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts (Fig. 173) to 28 Nm (250 inch lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Specifications > Page 3012 8. Install extension housing/adapter plate with a bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.). 9. Install differential cover with a bead of Mopar Silicone Rubber Adhesive Sealant (Fig. 174) and torque bolts (Fig. 175) to 28 Nm (250 inch lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Bolt, Extension Housing/Plate-to-Case 21 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3020 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3021 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3022 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3023 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3024 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity ...................................................................................................................................... ...................................................... 8.7Liters (9.2 Qt) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3027 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3028 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3029 Fluid - A/T: Testing and Inspection FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF +4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator (Fig. 178). The fluid level should be within the WARM range of the dipstick at 70° F fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3030 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 179). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF +4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3031 Fluid - A/T: Service and Repair STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 180). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 181). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening, DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3032 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula (R) or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF +4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 181). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. 1b prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair For further information regarding this component or the system it is a part of please refer to AUTOMATIC TRANSMISSION FLUID; SERVICE AND REPAIR. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Recalls: > NHTSA01V011002 > Jan > 01 > Recall 01V011002: A/T Cooler Hoses Defect Fluid Line/Hose: Recalls Recall 01V011002: A/T Cooler Hoses Defect Vehicle Description: Passenger vehicles equipped with automatic transmissions. A hose manufacturing process allowed the reinforcement yard to breach the inner layer of some automatic transmission hoses weakening the inner wall which could result in leakage of the automatic transmission fluid. Fluid leakage from the cooler hoses can cause transaxle driveability problems and smoke if the oil contacts the front exhaust pipe. Dealers will replace the transaxle oil cooler hoses. Owner notification began April 9, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > NHTSA01V011002 > Jan > 01 > Recall 01V011002: A/T Cooler Hoses Defect Fluid Line/Hose: All Technical Service Bulletins Recall 01V011002: A/T Cooler Hoses Defect Vehicle Description: Passenger vehicles equipped with automatic transmissions. A hose manufacturing process allowed the reinforcement yard to breach the inner layer of some automatic transmission hoses weakening the inner wall which could result in leakage of the automatic transmission fluid. Fluid leakage from the cooler hoses can cause transaxle driveability problems and smoke if the oil contacts the front exhaust pipe. Dealers will replace the transaxle oil cooler hoses. Owner notification began April 9, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07-004-00 > Jan > 00 > A/T - Cooler Line Splice Kit Fluid Line/Hose: All Technical Service Bulletins A/T - Cooler Line Splice Kit NUMBER: 07-004-00 GROUP: Cooling DATE: Jan. 12, 2001 SUBJECT: Transaxle Cooler Line Splice Kit MODELS: DISCUSSION: A connector kit p/n 05016918AA has been released to make transaxle cooler line service easier. This kit should be installed whenever service is performed that requires cooler line removal from the transaxle. This will make the lines easy to remove and install should service be required at a later time. An instruction sheet is included with each kit that details installation procedures. PARTS REQUIRED: POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 07-004-00 > Jan > 00 > A/T - Cooler Line Splice Kit Fluid Line/Hose: All Technical Service Bulletins A/T - Cooler Line Splice Kit NUMBER: 07-004-00 GROUP: Cooling DATE: Jan. 12, 2001 SUBJECT: Transaxle Cooler Line Splice Kit MODELS: DISCUSSION: A connector kit p/n 05016918AA has been released to make transaxle cooler line service easier. This kit should be installed whenever service is performed that requires cooler line removal from the transaxle. This will make the lines easy to remove and install should service be required at a later time. An instruction sheet is included with each kit that details installation procedures. PARTS REQUIRED: POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transaxle Oil Pan Transaxle Oil Pan Bolt, Oil Pan-to-Case 19 Nm (14 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Bolt, Oil Pump-to-Case 20 ft.lb Outer Gear To Pocket 0.0018 - 0.0056 in Outer Gear Side Clearance 0.0008 - 0.0018 in Inner Gear Side Clearance 0.0008 - 0.0018 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3064 Fluid Pump: Description and Operation DESCRIPTION The oil pump is located in the pump housing inside the bell housing of the transaxle case (Fig. 264). The oil pump consists of an inner and outer gear, a housing, and a cover that also serves as the reaction shaft support. OPERATION As the torque converter rotates, the converter hub rotates the inner and outer gears. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the valve body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3065 Fluid Pump: Testing and Inspection OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that transmission fluid is at the proper level. If adding fluid is necessary, fill to the proper level with Mopar ATF +4 (Automatic Transmission Fluid-Type 9602). The following procedure is to check oil pump output volume: 1. Using hose cutters or a suitable blade, cut the "to cooler" (Fig. 265) line off flush with the cooler inlet fitting and place a collection container under the open line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Start engine and run at curb idle speed, with the shift selector in neutral. 3. If one quart of ATF is collected in 20 seconds or less, flow is within acceptable limits. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF. 4. Inspect the cooler hose for damage. Replace if necessary. 5. Re-connect the to cooler line to the transmission using a service splice kit. Refer to instructions included with the kit. 6. Refill the transaxle to proper level with Mopar ATF +4 (Automatic Transmission Fluid-Type 9602). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3066 Fluid Pump: Service and Repair DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage. 1. Remove the reaction shaft support bolts. 2. Remove reaction shaft support from pump housing (Fig. 266). 3. Remove the pump gears (Fig. 267) and check for wear and damage on pump housing and gears. 4. Re-install the gears and check clearances. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3067 5. Measure the clearance between the outer gear and the pump pocket (Fig. 268). Clearance should be 0.045 - 0.141 mm (0.0018 - 0.0056 inch). 6. Position an appropriate piece of Plastigage across both pump gears. 7. Align the Plastigage to a flat area on the reaction shaft support housing. 8. Install the reaction shaft to the pump housing. Tighten the bolts to 27 Nm (20 ft. lbs.). 9. Remove bolts and carefully separate the housings. Measure the Plastigage following the instructions supplied. 10. Clearance between outer gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Clearance between inner gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). ASSEMBLY 1. Assemble oil pump as shown in (Fig. 269) 2. Install and torque reaction shaft support-to-oil pump housing bolts to 28 Nm (20 ft. lbs.) torque. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications End Play 0.005 - 0.025 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Application and ID Shift Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Shift Indicator ....................................................................................................................................... ...................................................... VF Display Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Application and ID > Page 3075 Shift Indicator: Service and Repair REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of transmission range indicator bezel from floor console. 3. Pull upward carefully on transmission range indicator bezel and disengage tabs from rear floor console bezel. 4. Disconnect wire connector to lamp assembly. 5. Remove transmission range indicator bezel and lamp assembly from vehicle. INSTALLATION 1. Position transmission range indicator bezel and lamp assembly to vehicle. 2. Connect wire connector to lamp assembly. 3. Engage tabs on transmission range indicator bezel to slots in rear floor console bezel. 4. Push downward on transmission range indicator bezel to engage to bezel to floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation Planetary Gears: Description and Operation DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case. The planetary geartrain consists of two sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig. 270). OPERATION The planetary geartrain utilizes two planetary gear sets that connect the transmission input shaft to the output shaft. Input and holding clutches drive or lock different planetary members to change output ratio or direction. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 294). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 295). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 3082 7. Remove solenoid/pressure switch assembly and gasket (Fig. 296). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 296). 2. Install and torque three (3) bolts (Fig. 295) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 294) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3087 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3088 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3097 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3102 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3103 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3104 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3110 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3116 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3121 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3122 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3123 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3128 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3134 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3140 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3145 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3146 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3147 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3148 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3149 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3150 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Remove transaxle from vehicle. 2. Using Tool C-3981-B, remove oil pump seal (Fig. 271). INSTALLATION 1. Using Tool C-4193, install oil pump seal (Fig. 272). 2. Install transaxle to vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3161 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3162 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3166 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3167 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3168 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3169 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3173 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3176 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3177 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3178 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3181 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation Shift Interlock Cable: Description and Operation DESCRIPTION The Brake Transmission Shifter/Ignition Interlock (BTSI) is a cable and solenoid operated system that prevents the transmission gear shifter from being moved out of PARK without a driver in place. Refer to the chart that expected shifter response, depending on ignition key/switch (Fig. 273) and brake pedal positions. OPERATION The Brake Transmission Shifter/Ignition Interlock (BTSI) is engaged whenever the ignition switch is in the LOCK or ACCESSORY position (Fig. 273). An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one-half inch. A magnetic holding device integral to the interlock cable is energized when the ignition is in the ON/RUN position. When the key is in the ON/RUN position and the brake pedal is depressed, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position, unless the shifter is in the gated PARK position. The following chart describes the normal operation of the Brake Transmission Shift Interlock (BTSI) system. If the "expected response" differs from the vehicle's response, then system repair and/or adjustment is necessary. ACTION/EXPECTED RESPONSE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3186 Shift Interlock Cable: Adjustments BRAKE TRANSMISSION SHIFT INTERLOCK CABLE VERIFICATION AND ADJUSTMENT VERIFICATION The following chart describes the normal operation of the Brake Transmission Shift Interlock (BTSI) system. If the "expected response" differs from the vehicle's response, then system repair and/or adjustment is necessary. Refer to the chart that expected shifter response, depending on ignition key/switch (Fig. 284) and brake pedal positions. ACTION/EXPECTED RESPONSE ADJUSTMENT 1. Disconnect and isolate, the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3187 2. Remove the gearshift knob set screw and knob (Fig. 285). 3. Remove the gearshift bezel to gain access to the interlock cable adjuster lock (Fig. 286). 4. Re-install the gearshift knob set screw and knob (Fig. 285). 5. Place the shift lever in PARK. Move the Ignition key to the LOCK position (Fig. 284) and remove the key. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3188 6. If the interlock cable is being replaced, remove the lock pin (Fig. 287). This will allow the cable to "self adjust" to the correct position. Tighten the locking clip by pushing it down (Fig. 288). 7. If the interlock cable is not being replaced, the lock pin will not exist. Pull outward on cable locking clip to allow cable to self adjust. Press clip down to lock in place (Fig. 288). 8. Verify Brake/Transmission Shift Interlock system operation. 9. Install the gearshift bezel (Fig. 286). 10. Install the gearshift knob and tighten set screw (Fig. 285) to 2 Nm (20 inch lbs.). 11. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3189 Shift Interlock Cable: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the gearshift knob set screw and knob (Fig. 274). 3. Remove gearshift bezel (Fig. 275). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3190 4. Remove center console assembly (Fig. 276). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3191 5. Release interlock cable adjuster end, by inserting pointed object into shift bracket to disengage lock (Fig. 277). Unsnap the shifter/ignition interlock cable adjuster end from the slot in the gearshift mechanism bracket and disconnect cable core from shifter assembly (Fig. 278). 6. Remove fuse panel cover from left end of instrument panel. Remove screw, holding end of instrument panel top cover (Fig. 279). 7. Remove lower knee bolster screws and knee bolster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3192 8. Remove steering column lower shroud (Fig. 280). 9. Tilt wheel to full down position and remove upper steering column shroud. 10. Disconnect interlock solenoid connector. 11. Disconnect nylon cable retainer from lower column mounting stud. 12. Place the ignition key in the ON/RUN position (Fig. 281). Grasp the interlock cable clip and connector. Remove the cable from the interlock housing (Fig. 282). 13. Remove interlock cable from underside of instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Description and Operation > Page 3193 INSTALLATION CAUTION: When installing interlock cable assembly, care must be taken not to bend exposed cable wire and slug at shifter end of cable. 1. Route interlock cable into lower dash panel and towards console as removed. 2. Turn the ignition switch to the ON/RUN position (Fig. 281). 3. Install the interlock cable into the interlock housing at the steering column (Fig. 283). Verify the cable snaps into the housing. 4. Install nylon cable retainer to lower column mounting stud. 5. Connect BTSI solenoid connector. 6. Insert interlock cable core wire into interlock adjustment lever groove. Make sure the interlock cable slug is seated in the groove (Fig. 278). 7. Insert interlock cable adjuster end into bracket and snap into place (Fig. 278). NOTE: The Interlock Cable MUST be adjusted. 8. Install center console assembly (Fig. 276). 9. Install gearshift bezel (Fig. 274). 10. Install the gearshift knob and tighten set screw (Fig. 274) to 2 Nm (20 inch lbs.). 11. Tilt wheel to full down position and install upper steering column shroud. 12. Install steering column lower shroud (Fig. 280). 13. Install lower knee bolster screws and knee bolster 14. Install fuse panel cover (Fig. 279). 15. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Solenoid And Solenoid Valves - Overall View Solenoid And Solenoid Valve Views A - D Name Symbol Solenoid And Pressure Switch Assembly D Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair GEARSHIFT MECHANISM REMOVAL 1. Disconnect negative battery cable and isolate. 2. Remove the gearshift knob set screw and knob (Fig. 190). 3. Remove gearshift bezel (Fig. 191). Disconnect range indicator lamp connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Page 3206 4. Remove center console assembly (Fig. 192). 5. Loosen nut on shift cable adjust lever. 6. Using a flat blade pry tool, remove the shifter cable core end from the shift lever pin (Fig. 193). 7. Using a flat blade pry tool, pry the cable conduit clip up from the shifter bracket. Pull up on the cable conduit and remove from bracket (Fig. 193). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Page 3207 8. Release interlock cable adjuster end by inserting pointed object into shift bracket to disengage lock (Fig. 194). Unsnap the shifter/ignition interlock cable adjuster end from the slot in the gearshift mechanism bracket and disconnect cable core from shifter assembly (Fig. 195). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Page 3208 9. Disconnect Autostick connector (if equipped) (Fig. 196). 10. Remove the five nuts at the base of the shifter assembly. Remove assembly from vehicle (Fig. 197). INSTALLATION 1. Install shifter mechanism (Fig. 197). mechanism-to-floor pan nuts to 17 Nm (150 inch lbs.). 2. Install gearshift cable into conduit bracket and onto shift pin. Install retainer clip (Fig. 193). 3. Tighten cable adjuster nut to 23 Nm (200 inch lbs.). 4. Insert interlock cable core wire into interlock adjustment lever groove. Make sure the interlock cable slug is seated in the groove (Fig. 195). 5. Insert interlock cable adjuster end into bracket and snap into place (Fig. 195). 6. Adjust the gearshift and interlock cables. NOTE: Gearshift and Interlock cables MUST be adjusted. 7. If equipped with Autostick, connect the Autostick connector (Fig. 196). 8. Install center console assembly (Fig. 192). 9. Connect range indicator lamp and install gearshift bezel (Fig. 191). 10. Install the gearshift knob and tighten set screw (Fig. 190) to 2 Nm (20 inch lbs.). 11. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Automatic Transmission Shift Boot > Component Information > Service and Repair Automatic Transmission Shift Boot: Service and Repair SHIFT BOOT REMOVAL Fig. 25 1. Remove the shifter knob set screw and pull knob off of the shifter (Fig. 25). NOTE: Do not use a trim stick or tool to remove transmission range indicator. 2. Remove transmission range indicator bezel by squeezing the sides slightly and lifting up until the locking tabs are free of the floor console. Refer to (Fig. 25) for pressure points. Fig. 26 3. Disconnect the electrical connector, if equipped, and remove the shift boot (Fig. 26). INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Automatic Transmission Shift Boot > Component Information > Service and Repair > Page 3213 Fig. 27 1. Place shift boot into position (Fig. 27). 2. Connect transmission range indicator bezel wire connector on the underside of bezel. 3. Install transmission range indicator bezel by align alignment pins with holes in console. Apply a downward pressure until the locking tabs snap into position. Fig. 28 4. Install the shifter knob and tighten the set screw to 3 N.m (23 in.lbs.) (Fig. 28). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments GEARSHIFT LINKAGE ADJUSTMENT Normal operation of the Park/Neutral Position Switch provides a quick check to confirm proper linkage adjustment. Move the selector level slowly forward until it clicks into the (P) Park position. The starter should operate. After checking the (P) position, move selector slowly toward the (N) Neutral position until lever is in the (N) position. If the starter will also operate at this point the gearshift linkage is properly adjusted. If the starter fails to operate in either position, linkage adjustment is required. ADJUSTMENT 1. Set parking brake. 2. Remove the gearshift knob set screw and knob. 3. Remove gearshift selector bezel and lamp wiring. 4. Install the gearshift knob set screw and knob. 5. Place gearshift lever in the (P) (PARK) position. 6. Loosen the gearshift cable adjuster nut at the shifter assembly (Fig. 189). 7. Move the gearshift lever on the transaxle to the park position. 8. Verify the shift lever and transaxle are in park position. Tighten the gearshift cable adjuster nut at the shifter assembly. The gearshift linkage should now be properly adjusted. 9. Check adjustment as follows: - Detent position for neutral and drive should be within limits of hand lever gate stops. - Key start must occur only when shift lever is in park or neutral positions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3217 Shift Cable: Service and Repair GEARSHIFT CABLE REMOVAL 1. Place transaxle in PARK. 2. Disconnect battery negative cable at left strut tower. 3. Remove air cleaner assembly. 4. Using a pry tool, pry up on cable at manual valve lever and remove cable from lever (Fig. 182). 5. Remove the screw from the cable bracket at the transaxle (Fig. 182). 6. Remove the gearshift knob set screw and knob (Fig. 183). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3218 7. Remove gearshift bezel (Fig. 184). Disconnect range indicator lamp connector. 8. Remove center console assembly (Fig. 185). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3219 9. Loosen nut on shift cable adjust lever (Fig. 186). 10. Using a flat blade pry tool, remove the shifter cable core end from the shift lever pin (Fig. 187). 11. Using a flat blade pry tool, pry the cable conduit clip up from the shifter bracket. Pull up on the cable conduit and remove from bracket (Fig. 187). 12. Raise vehicle on hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 3220 13. Remove the cable grommet from the floor pan area (Fig. 188). 14. Carefully remove the cable from the underbody by unfolding the cable retainer clip (Fig. 188) as you go along. INSTALLATION 1. Install cable assy. into floor pan tunnel hole and secure grommet. If necessary, use a synthetic based lubricant to aid in grommet installation. 2. Position cable into retainer clip (Fig. 188) and tighten clip to secure cable. Route cable up towards transaxle shift lever. 3. Lower vehicle. 4. Install cable to transaxle and tighten screw to 14 Nm (125 inch lbs.) (Fig. 182). 5. Install cable to transaxle shift lever (Fig. 182). 6. Connect cable to shifter conduit bracket and shift pin. Install cable retaining clip (Fig. 187). 7. Verify transaxle shift lever and floor shifter lever are in the PARK position. 8. Tighten cable adjuster nut (Fig. 186) to 23 Nm (200 inch lbs.). 9. Install center console assembly (Fig. 185). 10. Install gearshift bezel (Fig. 184). 11. Install gearshift knob (Fig. 183) and tighten set screw to 2 Nm (20 inch lbs.). 12. Verify proper cable adjustment. Engine starter should only engage in PARK and NEUTRAL gear shifter positions. If adjustment is required, Refer to GEAR SHIFT CABLE - ADJUSTMENTS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Bolt, Torque Converter-to-Driveplate 55 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3224 Torque Converter: Description and Operation DESCRIPTION The torque converter (Fig. 304) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the fluid cooler and lines. IMPELLER Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3225 The impeller (Fig. 305) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system. TURBINE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3226 The turbine (Fig. 306) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3227 The stator assembly (Fig. 307) is mounted on a stationary shaft, which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 308). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 309) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3228 The converter impeller (Fig. 310) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member) which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 311). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter clockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3229 "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston to the front cover's friction material, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Control Module (PCM). The engagement cannot be activated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3230 Torque Converter: Service and Repair REMOVAL NOTE: If torque converter assembly is being replaced, it is necessary to restart the TCC Break-In Strategy. 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION NOTE: If torque converter is being replaced, it is necessary to restart the TCC Break-In Strategy. Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 312). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. 10. If torque converter was replaced, it is necessary to reset the TCC Break-In Strategy. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Torque Converter Clutch Break-In Torque Converter Clutch: Technical Service Bulletins A/T - 41TE/42LE Torque Converter Clutch Break-In NUMBER: 21-010-01 GROUP: Transmission DATE: Oct. 5, 2001 SUBJECT: Torque Converter Clutch Break-In OVERVIEW: This bulletin describes the elimination of the torque converter clutch break-in feature. MODELS: 2001 - 2002 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2002 (LH) Concorde/Intrepid/LHS/300M DISCUSSION: 41TE/42LE transaxles are equipped with a torque converter clutch break-in feature that allows some slippage in the clutch when the converter is new. This feature prevents clutch shudder while the clutch material goes through the break-in cycle. A clutch burnishing procedure has been added to the manufacturing process of the torque converter making clutch break-in unnecessary. The clutch break-in feature has been turned off at the affected vehicle assembly plants. It will no longer be necessary to turn the clutch break-in feature on following a transaxle repair requiring a torque converter replacement. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair Torque Converter Cover: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 87). 3. Remove collar (Fig. 87). INSTALLATION CAUTION: The collar must be tightened using this service procedure, as damage to transaxle case and/or oil pan may occur. 1. Position structural collar (Fig. 87) on oil pan and transaxle. 2. Loosely install all bolts. 3. Tighten the collar to oil pan bolts to 55 Nm (40 ft. lbs.). 4. Tighten collar to transaxle bolts to 55 Nm (40 ft. lbs.). 5. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3246 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3251 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3252 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3253 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3259 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3265 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3270 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3271 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3272 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3277 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3283 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3289 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3294 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3295 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3296 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3297 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3298 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3299 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications Transmission Cooler: Mechanical Specifications Fitting, Oil Cooler Line 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 3304 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3305 Transmission Cooler: Description and Operation DESCRIPTION An external oil-to-air type automatic transmission oil cooler is mounted to the front of the radiator and is integral to the A/C condenser (Fig. 1). The six upper tubes are used for transaxle oil cooling, and the remaining tubes below are for the A/C system. The cooler uses tubes and rubber hoses to feed oil to and from the automatic transaxle. The replaceable inlet and outlet tubes use an O-ring for sealing. The bans oil cooler is replaced with the A/C condenser. OPERATION The oil flows from the transmission to the oil-to-air cooler. Heat is then transferred into the air. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3306 Transmission Cooler: Testing and Inspection TRANSMISSION OIL COOLER FLOW To determine whether the transmission oil has proper flow through the oil cooler, perform the following procedure: 1. Disconnect the "from cooler" line that connects to the transaxle. 2. Using Special Tool adaptors 6906-1-2 with a 5/16 in. transmission hose attached to one adaptor, connect Special Tool 8392 flow meter in-series with the oil cooler flow circuit (Fig. 2). 3. Start engine and observe the flow meter gauge. Refer to the following chart for specifications. 4. If oil flow is below minimum specifications, further diagnosis must be performed. a. Perform Oil Pump Volume Check. b. If oil pump volume is within specification, a possible restriction in the cooler lines or cooler has occurred. c. If oil pump volume is not within specification, possible internal transmission restrictions, component wear or damage has occurred. d. If an oil cooler restriction is suspected, perform further inspections and flow meter testing by isolating components (i.e. lines, coolers). e. After a restriction is isolated, perform cooler flush procedure. f. Re-test cooler flow. If cooler flow does not meet minimum specification, replace component(s) as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3307 Transmission Cooler: Service and Repair REMOVAL 1. Remove AC condenser. CLEANING Check the AC condenser for debris on the cooling fin surfaces. Clean as necessary. INSPECTION Inspect all hoses, tubes, clamps and connections for leaks, cracks, or damage. Replace as necessary. Use only approved transmission oil cooler hoses that are molded to fit the space available. INSTALLATION 1. Install AC condenser. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 3311 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 3312 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3316 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3317 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3318 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3319 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3326 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3329 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3330 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3331 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3334 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Solenoid Body Valve Body: Specifications Bolt, Solenoid/Pressure Switch Assy.-to-Case 110 in.lb Screw, Solenoid/Pressure Switch Assy. Connector 35 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Solenoid Body > Page 3339 Valve Body: Specifications Screw, Valve Body-to-Transfer Plate 45 in.lb Bolt, Valve Body-to-Case 105 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body Valve Body: Description and Operation Valve Body DESCRIPTION The valve body assembly consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, solenoid/pressure switch assembly, and frictional clutches. The valve body contains the following components (Fig. 317): Regulator valve - Solenoid switch valve - Manual valve - Converter clutch switch valve - Converter clutch control valve - Torque converter regulator valve - Low/Reverse switch valve In addition, the valve body also contains the thermal valve, #2,3&4 check balls, the #5 (overdrive) check valve and the 2/4 accumulator assembly. OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body > Page 3342 regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body > Page 3343 Valve Body: Description and Operation Solenoid Body SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 290) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body > Page 3344 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body Valve Body: Service and Repair Valve Body Removal REMOVAL NOTE: If valve body is replaced or reconditioned, the TCM Quick Learn Procedure must be performed. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect gearshift cable from manual valve lever. 4. Remove manual valve lever from manual shaft. 5. Disconnect transmission range sensor (TRS). 6. Raise vehicle on hoist. 7. Remove oil pan bolts (Fig. 318). 8. Remove oil pan (Fig. 319). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3347 9. Remove oil filter (Fig. 320). 10. Remove the valve body-to-transaxle case bolts (Fig. 321). NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise to low or first gear. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3348 11. Remove park rod rollers from guide bracket and remove valve body from transaxle (Fig. 322) (Fig. 323). CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. Disassembly DISASSEMBLY NOTE: If valve body assembly is being reconditioned, the TCM Quick Learn Procedure must be performed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3349 1. Remove manual shaft seal (Fig. 324). 2. Remove Transmission Range Sensor retaining screw (Fig. 325). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3350 3. Remove Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 326). 4. Remove 2/4 Accumulator Retaining Plate (Fig. 327). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3351 5. Remove 2/4 Accumulator components as shown in (Fig. 328). 6. Remove Valve Body to Transfer Plate screws (Fig. 329). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3352 7. Invert assembly and remove Transfer Plate (Fig. 330). Beware of loose check balls. 8. Remove oil screen (Fig. 331). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3353 9. Remove the overdrive clutch (#5) check valve (Fig. 332) 10. Remove separator plate (Fig. 333). 11. Remove thermal valve (Fig. 334). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3354 12. Remove check balls (Fig. 335). NOTE: Tag all valve/spring assemblies for reassembly identification. 13. Remove dual retainer plate using Tool 6301 (Fig. 336). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3355 14. Remove regulator valve spring retainer (Fig. 337). 15. Remove remaining retainers as shown in (Fig. 338). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3356 16. Remove valves and springs as shown in (Fig. 339). NOTE: Refer to Valve Body Cleaning and Inspection for cleaning procedures. Assembly ASSEMBLY NOTE: If valve body assembly is reconditioned, the TCM Quick Learn Procedure must be performed. 1. Install valves and springs as shown in (Fig. 339). 2. Install regulator valve spring retainer (Fig. 340). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3357 3. Install dual retainer plate using Tool 6301 (Fig. 341). 4. Verify that all retainers are installed as shown in (Fig. 342). Retainers should be flush or below valve body surface. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3358 5. Install check balls into position as shown in (Fig. 343). If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. 6. Install thermal valve into transfer plate (Fig. 344). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3359 7. Install separator plate to valve body (Fig. 345). 8. Install the overdrive clutch (#5) check valve to separator plate (Fig. 346) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3360 9. Install oil screen to separator plate (Fig. 347). 10. Install transfer plate to valve body and separator plate. Make sure oil screen and #6 check valve do not bind (Fig. 348). 11. Install twenty-four transfer plate to valve body screws (Fig. 349) and torque to 5 Nm (45 inch lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3361 12. Install 2/4 Accumulator components as shown in (Fig. 350). 13. Torque 2/4 Accumulator retainer to 5 Nm (45 inch lbs.) (Fig. 351). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3362 14. Install Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 352). 15. Make sure Manual Valve control pin is contained within the rooster comb slot (Fig. 353). Install Transmission Range Sensor retaining screw (Fig. 353) and torque to 5 Nm (45 inch lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3363 16. Install manual shaft seal (Fig. 354). Installation INSTALLATION NOTE: If valve body assembly is being replaced or reconditioned, it is necessary to perform the TCM Quick Learn Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3364 1. Install valve body assembly to transaxle (Fig. 355). Install and torque valve body-to-transaxle case bolts (Fig. 356) to 12 Nm (105 inch lbs.). 2. Install transaxle oil filter (Fig. 357). Inspect the O-ring and replace if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3365 3. Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry. Install a 1/8 inch bead of Mopar Silicone Rubber Adhesive Sealant to the oil pan and install (Fig. 358). Torque oil pan-to-transaxle case bolts (Fig. 359) to 19 Nm (165 inch lbs.). 4. Lower vehicle. 5. Connect transmission range sensor connector. 6. Install manual valve lever to manual shaft. 7. Install gearshift cable to manual valve lever. 8. Connect battery negative cable. 9. Fill transaxle with Mopar ATF +4 Transmission fluid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3366 Valve Body: Service and Repair Solenoid/Pressure Switch Assembly REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 291). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 292). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Valve Body > Page 3367 7. Remove solenoid/pressure switch assembly and gasket (Fig. 293). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 293). 2. Install and torque three (3) bolts (Fig. 292) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 291) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Nut, Ball Joint-to-Knuckle 70 ft.lb Nut, Halfshaft-to-Hub/Bearing 110 ft.lb Nut, Tie Rod-to-Knuckle 41 ft.lb Nut, Wheel-to-Hub 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3373 Axle Shaft: Description and Operation HALF SHAFT DESCRIPTION This vehicle is equipped with an unequal length halfshaft system (Fig. 1). These halfshafts consist of two constant velocity joints connected by a solid shaft. A solid short interconnecting shaft is used on the left side. A long solid interconnecting shaft is used on the right side. Both halfshafts use a tuned rubber damper weight. When replacing a halfshaft assembly, be sure the replacement halfshaft has the same damper weight as the original. Both halfshaft assemblies use the same type of inner and outer joints. The inner joint of both halfshaft assemblies is a tripod joint, and the outer joint of both halfshaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true constant velocity (C/V) joint assemblies. The inner tripod joint allows for the changes in halfshaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both halfshafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut. OPERATION Halfshaft assemblies are designed to transmit power from the transaxle to the front wheels, while allowing for powertrain and suspension flex. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3374 Axle Shaft: Testing and Inspection HALFSHAFT DIAGNOSIS VEHICLE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the halfshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the halfshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the halfshaft assembly. 3. A damaged or worn halfshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: 1. A worn or damaged halfshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3375 Axle Shaft: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove front tire and wheel assembly. 3. Remove caliper adapter-to-knuckle bolts. 4. Remove caliper/adapter assembly and support with mechanic's wire or equivalent (Fig. 2). Do not support assembly by the flexible brake hose. 5. Remove the brake rotor (Fig. 3). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3376 6. Remove the tie rod-to-steering knuckle nut (Fig. 4). Remove nut from tie rod end by holding tie rod end stud with a 11/32 socket and loosen and remove nut (Fig. 4). 7. Separate tie rod end from steering knuckle arm, using Tool MB-991113 (Fig. 5). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3377 8. Remove the halfshaft-to-hub and bearing retaining nut (Fig. 6). 9. Remove cotter pin and castle nut (Fig. 7) from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 10. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3378 10. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike steering knuckle boss until steering knuckle separates from stud of lower ball joint (Fig. 8). When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint. Driveshaft must be supported. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3379 11. Separate halfshaft from steering knuckle (Fig. 9). If difficulty is encountered separating halfshaft from knuckle, DO NOT strike halfshaft with a hammer to break free. Install Puller 1026 (Fig. 10) as shown in to press shaft out of hub/bearing assembly. CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be used to ensure no damage occurs to oil seal in transaxle case. 12. Support the outer end of the halfshaft assembly. Insert a pry bar between inner tripod joint and transaxle case (Fig. 11). Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3380 13. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig. 12). When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. INSTALLATION 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand (Fig. 12). 3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap wing is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle. 5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly (Fig. 13). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3381 6. Slide halfshaft back into front hub (Fig. 14). Then install steering knuckle onto the lower control arm ball joint stud. 7. Install the steering knuckle to ball joint stud castle nut (Fig. 15). Tighten the castle nut to 95 Nm (70 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3382 8. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary (Fig. 16), tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten the nut to 55 Nm (41 ft. lbs.)(Fig. 17). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3383 9. Install brake rotor to hub (Fig. 18). 10. Install caliper/adapter bracket assembly on steering knuckle. Install and torque caliper adapter-to-knuckle bolts to 88 Nm (65 ft. lbs.). 11. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of halfshaft (Fig. 19). With vehicle brakes Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3384 applied to keep braking disc from turning, tighten hub nut to 150 Nm (110 ft. lbs.) (Fig. 20). 12. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct sequence (Fig. 21). Tighten lug nuts to 135 Nm (100 ft. lbs.). 13. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3385 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Constant Velocity Joint Boot: Service and Repair Inner CV BOOT - INNER REMOVAL 1. Remove large boot clamp, which retains inner tripod joint sealing boot to tripod joint housing and discard. Remove small clamp, which retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider bunions to prevent the bearings from falling away. 2. Slide the tripod joint housing off the spider assembly and the interconnecting shaft (Fig. 22). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3390 3. Remove snap ring, which retains spider assembly to interconnecting shaft (Fig. 23). Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (Fig. 24). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft 4. Slide sealing boot off interconnecting shaft. 5. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. INSTALLATION 1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft (Fig. 25). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3391 2. Install spider assembly onto interconnecting shaft (Fig. 26). Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (Fig. 27). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3392 3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft (Fig. 28). Be sure the snap ring is fully seated into groove on interconnecting shaft. 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 29). 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3393 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp (Fig. 30). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 31). CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected. CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3394 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly (Fig. 32). When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and finally against the tripod housing. If this is not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the hard plastic sealing boot and soft rubber insert. 10. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure. 11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A. - Place crimping tool C-4975-A over bridge of clamp (Fig. 33) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3395 - Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 34). LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an equivalent. - Place prongs of clamp locking tool in the holes of the clamp (Fig. 35). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3396 - Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 36). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3397 Constant Velocity Joint Boot: Service and Repair Outer CV BOOT - OUTER REMOVAL 1. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing (Fig. 37) and discard. Remove small clamp that retains outer C/V joint sealing boot to interconnecting shaft and discard. Remove sealing boot from outer C/V joint housing and slide it down interconnecting shaft. 2. Wipe away grease to expose outer C/V joint and interconnecting shaft. 3. Remove outer C/V joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft faced hammer, sharply hit the end of the C/V joint housing to dislodge housing from internal circlip on interconnecting shaft (Fig. 38). Then slide outer C/V joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft faced hammer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3398 4. Remove large circlip (Fig. 39) from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. 5. Slide failed sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. INSTALLATION 1. Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft (Fig. 40). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. 2. Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3399 3. Install outer C/V joint assembly onto interconnecting shaft by using a soft faced hammer and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft (Fig. 41). 4. Outer C/V joint assembly must be installed on interconnecting shaft until cross of outer C/V joint assembly is seated against circlip on interconnecting shaft (Fig. 42). 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot. 6. Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3400 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp (Fig. 43). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 44). CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer C/V joint retaining clamp evenly on sealing boot. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner > Page 3401 9. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4976-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp (Fig. 45). Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 46). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Hub Nut 150 ft.lb Wheel Stud Lug Nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 3406 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB / BEARING - FRONT DESCRIPTION The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The hub and bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub and bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective. 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. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front > Page 3409 Wheel Bearing: Description and Operation Rear HUB / BEARING - REAR DESCRIPTION The hub and bearing is a combined rear wheel hub and wheel bearing unit. All vehicles are equipped with permanently lubricated and sealed for life rear hub and bearing assemblies. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing is mounted to the rear knuckle's spindle using a retaining nut. The tire and wheel assembly, and rear brake drum or disc attaches to the studs protruding from the hub flange with wheel mounting studs. OPERATION The hub and bearing has internal bearings that allow it to rotate with the tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING - FRONT The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 3412 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING - REAR The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT SUSPENSION REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 12 5. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a socket while loosening and removing nut with wrench. Fig. 13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3415 6. Remove the tie rod end from the steering knuckle arm, using Remover, Special Tool MB-991113. Fig. 14 7. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Fig. 15 8. Remove cotter pin and castle nut from the stud of the lower ball joint. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 9 below. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3416 Fig. 16 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 17 11. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3417 Fig. 18 12. Remove the cotter pin and nutfrom the upper ball joint stud to steering knuckle attachment. Fig. 19 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C3894-A. 14. Remove steering knuckle from vehicle. 15. Mount steering knuckle securely in a vise. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3418 Fig. 20 16. Remove the 3 boltsattaching the hub/bearing assembly to the steering knuckle. 17. Remove the hub and bearing assembly out from the front of the steering knuckle. NOTE: If bearing will not come out of steering knuckle, it can be tapped out using a soft faced hammer. INSTALLATION 1. Thoroughly clean all hub and bearing assembly mounting surfaces on steering knuckle. 2. Install the replacement hub and bearing assembly in steering knuckle aligning bolt boles in bearing flange with holes in steering knuckle. 3. Install the 3 mounting boltsand tighten evenly to ensure bearing is square to face of steering knuckle. The tighten the 3 mounting boltsto a torque of 110 Nm (80 ft. lbs.). 4. Slide drive shaft back into front hub and bearing assembly. 5. Install the steering knuckle on the lower control arm ball joint. 6. Install the steering knuckle to lower ball joint castle nut. 7. Install upper ball joint stud in steering knuckle. 8. Install the steering knuckle to upper ball joint stud castle nut. 9. Using a crow foot and torque wrench, tighten the upper and lower ball joint castle nuts to the following torque specifications. - Lower ball joint castle nut 74 Nm (56 ft. lbs.). - Upper ball joint castle nut 62 Nm (45 ft. lbs.). 10. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3419 Fig. 21 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 11. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding the stud of the tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 12. Install brake rotor, and caliper, shoes and adapter assembly. 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto the driveshaft stub axle. 14. With vehicle brakes applied to keep stub axle from turning, tighten hub nut to a torque of 203 Nm (150 ft. lbs.) of torque. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Tighten nuts to a torque of 135 Nm (100 ft. lbs.). 16. Lower vehicle. 17. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3420 Wheel Bearing: Service and Repair Rear REAR SUSPENSION REMOVAL - HUB AND BEARING 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the rear brake caliper and rotor. Remove the brake rotor by pulling the rotor straight off the wheel mounting studs. 4. Remove dust cap from rear hub and bearing assembly by prying it off. 5. Remove hub and bearing retaining nut. 6. Remove rear hub and bearing from the spindle by pulling it straight off the spindle by hand. INSTALLATION - HUB AND BEARING 1. Install the hub and bearing assembly on the knuckle spindle. Install a NEW retaining nut. Tighten the retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install the hub and bearing dust cap using a soft faced hammer. 3. Install the brake rotor on the hub and bearing. 4. Install the disc brake caliper. 5. Install the rear tire and wheel assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half the specified torque. Repeat pattern, fully tightening the stud nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flex Plate Torque Flex Plate Torque Bolt, Driveplate-to-Crankshaft 95 Nm (70 ft. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID Shift Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Shift Indicator ....................................................................................................................................... ...................................................... VF Display Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID > Page 3429 Shift Indicator: Service and Repair REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of transmission range indicator bezel from floor console. 3. Pull upward carefully on transmission range indicator bezel and disengage tabs from rear floor console bezel. 4. Disconnect wire connector to lamp assembly. 5. Remove transmission range indicator bezel and lamp assembly from vehicle. INSTALLATION 1. Position transmission range indicator bezel and lamp assembly to vehicle. 2. Connect wire connector to lamp assembly. 3. Engage tabs on transmission range indicator bezel to slots in rear floor console bezel. 4. Push downward on transmission range indicator bezel to engage to bezel to floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3435 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3436 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3445 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3450 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3451 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3452 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3458 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3464 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3469 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3470 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3471 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3476 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3482 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3488 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3493 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3494 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3495 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3496 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3497 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3498 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3507 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3508 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3512 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3513 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3514 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3515 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3519 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3522 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3523 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3524 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3527 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 294). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 295). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 3534 7. Remove solenoid/pressure switch assembly and gasket (Fig. 296). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 296). 2. Install and torque three (3) bolts (Fig. 295) to 13 Nm (110 in. lbs.). 3. Install input speed sensor (Fig. 294) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 in. lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Brake Transmission Shift Interlock Solenoid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Solenoid And Solenoid Valves - Overall View Solenoid And Solenoid Valve Views A - D Name Symbol Solenoid And Pressure Switch Assembly D Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID Shift Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Shift Indicator ....................................................................................................................................... ...................................................... VF Display Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Application and ID > Page 3546 Shift Indicator: Service and Repair REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of transmission range indicator bezel from floor console. 3. Pull upward carefully on transmission range indicator bezel and disengage tabs from rear floor console bezel. 4. Disconnect wire connector to lamp assembly. 5. Remove transmission range indicator bezel and lamp assembly from vehicle. INSTALLATION 1. Position transmission range indicator bezel and lamp assembly to vehicle. 2. Connect wire connector to lamp assembly. 3. Engage tabs on transmission range indicator bezel to slots in rear floor console bezel. 4. Push downward on transmission range indicator bezel to engage to bezel to floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3552 Control Module: Diagrams Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 3553 Transmission Control Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: Recalls Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3562 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3567 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3568 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Recalls: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3569 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: Customer Interest A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3575 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3581 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3586 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3587 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3588 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3593 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set Transmission Control System Relay: All Technical Service Bulletins A/T - MIL ON DTC P1767 Set NUMBER: 18-003-01 GROUP: Vehicle Performance DATE: Feb. 2, 2001 SUBJECT: Transmission MIL DTC P1767 - TRANSMISSION OUTPUT RELAY ALWAYS ON NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DECEMBER 6, 2000 (MDH 1206XX). OVERVIEW: This bulletin involves inspecting and if necessary replacing the transmission control relay. MODELS: 2001 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Customer complaining about transmission defaulting into limp-in; not shifting. The transmission is in limp-in (default to second gear) after starting, especially the first start after the vehicle has been parked in cold weather (35° F. or colder) and MIL light illuminated with DTC P1767 TRANSMISSION OUTPUT RELAY ALWAYS ON. DIAGNOSIS/REPAIR PROCEDURES: If transmission DTC P1767 is present inspect the transmission relay part number. If the part number is 04868244AA, perform the Repair Procedure. If the relay is any other part number, additional diagnosis is required; this bulletin does not apply. PARTS REQUIRED: Qty. Part No. Description 1 04671168 Relay, Auto Trans EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Open hood and remove the Power Distribution Center (PDC) cover. 2. Locate the transmission (ETAX) relay as indicated on the inside of the cover. NOTE: DO NOT MOVE RELAYS FROM ONE POSITION TO ANOTHER FOR TESTING PURPOSES, THIS WILL NOT FIX THE CONDITION. 3. Replace the transmission relay with p/n 04671168 4. Install the PDC cover. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-58-90 Transmission Relay - Replace 0.2 Hrs. FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 18-003-01 > Feb > 01 > A/T - MIL ON DTC P1767 Set > Page 3599 P8 New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement Transmission Control System Relay: All Technical Service Bulletins Campaign - EATX Relay Replacement March 2001 Dealer Service Instructions for: Customer Satisfaction Notification No. 974 Transmission Control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action 401-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923) IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC) 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay. 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance as shown: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 947 > Mar > 01 > Campaign - EATX Relay Replacement > Page 3605 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN, sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All Involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD974". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the preaddressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-0085 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement Technical Service Bulletin # 974 Date: 010301 Campaign - A/T Control Relay Replacement March 2001 Customer Satisfaction Notification No. 974 Transmission control (EATX) Relay Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Service Action # 01-001 and Technical Service Bulletin # 18-03-01 are being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2001 (JR) Chrysler Sebring Sedan and Dodge Stratus Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with an automatic transmission (Sales Code - DGL) built through November 29, 2000 (MDH 112923). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The transmission control (EATX) relay on about 16,800 of the above vehicles may not operate properly in cold temperatures. This may cause the transmission to stay in second gear and turn on the "Check Engine" light. Repair The transmission control relay must be replaced. Parts Information Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Control Relays, P/N 04671168, to service about 25% of those vehicles. Service Procedure 1. Remove the cover from the Power Distribution Center (PDC). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3610 2. Locate the transmission control (EATX) relay in the PDC and then remove and discard the relay (Figure 1). 3. Install the provided transmission control relay. 4. Install the PDC cover. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace transmission control relay 08-97-41-82 0.2 hours Add the cost of the relay plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD974". Owner Notification and Service Scheduling Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3611 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Control System Relay: > 974 > Mar > 01 > Campaign - A/T Control Relay Replacement > Page 3612 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3613 Transmission Control System Relay: Locations Power Distribution Center (PDC) Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3614 Transmission Control System Relay: Diagrams Power Distribution Center (PDC) Transmission Control Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Technical Service Bulletins > Page 3615 Transmission Control System Relay: Description and Operation TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 313) is located in the Power Distribution Center (PDC), which is located on the left side of the engine compartment. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Diagrams Clutch Interlock/Upstop Switch (JR-41) (MTX) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3624 Autostick Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3625 Transmission Mode Switch: Description and Operation AUTOSTICK SWITCH DESCRIPTION Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability of an automatic transaxle. OPERATION When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift and moving to the right (towards the passenger)causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd, or 3rd gear while in the Autostick mode. The speed control is operable in 3rd and 4th gear Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. AUTOMATIC OVERRIDES For safety, durability, and driveability, some shifts are executed automatically or prevented. AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS MANUAL SHIFTS ARE NOT PERMITTED UNDER THE FOLLOWING CONDITIONS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Sensor, Transmission Range Sensor 45 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3629 Transmission Range Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3630 Transmission Position Switch/Sensor: Description and Operation TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 314). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 315). OPERATION The Transmission Range Sensor (TRS) (Fig. 314) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3631 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 315) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3632 Transmission Position Switch/Sensor: Service and Repair TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 316). 3. Remove TRS from manual shaft. INSTALLATION 1. Install transmission range sensor (TRS) to the valve body and torque retaining screw (Fig. 316) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor, Input Speed 20 ft.lb Sensor, Output Speed 20 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 3636 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Input Speed Sensor Output Speed Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case (Fig. 294), sealed with an O-ring (Fig. 295), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3639 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 296), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The TCM compares the input speed signal with output speed signal to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3640 Transmission Speed Sensor: Description and Operation Output Speed Sensor SPEED SENSOR OUTPUT DESCRIPTION The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case (Fig. 299), sealed with an O-ring (Fig. 300), and is considered a primary input to the Transmission Control Module (TCM). OPERATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 3641 The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil (Fig. 301), an AC voltage is generated and sent to the TCM. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor. The TCM converts this signal into a pulse per mile signal and sends it to the PCM. The PCM, in turn, sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. If necessary, disconnect and cap off transmission oil cooler lines. 3. Disconnect input speed sensor connector. 4. Unscrew and remove input speed sensor (Fig. 297). 5. Inspect speed sensor O-ring (Fig. 298) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position. 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 3644 Transmission Speed Sensor: Service and Repair Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector. 4. Unscrew and remove output speed sensor (Fig. 302). 5. Inspect speed sensor O-ring (Fig. 303) and replace if necessary. INSTALLATION 1. Verify O-ring is installed into position (Fig. 303). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3653 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3654 Electronic Brake Control Module: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Anti-Lock Brake ................................................................................................................................... .............................................................. PC161 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3655 Electronic Brake Control Module: Description and Operation Fig.1 Integrated Control Unit (Typical) CONTROLLER ANTILOCK BRAKE The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the Integrated Control Unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRB III scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. when a fault is detected, the amber ABS warning indicator lamp is turned ON and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB III scan tool. If not cleared with a DRB III scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Cab Inputs - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Diagnostic communication (PCI) Cab Outputs - Amber ABS warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Diagnostic communication (PCI, via BUS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3656 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) 3. Pull up on the CAB connector lock and disconnect the 2-way electrical connector and the pump/motor connector from the CAB. 4. Remove the bolts securing the integrated control unit's (ICU's) mounting bracket to the lower radiator support. 5. Carefully move the ICU toward the right side of the car. Move the ICU far enough to access the CAB mounting screws. Be careful not to bend the brake tubes connected to the ICU. 6. Remove the screws securing the CAB to the HCU. Remove the CAB. INSTALLATION 1. Install screws to secure the CAB to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.) torque. 2. Remount the ICU mounting bracket to the lower radiator support. Tighten the mounting bolts to 28 Nm (21 ft. lbs.) torque. 3. Reconnect the 24-way electrical and the pump/motor connector. 4. Lower vehicle. 5. Connect negative battery cable. 6. Connect a DRB III to the vehicle and initialize the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS ICU Mounting Bolts To Bracket 97 in.lb Mounting Bracket-To- Lower Radiator Support Bolts 21 ft.lb ABS CAB To-HCU Mounting Screws 17 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 3660 Hydraulic Control Assembly - Antilock Brakes: Description and Operation DESCRIPTION The Hydraulic Control Unit (HCU) and the Controller Antilock Brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU is located below the air cleaner housing on the lower radiator support. The ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any individual components of the HCU or CAB. For information on the CAB. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ CONTROLLER ANTILOCK BRAKE (CAB) ^ HYDRAULIC CONTROL UNIT (HCU) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL - ICU 1. Remove the remote ground cable from the ground stud on the left strut tower. 2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud. This will prevent accidental grounding of the remote ground cable. Brake Pedal Holding Tool Installed 3. Using a brake pedal positioning tool, depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir. 4. Remove the air cleaner housing. 5. Clean any debris away from the fittings on top of the ICU. 6. Remove the two brake tubes coming from the primary and secondary master cylinder ports at the ICU. 7. Remove the four chassis brake tubes going to each brake, mounted in-line across the top of the junction block. 8. Disconnect the 24-way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 24-way connector and pull it up from the connector as far as possible. This will unlock and raise the connector out of the socket on the CAB. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3663 9. Remove the three bolts fastening the ICU to its mounting bracket. Remove the ICU from the vehicle. 10. To separate the HCU from the CAB. INSTALLATION - ICU 1. Install the ICU back in the vehicle on its mounting bracket. 2. Install isolators, washers and attaching bolts, mounting the ICU to its mounting bracket. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: Before installing the 24-way connector in the CAB be sure that the seal is properly installed in the connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3664 3. Install the 24-way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 24-way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the connector into the socket on the CAB and lock it in the installed position. 4. Install the four chassis brake tubes (going to each brake) to the top of the ICU. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 5. Install the two brake tubes coming from the primary and secondary master cylinder ports to the top corners of the ICU. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 6. Install the air cleaner housing.. 7. Remove the brake pedal holding tool. 8. Install the remote. ground cable onto the ground stud located on left shock tower. 9. Bleed the base brakes and the ABS brakes hydraulic system. 10. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3665 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly DISASSEMBLY - ICU 1. Remove the ICU from the vehicle. 2. Disconnect the pump/motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3666 4. Remove the CAB from the HCU. ASSEMBLY - ICU 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle and bleed the base and ABS hydraulic systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications ABS Wheel Speed Sensor Mounting Bolt 75 ft.lb Front Sensor 0.017 - 0.067 in Rear Sensor 0.015 - 0.052 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3672 Wheel Speed Sensor: Connector Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3673 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Left Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3674 Right Wheel Front Speed Sensor Right Wheel Front Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3675 Wheel Speed Sensor: Testing and Inspection INSPECTION - TONE WHEEL Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ Wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the tone wheel is incorporated into the hub and bearing assembly and the hub and bearing must be replaced. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL This procedure is for the removal and installation of one of the two front wheel speed sensors. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Vehicle Lifting for the required lifting procedure to be used for this vehicle. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3678 5. Remove bolt attaching speed sensor to steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly. Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. INSTALLATION This procedure is for the removal and installation of one of the two front wheel speed sensors. CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3679 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3680 CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber as shown. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3681 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Fold down rear seat back. 2. Disconnect speed sensor connector at vehicle wiring harness found at lower outside comer of seat back 3. Raise vehicle. 4. Remove rear tire and wheel assembly from vehicle. 5. Remove speed sensor harness sealing grommet retainer from the rear frame rail of the vehicle. 6. Remove speed sensor harness sealing grommet and harness from hole in body of vehicle. 7. Remove speed sensor routing clips from the rear upper control arm. 8. Remove bolt, then wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor harness is critical to continued system operation. Be sure that harness is installed properly to avoid harness contact with moving parts or overextension, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3682 1. Install speed sensor head into brake adapter. Install bolt through routing clip and secure wheel speed sensor in place. Tighten bolt to 8 Nm (75 inch lbs.) 2. Install speed sensor harness routing clip on upper control arm. Install and securely tighten the routing clip attaching bolt. 3. Install connector end of speed sensor harness through hole at frame rail. 4. Install speed sensor harness sealing grommet into hole. Install the sealing grommet retainer and attaching bolt. Securely tighten retainer attaching bolt. 5. Install the tire and wheel assembly on vehicle. 6. Lower vehicle. 7. Connect speed sensor harness connector to vehicle wiring harness behind rear seat back. Install sleeve back over the speed sensor harness connection to prevent rattling. 8. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise using only the mounting flange. 2. Thread Bleeding Tubes, Special Tool 8358, into master cylinder primary and secondary ports. Position outlet ends of bleeding tubes in reservoir with the outlets below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with Mopar(R) brake fluid or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap on master cylinder fluid reservoir. 8. Install master cylinder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3687 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system. CAUTION: ^ Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. ^ Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3688 Use bleeder tank, Special Tool C-3496-B or equivalent, with master cylinder reservoir adapter, Special Tool 8224, to pressurize the hydraulic system for bleeding. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 3. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat this procedure at all the remaining bleeder screws. 5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 6. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3689 Brake Bleeding: Service and Repair Antilock Brake System ANTILOCK BRAKE SYSTEM BLEEDING STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII(R) scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Application and ID Brake Warning Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Brake Warning ..................................................................................................................................... .............................................................. PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Application and ID > Page 3693 Brake Warning Indicator: Service and Repair CLUSTER ILLUMINATION AND WARNING LAMPS REPLACEMENT REMOVAL 1. Remove the Instrument Cluster. 2. Turn over cluster and expose the illumination bulbs or warning indicator bulbs/socketed LEDs by removing the cluster cardboard back cover. For accurate identification of the defective bulb or LED, see the labels on the PC board. 3. After Identifying the defective bulb or LED, twist it out of the cluster using a counterclockwise motion. INSTALLATION 1. Install the new bulb/LED socket into the cluster using a clockwise motion. 2. Install the cluster cardboard back cover. 3. Install the Instrument Cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Guide Pin Bolts 26 ft.lb Bleeder Screw 125 in.lb Adapter Mounting Bolts 60 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front REMOVAL - FRONT DISC BRAKE CALIPER 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove front wheel and tire assembly. 4. Remove the anti-rattle spring from the outboard side of the caliper and adapter. 5. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 6. Remove the two caps in place over the caliper guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3700 7. Remove the two caliper guide pin bolts. 8. Remove caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed. INSTALLATION - FRONT DISC BRAKE CALIPER 1. Completely retract the caliper piston back into piston bore of the caliper. 2. Lubricate both caliper adapter abutments where the shoes slide with a sufficient amount of Mopar(R) Dielectric Grease, or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3701 NOTE: If shoes are being transferred or newly installed, make note that the inboard brake shoes are stamped L or R for left or right side of the vehicle. The P-slot or void on piston insulator must be positioned upward when brake caliper is mounted. CAUTION: Use care when installing the brake caliper assembly onto the adapter, so that the seals on the caliper guide pin bushings do not get damaged by the adapter bosses. 3. Carefully position the brake caliper (with inboard shoe) over the brake rotor, outboard shoe and adapter. For proper positioning of shoes when installing caliper. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3702 4. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 5. Install the caps over the ends of the guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3703 6. Install the anti-rattle spring on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers. 7. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 35 Nm (26 ft. lbs.). 8. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Remove the brake pedal depressor (holding) tool. 11. Bleed the hydraulic brake circuit to the brake caliper. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Rear REMOVAL - REAR DISC BRAKE CALIPER 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise vehicle. 3. Remove rear wheel and tire from vehicle. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. Caliper Assembly Guide Pin Bolts 5. Remove the 2 guide pin bolts mounting the caliper to the adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3704 Caliper Removal/Installation 6. Remove caliper from adapter and rotor by first rotating top of caliper away from the adapter, then lifting the caliper off lower machined abutment on adapter. INSTALLATION - REAR DISC BRAKE CALIPER 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar(R) Multipurpose Lubricant, or equivalent. 3. If removed, install the rotor on the hub making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3705 Caliper Removal/Installation 4. Carefully lower caliper and brake shoes over rotor reversing the removal procedure. Make sure that the caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. Caliper Assembly Guide Pin Bolts 5. Install the caliper guide pin bolts. Tighten the caliper guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 35 Nm (26 ft. lbs.). 7. Install wheels and tire assembly. 8. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 9. Lower vehicle. 10. Remove the brake pedal depressor (holding) tool. 11. Bleed the hydraulic brake circuit to the brake caliper. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3706 Brake Caliper: Service and Repair Disassembly and Assembly Front Disc Brake Caliper DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: ^ Before disassembling the brake caliper, clean and inspect it. ^ The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES found, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper In vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3707 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore . Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar(R) Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3708 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary. 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. Rear Disc Brake Caliper DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3709 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: ^ Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING or INSPECTION. ^ The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3710 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar(R) Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3711 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary. 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3712 Brake Caliper: Service and Repair Cleaning and Inspection Front Disc Brake Caliper CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear Disc Brake Caliper CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or less, they should be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 3717 Brake Pad: Specifications Rear Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation Brake Pad: Service and Repair Removal and Installation Front REMOVAL - FRONT DISC BRAKE SHOES 1. Raise the vehicle. (Refer to Vehicle Lifting - STANDARD PROCEDURE). 2. Remove both front wheel and tire assemblies. NOTE: Using this procedure, begin on one side of the vehicle. 3. Remove the anti-rattle spring from the outboard side of the caliper and adapter. 4. Remove the two caps in place over the caliper guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3720 5. Remove the two caliper guide pin bolts. 6. Remove caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed. CAUTION: Supporting weight of caliper by the flexible brake fluid hose can damage the hose. 7. Using wire or cord, hang the caliper from the front strut assembly. Support the caliper firmly to prevent weight of caliper from being supported by the brake fluid hose. 8. Remove the outboard brake shoe from the caliper adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3721 9. Pull the inboard brake shoe away from the caliper piston until the retaining clip on shoe is free from the cavity in the caliper piston. 10. Repeat the above procedure on other side of the vehicle. INSTALLATION - FRONT DISC BRAKE SHOES NOTE: There may be more than 1 lining material released. Make sure proper linings are being installed. 1. Begin on one side of the vehicle or the other. 2. Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake shoes installed). 3. If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake shoe assemblies. NOTE: Inboard brake shoes are stamped L or R for left or right side of the vehicle. The P-slot or void on piston insulator must be positioned Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3722 upward when brake caliper is mounted. 4. Install the new inboard brake shoe into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston. 5. Lubricate both adapter abutments where the shoes slide with a small amount of Mopar(R) Dielectric grease, or equivalent. 6. Slide the new outboard brake shoe into the caliper adapter with the lining up against the outside of the brake rotor. CAUTION: Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses. 7. Carefully position the brake caliper over the brake rotor and adapter. 8. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 9. Install the caps over the caliper guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3723 10. Install the new caliper hold down spring (antirattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. 11. Repeat the above procedure on other side of the vehicle. 12. Install the wheel and tire assemblies. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 13. Lower vehicle. 14. Pump the brake pedal several times. This will set the shoes to the brake rotor. 15. Check and adjust brake fluid level as necessary. 16. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Rear REMOVAL - REAR DISC BRAKE SHOES 1. Raise vehicle. 2. Remove rear wheels and tires from vehicle. Caliper Assembly Guide Pin Bolts 3. Remove the 2 guide pin bolts mounting the caliper to the adapter. Caliper Removal/Installation 4. Remove caliper from adapter and rotor by first rotating the top of the caliper away from adapter, and then lifting the caliper off the lower machined abutment on adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3724 5. Support caliper from rear strut to prevent weight of caliper from damaging the flexible brake hose. 6. Remove rear rotor from hub/bearing. Then inspect drum-in-hat parking brake shoes and parking brake braking surface on rotor for any signs of excessive wear or damage. Replace parking brake shoes if required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3725 Removing/Installing Outboard Brake Shoe 7. Remove outboard brake pad from caliper by prying brake pad retaining clip over raised area on caliper. Then slide brake pad down and off the caliper. Removing Installing Inboard Brake Shoe 8. Pull inboard brake pad away from caliper piston, until retaining clip is free from cavity in piston. INSTALLATION - REAR DISC BRAKE SHOES 1. Completely retract the caliper piston back into the piston bore of the caliper. This is required for caliper installation when new brake pad assemblies are installed on caliper. 2. Lubricate both adapter abutments with a liberal amount of Mopar(R) Multipurpose Lubricant, or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3726 3. Install rear rotor on hub making sure it is squarely seated on face of hub. 4. Remove protective paper from noise suppression gasket on both inner and outer brake pad assemblies (if equipped). Removing/Installing Outboard Brake Shoe 5. Install new inboard brake pad into caliper piston by firmly pressing it into bore of piston using thumbs. Be sure inboard brake shoe is positioned squarely against face of piston. 6. Slide new outboard brake pad onto the caliper. Be sure retaining clip is squarely seated in the depressed areas on the caliper. CAUTION: Use care when installing caliper assembly onto adapter, so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3727 Caliper Removal/Installation 7. Carefully lower caliper and brake shoes over rotor reversing the required removal procedure. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. Caliper Assembly Guide Pin Bolts 8. Install caliper guide pin bolts into adapter.. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 9. Install the wheels and tires. 10. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 11. Lower vehicle. 12. Check brake fluid level. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 13. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3728 Brake Pad: Service and Repair Cleaning and Inspection Front CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. - For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. - For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. - Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were remove from. Rear CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm. (5/16 inch), they should be replaced. - For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 min (9/32 inch), they should be replaced. - Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3729 If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were remove from. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Rotor Specifications Rotor Specifications BRAKE ROTOR Front Rotor Rear Rotor ROTOR THICKNESS 22.87 - 23.13 mm (0.900 - 0.911 in.) 8.87 - 9.13 mm (0.349 - 0.359 in.) MINIMUM ROTOR THICKNESS 21.4 mm (0.843 in.) 7.25 mm (0.285 in.) ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.13 mm (0.005 in.) 0.13 mm (0.005 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3733 Brake Rotor/Disc: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be checked and inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. For information on brake rotor machining. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Minimum thickness specifications are cast on the rotor's unmachined surface. Limits can also be found in the table at the end of this brake rotor information. ROTOR THICKNESS VARIATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3734 Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary by more than 0.013 mm (0.0005 inch), the rotor should refaced or replaced. For information on brake rotor machining. ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adapter, Special Tool SP1910 on steering arm. The dial indicator plunger should contact braking surface of rotor approximately 25 mm (one inch) from outer edge of rotor. Check lateral runout on both sides of the rotor, marking the low and high spots on both. Runout limits can be found in the table at the end of this brake rotor information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3735 If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. Remove the rotor from the hub. NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an accurate indicator reading. Mount Dial Indicator, Special r1bol C-3339, and Mounting Adapter, Special Tool SP-1910, to the steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter. Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub rim. Hub runout should not exceed 0.05 mm (0.0019 inch). If runout exceeds this specification, the hub must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 3736 If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud. Tighten nuts in the proper sequence and torque to specifications. Recheck brake rotor runout to see if the runout is now within specifications. If runout is not within specifications, reface or replace the brake rotor. For information on brake rotor machining. BRAKE ROTOR LIMITS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation Brake Rotor/Disc: Service and Repair Brake Rotor - Removal and Installation Front Brake Rotor REMOVAL - FRONT ROTOR 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Slide the caliper outward in an effort to retract the caliper piston into its bore. 4. Remove the two bolts securing disc brake caliper adapter to the steering knuckle. 5. Remove the disc brake caliper and adapter from the knuckle as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 6. Remove the clips retaining the brake rotor to the wheel studs. 7. Remove the brake rotor. INSTALLATION - FRONT ROTOR 1. Install the brake rotor over the studs on the hub. 2. Install the disc brake caliper and adapter assembly over the brake rotor. 3. Install the mounting bolts securing the caliper adapter to the steering knuckle. Tighten the bolts to a torque of 80 Nm (60 ft. lbs.). 4. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 5. Lower the vehicle. 6. Pump the brake pedal several times before moving the vehicle to set the shoes to the brake rotor. 7. Road test the vehicle and make several stops to seat the brake shoes to the rotor. Rear Brake Rotor REMOVAL - REAR ROTOR 1. Raise vehicle. 2. Remove rear tire and wheel. 3. Remove the caliper and shoes from adapter and hang out of way. 4. Remove any clips on the wheel mounting studs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 3739 5. Remove rotor from hub. INSTALLATION - REAR ROTOR 1. Install rotor on wheel mounting studs. 2. Install caliper and shoes on vehicle. 3. Install wheel and tire assembly. 4. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 3740 Brake Rotor/Disc: Service and Repair Brake Rotor Machining STANDARD PROCEDURE - BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. On-Car Brake Lathe If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe, or replaced. The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. Minimum Brake Rotor Thickness Markings (Typical) NOTE: All rotors have markings for minimum allowable thickness cast on an unmachined surface of the rotor. Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise using only the mounting flange. 2. Thread Bleeding Tubes, Special Tool 8358, into master cylinder primary and secondary ports. Position outlet ends of bleeding tubes in reservoir with the outlets below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with Mopar(R) brake fluid or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap on master cylinder fluid reservoir. 8. Install master cylinder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3746 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system. CAUTION: ^ Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. ^ Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least 1 full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry. 7. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3747 Use bleeder tank, Special Tool C-3496-B or equivalent, with master cylinder reservoir adapter, Special Tool 8224, to pressurize the hydraulic system for bleeding. Following the same wheel circuit sequence as prescribed for manual bleeding. 1. Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 3. After approximately 4-8 ounces of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat this procedure at all the remaining bleeder screws. 5. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Rebleed the brakes as necessary. 6. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 3748 Brake Bleeding: Service and Repair Antilock Brake System ANTILOCK BRAKE SYSTEM BLEEDING STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRBIII(R) scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Guide Pin Bolts 26 ft.lb Bleeder Screw 125 in.lb Adapter Mounting Bolts 60 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front REMOVAL - FRONT DISC BRAKE CALIPER 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove front wheel and tire assembly. 4. Remove the anti-rattle spring from the outboard side of the caliper and adapter. 5. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 6. Remove the two caps in place over the caliper guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3754 7. Remove the two caliper guide pin bolts. 8. Remove caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed. INSTALLATION - FRONT DISC BRAKE CALIPER 1. Completely retract the caliper piston back into piston bore of the caliper. 2. Lubricate both caliper adapter abutments where the shoes slide with a sufficient amount of Mopar(R) Dielectric Grease, or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3755 NOTE: If shoes are being transferred or newly installed, make note that the inboard brake shoes are stamped L or R for left or right side of the vehicle. The P-slot or void on piston insulator must be positioned upward when brake caliper is mounted. CAUTION: Use care when installing the brake caliper assembly onto the adapter, so that the seals on the caliper guide pin bushings do not get damaged by the adapter bosses. 3. Carefully position the brake caliper (with inboard shoe) over the brake rotor, outboard shoe and adapter. For proper positioning of shoes when installing caliper. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3756 4. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 5. Install the caps over the ends of the guide pin bolts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3757 6. Install the anti-rattle spring on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers. 7. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 35 Nm (26 ft. lbs.). 8. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Remove the brake pedal depressor (holding) tool. 11. Bleed the hydraulic brake circuit to the brake caliper. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Rear REMOVAL - REAR DISC BRAKE CALIPER 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise vehicle. 3. Remove rear wheel and tire from vehicle. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. Caliper Assembly Guide Pin Bolts 5. Remove the 2 guide pin bolts mounting the caliper to the adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3758 Caliper Removal/Installation 6. Remove caliper from adapter and rotor by first rotating top of caliper away from the adapter, then lifting the caliper off lower machined abutment on adapter. INSTALLATION - REAR DISC BRAKE CALIPER 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar(R) Multipurpose Lubricant, or equivalent. 3. If removed, install the rotor on the hub making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3759 Caliper Removal/Installation 4. Carefully lower caliper and brake shoes over rotor reversing the removal procedure. Make sure that the caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. Caliper Assembly Guide Pin Bolts 5. Install the caliper guide pin bolts. Tighten the caliper guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 35 Nm (26 ft. lbs.). 7. Install wheels and tire assembly. 8. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 9. Lower vehicle. 10. Remove the brake pedal depressor (holding) tool. 11. Bleed the hydraulic brake circuit to the brake caliper. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3760 Brake Caliper: Service and Repair Disassembly and Assembly Front Disc Brake Caliper DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: ^ Before disassembling the brake caliper, clean and inspect it. ^ The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES found, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper In vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3761 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore . Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar(R) Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3762 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary. 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. Rear Disc Brake Caliper DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3763 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: ^ Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING or INSPECTION. ^ The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3764 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore. Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar(R) Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. Installing New Piston Seal In Caliper 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove using only your clean fingers to seat it. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3765 2. Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Installing Piston Into Caliper Bore 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary. 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3766 Brake Caliper: Service and Repair Cleaning and Inspection Front Disc Brake Caliper CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear Disc Brake Caliper CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3770 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3771 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3772 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs are marked, FULL and MIN, indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Although there is a range, the preferred level is FULL. If necessary, adjust the brake fluid level, bringing it to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 3776 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch on the side of the reservoir. 2. Using a small screwdriver, release the retaining tabs on the opposite end of brake fluid level switch (on right side of reservoir) securing it to the reservoir. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Tube Nuts 145 in.lb Brake Hose Intermediate Bracket Bolt 105 in.lb To-Caliper Mounting Bolt 26 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 3780 Brake Hose/Line: Description and Operation DESCRIPTION - BRAKE TUBES AND HOSES The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses are made of reinforced rubber with fittings at each end. OPERATION - BRAKE TUBES AND HOSES The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle's suspension. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 3781 Brake Hose/Line: Testing and Inspection INSPECTION - BRAKE TUBES AND HOSES Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. The brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the master cylinder to the ABS hydraulic control unit connections must also be inspected. This flexible tubing must be inspected for kinks, fraying and contact with other components or with the body of the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation DESCRIPTION Proportioning valves are included on vehicles without Antilock Brakes (ABS). They are located in the junction block. NOTE: Vehicles with ABS do not have proportioning valves. They have Electronic Brake Distribution (EBD). OPERATION Proportioning valves balance front to rear braking by controlling (at a given ratio) brake hydraulic pressure to the rear brakes above a preset level (split point). On light pedal applications equal brake pressure is transmitted to both the front and rear brakes. On heavier pedal applications, through the use of proportioning valves, the pressure transmitted to the rear will be lower than the front brakes. This prevents premature rear wheel skid. If hydraulic pressure is lost in one-half of the diagonally split brake hydraulic system, the operation of the proportioning valve in the remaining half is not affected. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS ICU Mounting Bolts To Bracket 97 in.lb Mounting Bracket-To- Lower Radiator Support Bolts 21 ft.lb ABS CAB To-HCU Mounting Screws 17 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 3788 Hydraulic Control Assembly - Antilock Brakes: Description and Operation DESCRIPTION The Hydraulic Control Unit (HCU) and the Controller Antilock Brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU is located below the air cleaner housing on the lower radiator support. The ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any individual components of the HCU or CAB. For information on the CAB. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ CONTROLLER ANTILOCK BRAKE (CAB) ^ HYDRAULIC CONTROL UNIT (HCU) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL - ICU 1. Remove the remote ground cable from the ground stud on the left strut tower. 2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud. This will prevent accidental grounding of the remote ground cable. Brake Pedal Holding Tool Installed 3. Using a brake pedal positioning tool, depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir. 4. Remove the air cleaner housing. 5. Clean any debris away from the fittings on top of the ICU. 6. Remove the two brake tubes coming from the primary and secondary master cylinder ports at the ICU. 7. Remove the four chassis brake tubes going to each brake, mounted in-line across the top of the junction block. 8. Disconnect the 24-way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 24-way connector and pull it up from the connector as far as possible. This will unlock and raise the connector out of the socket on the CAB. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3791 9. Remove the three bolts fastening the ICU to its mounting bracket. Remove the ICU from the vehicle. 10. To separate the HCU from the CAB. INSTALLATION - ICU 1. Install the ICU back in the vehicle on its mounting bracket. 2. Install isolators, washers and attaching bolts, mounting the ICU to its mounting bracket. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: Before installing the 24-way connector in the CAB be sure that the seal is properly installed in the connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3792 3. Install the 24-way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 24-way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the connector into the socket on the CAB and lock it in the installed position. 4. Install the four chassis brake tubes (going to each brake) to the top of the ICU. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 5. Install the two brake tubes coming from the primary and secondary master cylinder ports to the top corners of the ICU. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 6. Install the air cleaner housing.. 7. Remove the brake pedal holding tool. 8. Install the remote. ground cable onto the ground stud located on left shock tower. 9. Bleed the base brakes and the ABS brakes hydraulic system. 10. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3793 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly DISASSEMBLY - ICU 1. Remove the ICU from the vehicle. 2. Disconnect the pump/motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Installation > Page 3794 4. Remove the CAB from the HCU. ASSEMBLY - ICU 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle and bleed the base and ABS hydraulic systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Description and Operation Hydraulic System Junction Block: Description and Operation DESCRIPTION A junction block is used on vehicles that are not equipped with Antilock Brakes (ABS). The junction block is located on the left side of the lower radiator support . The junction block mounts in the same location as the ABS Integrated Control Unit (ICU) does on vehicles with ABS. It has six threaded ports to which the brake tubes connect. Two are for the brake tubes coming from the master cylinder. The remaining four ports are for the brake tubes going to each brake assembly. The valve is permanently mounted to a bracket which fastens to the lower radiator support. The junction block includes two proportioning valves for the rear brakes. One valve is mounted in each end of the block. The proportioning valves are not serviced separately from the junction block. OPERATION The junction block distributes the brake fluid coming from the master cylinder primary and secondary ports to the four brake tubes leading to the brakes. Since the junction block mounts in the same location as the ABS Integrated Control Unit (ICU), it allows for the common use of brake tubes on the vehicle whether it is equipped with or without ABS. The junction block includes two proportioning valves. Placed in the fluid flow passages leading to the rear brake tube ports, they balance front-to-rear braking. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Description and Operation > Page 3798 Hydraulic System Junction Block: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery connection at the left front strut tower. Brake Pedal Holding Tool 2. Using a brake pedal holding tool such as shown, depress brake pedal past its first 1 inch of travel and secure in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir. 3. Remove the air cleaner housing. 4. Clean any debris away from the fittings on top of the junction block. 5. Remove the two brake tubes coming from the primary and secondary master cylinder ports at the junction block. 6. Remove the four chassis brake tubes going to each brake, mounted across the front top of the junction block. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Description and Operation > Page 3799 7. Remove the bolts fastening the junction block mounting bracket to the lower radiator support. 8. Remove the junction block and bracket from the vehicle. INSTALLATION 1. Install the junction block with mounting bracket onto the lower radiator support. Install and tighten the mounting bolts to 38 Nm (28 ft. lbs.) torque. 2. Install the four chassis brake tubes (going to each brake) to the junction block. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 3. Install the two brake tubes coming from the primary and secondary master cylinder ports to the top rear comers of the junction block. Tighten the tube fittings to 17 Nm (145 inch lbs.) torque with the aid of a crow foot wrench. 4. Install the air cleaner housing. 5. Remove the brake pedal holding tool. 6. Reconnect the battery negative cable. 7. Bleed the base brake system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 19 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE - MASTER CYLINDER BLEEDING 1. Clamp the master cylinder in a vise using only the mounting flange. 2. Thread Bleeding Tubes, Special Tool 8358, into master cylinder primary and secondary ports. Position outlet ends of bleeding tubes in reservoir with the outlets below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with Mopar(R) brake fluid or equivalent conforming to DOT 3 specifications. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap on master cylinder fluid reservoir. 8. Install master cylinder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 3805 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation REMOVAL 1. Remove vehicle wiring harness connector from brake fluid level switch in side of master cylinder brake fluid reservoir. 2. Disconnect the primary and secondary brake tubes from master cylinder outlet ports. Install plugs at open brake tube outlets on master cylinder assembly. 3. Using Mopar(R) Brake Parts Cleaner or equivalent, clean area where master cylinder attaches to booster. 4. Remove the 2 nuts attaching master cylinder assembly to power brake vacuum booster. 5. Slide master cylinder assembly straight off its mounting studs on power brake vacuum booster. INSTALLATION 1. Position master cylinder assembly on studs of power brake unit, aligning push rod on power brake vacuum booster with piston of master cylinder. 2. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 26 Nm (230 inch lbs.). 3. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). 4. Connect wiring harness connector to brake fluid level switch. 5. Fill master cylinder with clean, fresh Mopar(R) Brake Fluid or equivalent. 6. Road test vehicle to ensure proper operation of brakes. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair Parking Brake Cable: Service and Repair REMOVAL For servicing of either the left or right rear parking brake cable, follow the procedure as listed below. 1. Remove center floor console. 2. Lower park brake lever handle. 3. Loosen adjusting nut on park brake cable output cable. This will take tension off park brake cables, allowing rear park brake cables to be easily removed from tension equalizer. 4. Remove the rear park brake cable requiring service from the park brake cable tension equalizer. 5. Remove rear seat cushion from vehicle. 6. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 7. Fold rear carpeting forward to expose park brake cables. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3810 8. Remove the routing clip attaching the rear park brake cables to the floor pan of the vehicle. 9. Install the box end of a 1/2 inch wrench over the park brake cable retainer as indicated. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 10. Raise vehicle. 11. Remove rear wheel and tire assembly from the side of the vehicle requiring park brake cable service. 12. Remove parking brake shoes. 13. Remove the park brake cable from the park brake shoe actuating lever. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3811 14. Remove park brake cable from rear brake adapter. To do this, Place a 1/2 inch wrench on cable housing and compress locking tabs on park brake cable retainer. 15. Remove the fasteners securing the 2 brake cable routing clips to the frame rail. 16. Remove the park brake cable and sealing grommet from the floor pan of the vehicle. INSTALLATION For servicing of either the left or right rear parking brake cable, follow the procedure as listed below. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3812 1. Install parking brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure a proper seal. 2. Install park brake cable into the rear brake adapter. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in the adapter. NOTE: The park brake cable routing and routing clips are different on the right and left side of the vehicle. Be sure the correct routing clips are installed on the correct side of the vehicle. 3. Attach the 2 park brake cable routing clips on the rear frame rail. Install and securely tighten routing clip attaching screws. 4. Install the park brake cable on the park brake shoe actuating lever. 5. Install the parking brake shoes, hub and bearing, rotor and caliper. 6. Install rear wheel and tire assembly on vehicle. Tighten all wheel lug nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening nuts to 135 Nm (100 ft. lbs.). 7. Lower vehicle. 8. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. 9. Route park brake cable under carpeting and up to park brake cable hole in console bracket on floor pan. 10. Install park brake cable into console bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in console bracket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3813 11. Install the routing bracket holding park brake cables to the floor pan of the vehicle. CAUTION: Discard output cable retaining clip and tension equalizer after removing it from the park brake output cable. A new tension equalizer and retaining clip is to be used when installing a new rear park brake cable. 12. Using a screwdriver, unlatch the park brake output cable retainer. Then remove cable retainer and park brake cable tension equalizer from park brake lever output cable and discard components. CAUTION: A new cable tension equalizer must be installed when replacing a rear park brake cable . The new cable tension equalizer is required to correctly adjust park brake cable tension after installing a new rear park brake cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3814 13. Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables. CAUTION: A new retainer must be used when installing the park brake mechanism output cable on the cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. 14. Install a NEW park brake lever output cable to tension equalizer retaining clip on tension equalizer. The cable retainer must be closed and securely latched. 15. Adjust cable tension for the parking brake system using the following steps. ^ Position parking brake lever so it is in the fully released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Page 3815 ^ Tighten the adjusting nut on the parking brake lever output cable until 26 mm millimeters of thread is out past top edge of adjustment nut. ^ Actuate the parking brake lever to its fully applied position (22 clicks) 1 time and then reposition the lever to its fully released position. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 Inch. This process will correctly set the parking brake cable tension. 16. Check the rear wheels of the vehicle with the park brake lever fully released, they should rotate freely without dragging. 17. After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 21 clicks of lever travel possible. 18. Install the center floor console. 19. Install rear carpeting. 20. Install both rear door sill plate moldings by snapping them onto rear door sills. 21. Install lower rear seat cushion. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking Brake Lever Mounting Bolts 21 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3819 Parking Brake Lever: Service and Repair LEVER - PARKING BRAKE REMOVAL 1. Remove the floor console. 2. Lower parking brake lever handle. 3. Loosen adjusting nut on park brake lever output cable. This will take tension off output cable, allowing it to be easily removed from tension equalizer. CAUTION: Discard output cable retaining clip after removing it from park brake cable tension equalizer. Retainer is not to be re-used, a new retainer is to be installed when attaching output cable to tension equalizer. 4. Using a screwdriver, unlatch the park brake output cable retainer, then remove cable retainer from park brake cable tension equalizer. 5. Remove the park brake cable tension equalizer from the park brake lever output cable. 6. Remove the electrical connector from the ground switch on the park brake lever mechanism. 7. Unclip the wiring harness from the park brake mechanism bracket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3820 8. Remove the 4 bolts attaching the park brake lever mechanism bracket. 9. Remove the park brake lever mechanism from the vehicle. INSTALLATION 1. Place the park brake lever mechanism on the console bracket. Install the 4 bolts mounting the park brake lever mechanism to the console bracket. Tighten the 4 mounting bolts to a torque of 28 Nm (250 inch lbs.). 2. Install the wiring harness on the park brake mechanism bracket. 3. Install the electrical connector on the ground switch of the park brake lever mechanism. CAUTION: A new cable tension equalizer must be installed when replacing the park brake mechanism. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing park brake mechanism. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3821 4. Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables. CAUTION: A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. 5. Install a NEW parking brake lever output cable to tension equalizer retaining clip on tension equalizer. The cable retainer must be closed and securely latched. 6. Adjust cable tension for the parking brake system using the following steps. ^ Position park brake lever so it is in the fully released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3822 ^ Tighten the adjusting nut on the parking brake lever output cable until 26 millimeters of thread is out past top edge of adjustment nut. ^ Actuate the parking brake lever to its fully applied position (22 clicks) 1 time and then reposition the lever to its fully released position. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 inch. This process will correctly set the parking brake cable tension. 7. Check the rear wheels of the vehicle with the park brake lever fully released, they should rotate freely without dragging. 8. After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 22 clicks of lever travel possible. 9. Install the floor console back in the vehicle Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair SHOES - PARKING BRAKE REMOVAL 1. Remove disc brake caliper from adapter and rotor (See Disc Brake Shoe Removal). 2. Remove rotor from hub/bearing. 3. Remove dust cap from hub/bearing . 4. Remove hub/bearing rear retaining nut and washer. 5. Remove hub/bearing from knuckle. 6. Remove hold down clip from rear park brake shoe. 7. Turn park brake shoe adjuster wheel until adjuster is at its shortest length. 8. Remove the park brake shoe adjuster from the park brake shoes. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 3826 9. Remove the lower return spring between the park brake shoes. 10. Pull the rear park brake shoe away from the caliper adapter. Remove the upper return spring from between the park brake shoes. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 3827 11. Remove the hold-down clip from the front park brake shoe. Then remove front park brake shoe. INSTALLATION 1. Install front brake shoe and hold down clip. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 3828 2. Install the rear park brake shoe and the park brake shoe upper return spring. 3. Pull rear brake shoe over anchor block until properly located on adapter. 4. Install the park brake lower return spring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 3829 5. Install the adjuster between the park brake shoes. Adjuster must be installed with the star wheel toward the rear of the vehicle. 6. Install hold down clip on rear park brake shoe. 7. Adjust park brake shoes to an outside diameter of 171 mm (6.75 inch). 8. Install hub/bearing on knuckle. 9. Install A NEW hub/bearing retaining nut. Tighten the hub/ bearing retaining nut to a torque of 250 Nm (185 ft. lbs.). 10. Install dust cap on hub/bearing. 11. Install rotor. 12. Install rear disc brake caliper on adapter (See Brake Shoe Removal). 13. Install wheel and tire. 14. Tighten wheel stud nuts to 135 Nm (100 ft.lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power Brake Booster Mounting Nuts 19 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3834 Vacuum Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose on the side of the vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose on the side of the power brake booster vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. 2. Remove the remaining hose on the vacuum check valve that is not the vacuum supply hose coming from the intake manifold. Cap off the open port on the check valve. 3. Start the engine. 4. Allow the engine to warm up to normal operating temperature and engine idle. 5. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 6. Remove the pliers from the hose temporarily. 7. Apply light effort (approximately 15 lbs. of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 8. Have an assistant reattach the pliers to the vacuum supply hose. 9. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3835 Vacuum Brake Booster: Service and Repair REMOVAL - POWER BRAKE BOOSTER 1. Remove the remote ground cable from the ground stud located on the left shock tower. 2. Correctly isolate remote ground cable by installing the ground cable insulator on the strut tower ground stud as shown. This will prevent accidental grounding of the remote ground cable. 3. Disconnect the wiring harness connector and vacuum hose at speed control servo. 4. Remove speed control servo mounting nuts. Leaving cable attached, move servo out off to the side. 5. Remove the master cylinder from the booster. 6. Remove the vacuum hoses from the check valve located on the power brake vacuum booster. 7. Remove the electrical connector and mounting screw from the purge solenoid mounted on the left frame rail. Allow the solenoid to drop downward. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3836 8. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. Replace only with a new retaining clip when assembled. 9. Remove the 4 nuts attaching power brake vacuum booster to dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly. 10. Slide power brake vacuum booster straight forward until mounting studs clear dash panel, and remove from vehicle. CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly. INSTALLATION - POWER BRAKE BOOSTER 1. Position power brake booster onto dash panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3837 2. Install and torque the 4 power brake vacuum booster mounting nuts to 29 Nm (250 inch lbs.) torque. 3. Using Lubriplate, or an equivalent, coat the surfaces of the brake pedal pin that contact the power brake vacuum booster input rod. 4. Connect power brake vacuum booster input rod to brake pedal pin and install a NEW retaining clip. Use only a new retainer clip DO NOT USE the old clip. 5. Install the purge solenoid to the left frame rail and connect its wiring harness. 6. Install the vacuum hoses on the booster check valve. 7. Install the master cylinder and connect the fluid level switch. 8. If equipped, install speed control servo on the mounting studs. Install the 2 speed control servo bracket mounting nuts and tighten to a torque of 6 Nm (55 inch lbs.). Install electrical connector and vacuum hose on speed control servo. 9. Install the throttle cable, and if equipped, the speed control cable on the cam of the throttle body assembly. 10. Install the remote ground cable on the ground stud located on the left strut tower. Install and securely tighten the ground cable attaching nut. 11. Check brake lamp operation. If required, adjust brake lamp switch as necessary. 12. Road test vehicle to ensure proper operation of the vehicles brake system and speed control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3842 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3843 Electronic Brake Control Module: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Anti-Lock Brake ................................................................................................................................... .............................................................. PC161 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3844 Electronic Brake Control Module: Description and Operation Fig.1 Integrated Control Unit (Typical) CONTROLLER ANTILOCK BRAKE The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the Integrated Control Unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRB III scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn ON the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. when a fault is detected, the amber ABS warning indicator lamp is turned ON and the fault Diagnostic Trouble Code (DTC) is then stored in a diagnostic program memory. These DTC's will remain in the CAB memory even after the ignition has been turned OFF. The DTC's can be read and cleared from the CAB memory by a technician using the DRB III scan tool. If not cleared with a DRB III scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Cab Inputs - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Diagnostic communication (PCI) Cab Outputs - Amber ABS warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Diagnostic communication (PCI, via BUS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3845 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) 3. Pull up on the CAB connector lock and disconnect the 2-way electrical connector and the pump/motor connector from the CAB. 4. Remove the bolts securing the integrated control unit's (ICU's) mounting bracket to the lower radiator support. 5. Carefully move the ICU toward the right side of the car. Move the ICU far enough to access the CAB mounting screws. Be careful not to bend the brake tubes connected to the ICU. 6. Remove the screws securing the CAB to the HCU. Remove the CAB. INSTALLATION 1. Install screws to secure the CAB to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.) torque. 2. Remount the ICU mounting bracket to the lower radiator support. Tighten the mounting bolts to 28 Nm (21 ft. lbs.) torque. 3. Reconnect the 24-way electrical and the pump/motor connector. 4. Lower vehicle. 5. Connect negative battery cable. 6. Connect a DRB III to the vehicle and initialize the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 3850 Brake Fluid Level Sensor/Switch: Service and Repair REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch on the side of the reservoir. 2. Using a small screwdriver, release the retaining tabs on the opposite end of brake fluid level switch (on right side of reservoir) securing it to the reservoir. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications ABS Wheel Speed Sensor Mounting Bolt 75 ft.lb Front Sensor 0.017 - 0.067 in Rear Sensor 0.015 - 0.052 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 3856 Wheel Speed Sensor: Connector Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3857 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left front Wheel Speed Sensor Connector (Sensor Side) Left Rear Wheel Speed Sensor Left Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3858 Right Wheel Front Speed Sensor Right Wheel Front Speed Sensor Connector (Sensor Side) Right Rear Wheel Speed Sensor Right Rear Wheel Speed Sensor Connector (Sensor Side) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 3859 Wheel Speed Sensor: Testing and Inspection INSPECTION - TONE WHEEL Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ Wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If a rear tone wheel is found to need replacement, the tone wheel is incorporated into the hub and bearing assembly and the hub and bearing must be replaced. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL This procedure is for the removal and installation of one of the two front wheel speed sensors. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Vehicle Lifting for the required lifting procedure to be used for this vehicle. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3862 5. Remove bolt attaching speed sensor to steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly. Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. INSTALLATION This procedure is for the removal and installation of one of the two front wheel speed sensors. CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3863 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3864 CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber as shown. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3865 Wheel Speed Sensor: Service and Repair Rear REAR WHEEL SPEED SENSOR REMOVAL 1. Fold down rear seat back. 2. Disconnect speed sensor connector at vehicle wiring harness found at lower outside comer of seat back 3. Raise vehicle. 4. Remove rear tire and wheel assembly from vehicle. 5. Remove speed sensor harness sealing grommet retainer from the rear frame rail of the vehicle. 6. Remove speed sensor harness sealing grommet and harness from hole in body of vehicle. 7. Remove speed sensor routing clips from the rear upper control arm. 8. Remove bolt, then wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor harness is critical to continued system operation. Be sure that harness is installed properly to avoid harness contact with moving parts or overextension, resulting in an open circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 3866 1. Install speed sensor head into brake adapter. Install bolt through routing clip and secure wheel speed sensor in place. Tighten bolt to 8 Nm (75 inch lbs.) 2. Install speed sensor harness routing clip on upper control arm. Install and securely tighten the routing clip attaching bolt. 3. Install connector end of speed sensor harness through hole at frame rail. 4. Install speed sensor harness sealing grommet into hole. Install the sealing grommet retainer and attaching bolt. Securely tighten retainer attaching bolt. 5. Install the tire and wheel assembly on vehicle. 6. Lower vehicle. 7. Connect speed sensor harness connector to vehicle wiring harness behind rear seat back. Install sleeve back over the speed sensor harness connection to prevent rattling. 8. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center (PDC) Engine Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3881 Starter Relay: Diagrams Power Distribution Center (PDC) Engine Starter Motor Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3882 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3883 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service Precautions Battery Cable: Service Precautions WARNING: - IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. - EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. - THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. - IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service Precautions > Page 3888 Battery Cable: Description and Operation The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of soft lead that is die cast onto one end of the battery cable wire. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some models. Refer to the appropriate wiring information in for the location of the proper battery cable wire harness diagrams. The wiring information also includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. The battery positive cable terminal clamp is die cast onto the ends of two wires. One wire has an eye-let terminal that connects the battery positive cable to the B(+) terminal stud of the Power Distribution Center (PDC), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp is also die cast onto the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the right side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the right front fender inner shield, near the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service Precautions > Page 3889 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service Precautions > Page 3890 Battery Cable: Service and Repair REMOVAL 1. Turn the ignition switch to the OFF position. Be certain that all electrical accessories are turned OFF. 2. Disconnect and isolate the remote battery negative cable terminal. 3. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cables are free from the vehicle. 4. Remove the battery cable from the engine compartment. INSTALLATION 1. Position the battery cables in the engine compartment. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cables are installed exactly where they were in the vehicle. 3. Connect the remote battery negative cable terminal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient battery temperature. As battery temperature increases, the charging rate should decrease. As battery temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the optimal out- put of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Raise and support the vehicle. 3. Remove the left front wheel and tire assembly from the vehicle. 4. Remove battery splash shield. Refer to the Body for the procedure. 5. Remove the short bolt from the battery hold down and remove the hold down. INSTALLATION 1. Install the battery hold down and install the hold down bolt. Torque to 8.5 Nm (75 in. lbs.). 2. Install the left front wheel and tire assembly on the vehicle. Refer to the Tires/Wheels for the procedure 3. Install battery splash shield. Refer to the Body for the procedure 4. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 3898 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Disconnect and isolate the remote negative battery cable. 2. Remove the battery from the vehicle. Refer to the procedure. 3. Remove the left headlamp assembly from the vehicle. Refer to the Lamps for the procedure. Fig.18 Battery Tray Location 4. Remove the battery tray retaining bolts (Fig. 18) and remove the battery tray from the vehicle. INSTALLATION 1. Install the battery tray and retaining bolts. Torque the bolts to 14 Nm (160 in. lbs) 2. Install the battery in the vehicle Refer to the procedure. 3. Install the left headlamp assembly in the vehicle. Refer to the Lamps for the procedure. 4. Connect the remote negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Information not supplied by the manufacturer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3903 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3904 Alternator: Diagrams Generator Generator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3905 Alternator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Generator ............................................................................................................................................ ................................................................ PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3906 Alternator: Description and Operation The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: - Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode - Damaged internal fins Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3907 Alternator: Service and Repair REMOVAL 1. Open Hood. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. 4. Remove the accessory drive belt splash shield. 5. Loosen the accessory drive belt refer to the cooling. 6. Remove the lower mounting bolt. 7. Lower the vehicle. Fig.5 Generator Battery Cable 8. Remove the battery cable and field connection (Fig. 5). 9. Disconnect the electrical connector to the A/C pressure switch and A/C clutch. 10. Remove the engine oil dip stick. 11. Remove the 2 upper mounting bolts. Fig.6 Generator 12. Remove the generator (Fig. 6). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 3908 INSTALLATION 1. Install generator (Fig. 6). 2. Install the 2 upper bolts but do not tighten. 3. Install the engine dip stick tube. 4. Connect the A/C pressure switch and A/C clutch electrical connectors. 5. Connect the battery cable and field connectors (Fig. 5). 6. Raise vehicle and support. 7. Install the lower bolt and tighten. 8. Install the accessory drive belt, refer to the cooling. 9. Install the accessory drive splash shield. 10. Lower the vehicle. 11. Tighten the 2 upper mounting bolts to 12. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 3912 Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature or inlet air temperature sensor (refer to Battery Temperature Sensor or Inlet Air Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 325 mv or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 325 mv above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 250 times per second (250Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Service Precautions Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Service Precautions NUMBER: 19-02-00 Rev. A GROUP: Steering DATE: July 28, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-02-00 DATED MARCH 3, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Ignition Lock Cylinder Service MODELS: 2001 (PT) PT Cruiser 2000 - **2001** (PL) Neon 2000 (JA) Cirrus/Stratus **2001 (JR) Stratus Sedan/Sebring Sedan/Sebring Convertible** 2000 (JX) Sebring Convertible 2000 - **2001** (XJ) Cherokee 2000 - **2001** (TJ) Wrangler DISCUSSION: Recent changes to the ignition lock cylinder have resulted in the removal of a chamfer on the lock cylinder retaining pin. This may cause the pin to hang up on the plastic trim ring when the lock cylinder is removed. If this situation is encountered on any of the models listed above, it may be necessary to remove the trim ring prior to removing the lock cylinder. This is done by unseating the retaining tabs on the trim ring and removing it. The lock cylinder can then be removed without any Interference (See Figure 1). Future models will modify the lock housing to eliminate this condition. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair Starter Motor: Service and Repair REMOVAL 1. Open Hood. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. 4. Disconnect the electrical connector from the O(2) sensor. Fig.5 O(2) Sensor 5. Remove the O(2) sensor from the exhaust manifold (Fig. 5). 6. Remove the front mount through bolt. 7. Remove the front mount bracket from engine block. Fig.6 Starter Motor 8. Remove the battery cable from starter (Fig. 6). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Page 3922 Fig.7 Starter Motor Removal 9. Remove the lower starter bolt and remove starter (Fig. 7). INSTALLATION 1. Install starter to transmission. 2. Start the upper starter bolt. 3. Start the lower bolt and snug it so that the starter will not move. 4. Remove the upper bolt. 5. Connect the battery cable and torque nut to 8.5 Nm (75 in. lbs.). 6. Install the front mount bracket and check heat shield location. 7. Install bolt the upper bolt and torque bolt to 54 Nm (40 ft. lbs.). 8. Install the lower and torque bolt to 54 Nm (40 ft. lbs.). 9. Install the front mount through bolt and torque bolt to 61 Nm (45 ft. lbs.). 10. Install the O(2) sensor and torque to 27 Nm (20 ft. lbs.). 11. Lower vehicle. 12. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center (PDC) Engine Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3926 Starter Relay: Diagrams Power Distribution Center (PDC) Engine Starter Motor Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3927 Starter Relay: Description and Operation The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter solenoid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3928 Starter Relay: Service and Repair REMOVAL The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Battery Nut ................................................................................................................ .................................................... 10 Nm (90 in. lbs.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 3932 Starter Solenoid: Description and Operation The Starter Solenoid is a switching device used to activate the high amperage starter motor circuit from a low amperage control circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 3956 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove left side console lower cover. 3. Disconnect wire harness connectors from power outlet. 4. Twist power outlet retainer from the back of power outlet. 5. Remove power outlet. INSTALLATION 1. Install power outlet to instrument panel. 2. Install retainer to power outlet. 3. Connect wire harness connectors. 4. Install left side console lower cover. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3960 Circuit Breaker: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3961 Circuit Breakers (JB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 3965 Electrical Accessory Panel: Diagrams Power Distribution Center Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 3966 Fuses (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 3967 Electrical Accessory Panel: Description and Operation POWER DISTRIBUTION This information covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle is designed to provide safe, reliable, centralized and convenient to access distribution of the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, comfort and convenience systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many after market vehicle accessory and convenience items. These power distribution systems also incorporate various types of circuit control and protection features, including: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Accessory power outlet. Following are general descriptions of the major components in the power distribution system. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of all of the power distribution system components. JUNCTION BLOCK An electrical Junction Block (JB) is located in the left end cap of the instrument panel. The JB combines the functions previously provided by a separate fuse block module and relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. Fig.1 Junction Block Location The JB is positioned on a mounting bracket up and under the left instrument panel (Fig. 1). It is secured by three screws. The JB is concealed behind the left instrument panel endcap. The left instrument panel endcap is a snap-fit fuse access cover that conceals the JB fuses and includes the fuse layout to ensure proper fuse identification. The left instrument panel endcap must be removed to access components other than the fuses in the JB. All of the current entering and leaving the JB does so through wire harnesses, which are connected to the JB through integral connector receptacles molded into the JB housing. The JB houses blade-type fuses, blade-type automatic resetting circuit breakers, full International Standards Organization (ISO) relays, and ISO micro-relays. Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 3968 and bus bars. The fuses, circuit breakers, relays, and are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire Junction Block assembly must be replaced. POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment. The PDC housing has a molded plastic cover that includes an integral hinge feature on the inboard side, and an integral latch on the outboard side. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The PDC housing is secured in the engine compartment on the left front corner with three screws to the transmission and engine control module bracket. A small red molded plastic protective cover on the top near the rear of the PDC is unsnapped to access the battery/generator cable input connection stud. All of the PDC outputs are through the integral engine compartment wire harness, which exits from the rear of the PDC housing. All of the current from the battery/generator cable connection enters the PDC through a 140 ampere fusible link that is secured to the top of the PDC housing. The PDC houses up to fourteen maxi-fuse cartridges, which replace all in4ine fusible links. The PDC also houses up to eleven blade-type fuses, up to four full International Standards Organization (ISO) relays, and up to eight ISO micro-relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. The fusible link, fuse cartridges, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the PDC is faulty or damaged, the engine compartment wire harness assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 3969 Electrical Accessory Panel: Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the Air Inlet System (housing and resonator). 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Remove the three screws retaining the PDC to its mounting bracket. 7. Remove the PDC and the engine compartment wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced. NOTE: If the power distribution center is being replaced with a new unit, be certain to transfer each of the fuses, fuse cartridges, fusible links and relays from the old power distribution center to the proper cavities of the new power distribution center. 1. Position the PDC over the mounting bracket between the Powertrain and Transmission Control Modules in the engine compartment. 2. Align the PDC mounting slots with the blades on the PDC mounting bracket. 3. Install the three mounting screws into the PDC. 4. Route the engine compartment wire harness from the PDC through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 5. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 6. Reconnect each of the engine compartment wire harness connectors. 7. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 3974 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3975 Fuse: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3976 Fuses (JB) Power Distribution Center Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3977 Fuses (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 3980 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 3981 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 3982 Fuse: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 3987 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Fuse Block: Connector Views Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 Junction Block (Bottom) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Junction Block/Body Control Module - 12 Way Junction Block C1 Junction Block C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Junction Block C3 Junction Block C4 Junction Block C5 Junction Block C6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Junction Block C7 Junction Block C8 Junction Block C9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 Junction Block C10 Junction Block C11 (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 Fuse Block: Electrical Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 8w-12-2 Wiring Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 8w-12-7 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 8w-12-8 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 8w-12-9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 8w-12-10 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 8w-12-11 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 8w-12-12 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 8w-12-13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 8w-12-14 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 8w-12-15 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 8w-12-16 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 8w-12-17 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 8w-12-20 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 8w-12-21 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 8w-12-22 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 8w-12-23 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4034 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4037 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4038 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4039 Fuse Block: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4040 Fuse Block: Description and Operation An electrical Junction Block (JB) is located in the left end cap of the instrument panel. The JB combines the functions previously provided by a separate fuse block module and relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. Fig.1 Junction Block Location The JB is positioned on a mounting bracket up and under the left instrument panel (Fig. 1). It is secured by three screws. The JB is concealed behind the left instrument panel endcap. The left instrument panel endcap is a snap-fit fuse access cover that conceals the JB fuses and includes the fuse layout to ensure proper fuse identification. The left instrument panel endcap must be removed to access components other than the fuses in the JB. All of the current entering and leaving the JB does so through wire harnesses, which are connected to the JB through integral connector receptacles molded into the JB housing. The JB houses blade-type fuses, blade-type automatic resetting circuit breakers, full International Standards Organization (ISO) relays, and ISO micro-relays. Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses, circuit breakers, relays, and are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire Junction Block assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4041 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig.2 Junction Block/BCM Location The Junction Block (JB) and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle (Fig. 2). Fig.3 Battery Negative Remote Cable 1. Open hood then disconnect and isolate the battery negative remote cable from the remote terminal on the left shock tower (Fig. 3). 2. Open the front driver's door and remove end cap. 3. Remove center bezel. 4. Remove instrument cluster hood. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4042 12. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 13. Disconnect BCM from the Junction Block. INSTALLATION 1. Connect BCM to the Junction Block. 2. Install the BCM to the Junction Block and install the attaching screws. 3. Install Junction Block/BCM to vehicle. 4. Connect BCM wire connectors. 5. Install Junction Block mounting screws. 6. Connect wire harness connectors to Junction Block. 7. Install silencer. 8. Install instrument cluster hood. 9. Install center bezel. 10. Install end cap. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Testing and Inspection Power Interrupt Connector/Switch: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. If equipped, determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4051 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4054 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4055 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4056 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4061 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4064 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4065 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4066 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Testing and Inspection Power Interrupt Connector/Switch: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. If equipped, determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4094 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove left side console lower cover. 3. Disconnect wire harness connectors from power outlet. 4. Twist power outlet retainer from the back of power outlet. 5. Remove power outlet. INSTALLATION 1. Install power outlet to instrument panel. 2. Install retainer to power outlet. 3. Connect wire harness connectors. 4. Install left side console lower cover. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4098 Circuit Breaker: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4099 Circuit Breakers (JB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4103 Electrical Accessory Panel: Diagrams Power Distribution Center Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4104 Fuses (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4105 Electrical Accessory Panel: Description and Operation POWER DISTRIBUTION This information covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle is designed to provide safe, reliable, centralized and convenient to access distribution of the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, comfort and convenience systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many after market vehicle accessory and convenience items. These power distribution systems also incorporate various types of circuit control and protection features, including: Fuses - Fuse cartridges - Fusible links - Automatic resetting circuit breakers - Relays - Flashers - Timers - Circuit splice blocks. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Accessory power outlet. Following are general descriptions of the major components in the power distribution system. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of all of the power distribution system components. JUNCTION BLOCK An electrical Junction Block (JB) is located in the left end cap of the instrument panel. The JB combines the functions previously provided by a separate fuse block module and relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. Fig.1 Junction Block Location The JB is positioned on a mounting bracket up and under the left instrument panel (Fig. 1). It is secured by three screws. The JB is concealed behind the left instrument panel endcap. The left instrument panel endcap is a snap-fit fuse access cover that conceals the JB fuses and includes the fuse layout to ensure proper fuse identification. The left instrument panel endcap must be removed to access components other than the fuses in the JB. All of the current entering and leaving the JB does so through wire harnesses, which are connected to the JB through integral connector receptacles molded into the JB housing. The JB houses blade-type fuses, blade-type automatic resetting circuit breakers, full International Standards Organization (ISO) relays, and ISO micro-relays. Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4106 and bus bars. The fuses, circuit breakers, relays, and are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire Junction Block assembly must be replaced. POWER DISTRIBUTION CENTER All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment. The PDC housing has a molded plastic cover that includes an integral hinge feature on the inboard side, and an integral latch on the outboard side. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The PDC housing is secured in the engine compartment on the left front corner with three screws to the transmission and engine control module bracket. A small red molded plastic protective cover on the top near the rear of the PDC is unsnapped to access the battery/generator cable input connection stud. All of the PDC outputs are through the integral engine compartment wire harness, which exits from the rear of the PDC housing. All of the current from the battery/generator cable connection enters the PDC through a 140 ampere fusible link that is secured to the top of the PDC housing. The PDC houses up to fourteen maxi-fuse cartridges, which replace all in4ine fusible links. The PDC also houses up to eleven blade-type fuses, up to four full International Standards Organization (ISO) relays, and up to eight ISO micro-relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. The fusible link, fuse cartridges, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the PDC is faulty or damaged, the engine compartment wire harness assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4107 Electrical Accessory Panel: Service and Repair REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the Air Inlet System (housing and resonator). 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Remove the three screws retaining the PDC to its mounting bracket. 7. Remove the PDC and the engine compartment wire harness from the engine compartment as a unit. INSTALLATION The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced. NOTE: If the power distribution center is being replaced with a new unit, be certain to transfer each of the fuses, fuse cartridges, fusible links and relays from the old power distribution center to the proper cavities of the new power distribution center. 1. Position the PDC over the mounting bracket between the Powertrain and Transmission Control Modules in the engine compartment. 2. Align the PDC mounting slots with the blades on the PDC mounting bracket. 3. Install the three mounting screws into the PDC. 4. Route the engine compartment wire harness from the PDC through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. 5. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 6. Reconnect each of the engine compartment wire harness connectors. 7. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 4112 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4113 Fuse: Diagrams Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4114 Fuses (JB) Power Distribution Center Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4115 Fuses (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4118 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4119 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4120 Fuse: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 4125 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Fuse Block: Connector Views Junction Block (Top) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Junction Block (Bottom) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Junction Block/Body Control Module - 12 Way Junction Block C1 Junction Block C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Junction Block C3 Junction Block C4 Junction Block C5 Junction Block C6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Junction Block C7 Junction Block C8 Junction Block C9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Junction Block C10 Junction Block C11 (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Fuse Block: Electrical Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 8w-12-2 Wiring Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 8w-12-7 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 8w-12-8 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 8w-12-9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 8w-12-10 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 8w-12-11 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 8w-12-12 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 8w-12-13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 8w-12-14 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 8w-12-15 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 8w-12-16 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 8w-12-17 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 8w-12-19 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 8w-12-20 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 8w-12-21 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 8w-12-22 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 8w-12-23 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 8w-12-24 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams See: Diagrams/Electrical Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4172 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4175 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4176 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4177 Fuse Block: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4178 Fuse Block: Description and Operation An electrical Junction Block (JB) is located in the left end cap of the instrument panel. The JB combines the functions previously provided by a separate fuse block module and relay center. It also serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. Fig.1 Junction Block Location The JB is positioned on a mounting bracket up and under the left instrument panel (Fig. 1). It is secured by three screws. The JB is concealed behind the left instrument panel endcap. The left instrument panel endcap is a snap-fit fuse access cover that conceals the JB fuses and includes the fuse layout to ensure proper fuse identification. The left instrument panel endcap must be removed to access components other than the fuses in the JB. All of the current entering and leaving the JB does so through wire harnesses, which are connected to the JB through integral connector receptacles molded into the JB housing. The JB houses blade-type fuses, blade-type automatic resetting circuit breakers, full International Standards Organization (ISO) relays, and ISO micro-relays. Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring and bus bars. The fuses, circuit breakers, relays, and are available for service replacement. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire Junction Block assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4179 Fuse Block: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL/RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig.2 Junction Block/BCM Location The Junction Block (JB) and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle (Fig. 2). Fig.3 Battery Negative Remote Cable 1. Open hood then disconnect and isolate the battery negative remote cable from the remote terminal on the left shock tower (Fig. 3). 2. Open the front driver's door and remove end cap. 3. Remove center bezel. 4. Remove instrument cluster hood. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4180 12. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 13. Disconnect BCM from the Junction Block. INSTALLATION 1. Connect BCM to the Junction Block. 2. Install the BCM to the Junction Block and install the attaching screws. 3. Install Junction Block/BCM to vehicle. 4. Connect BCM wire connectors. 5. Install Junction Block mounting screws. 6. Connect wire harness connectors to Junction Block. 7. Install silencer. 8. Install instrument cluster hood. 9. Install center bezel. 10. Install end cap. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Testing and Inspection Power Interrupt Connector/Switch: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. If equipped, determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4189 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4192 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4193 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4194 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4199 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4202 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4203 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4204 Relay Box: Application and ID Power Distribution Center Power Distribution Center (PDC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Testing and Inspection Power Interrupt Connector/Switch: Testing and Inspection Ignition-Off Draw Test The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty days or more (stored), remove the IOD fuse from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: - Electrical items left ON. - Faulty or improperly adjusted switches. - Faulty or shorted electronic modules and components. - An internally shorted generator. - Intermittent shorts in the wiring. If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. Electronic Module Ignition-Off Draw (IOD) Table 1. Verify that all electrical accessories are OFF. Turn OFF all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. See the Electronic Module Ignition-Off Draw Table for more information. 2. If equipped, determine that the underhood lamp is operating properly, then disconnect the lamp wire harness connector or remove the lamp bulb. 3. Disconnect the battery negative cable. 4. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. 5. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Power Distribution Center (PDC) and then in the Junction Block (JB), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information for complete PDC and JB fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn ON any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. 6. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications Front Wheel Alignment Camber Preferred +0.1 deg Acceptable -0.5 to +0.7 deg Cros Camber Preferred 0.0 deg Acceptable 0.7 deg Caster Preferred +3.1 deg Acceptable +2.1 to +4.1 deg Cross Caster Preferred 0.0 deg Acceptable 1.0 deg Toe (Right or Left) Preferred +0.05 deg Acceptable -0.05 to +0.15 deg Total Toe Preferred +0.1 deg Acceptable -0.1 to +0.3 deg Curb Height 28.0 +/- 0.75 in Rear Wheel Alignment Camber Preferred -0.1 deg Acceptable -0.5 to +0.3 deg Toe (Right or Left) Preferred +0.05 deg Acceptable -0.05 to +0.15 deg Total Toe Preferred +0.1 deg Acceptable -0.1 to +0.3 deg Thrust Angle Preferred 0.0 deg Acceptable 0.0 +/- 0.15 deg Curb Height 28.0 +/- 0.75 in Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4213 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION - WHEEL ALIGNMENT Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. On this vehicle, the suspension angles that can be adjusted are as follows: Front Camber (using special procedure) - Toe Rear Camber - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Testing and Inspection; Procedures; Curb Height Measurement. Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Fig. 1 Camber is the inward or outward tilt of the top of the tire and wheel assembly. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. ID achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is +0.3° and the right camber is 0.0°, the cross camber would be +0.3°. CASTER Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4214 Fig. 2 Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster angle. CROSS CASTER Cross caster is the difference between left and right caster. TOE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4215 Fig. 3 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equally distant. TOE-OUT ON TURNS Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4216 Fig. 4 Toe-out on turns is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4217 Fig. 5 Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Fig. 6 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection STANDARD PROCEDURE- PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications, check for broken or sagged springs. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4220 Alignment: Service and Repair Wheel Alignment STANDARD PROCEDURE - WHEEL ALIGNMENT 1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. NOTE: Set the rear wheel alignment first before proceeding to the front to set the front wheel alignment. 5. If rear camber or toe is not within specifications, proceed to REAR CAMBER AND TOE below. If rear camber and toe are within specifications, but front camber and caster are not, proceed to FRONT CAMBER AND CASTER which can be found following REAR CAMBER AND TOE. If rear camber and toe, and front camber and caster are within specifications, proceed to FRONT TOE. Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating, bending or modifying any component of the suspension. REAR CAMBER AND TOE Fig. 7 Rear Camber on this vehicle is adjustable. The rear camber on this vehicle is adjusted using the adjusting screw located in the forward and rear lateral links of the vehicles rear suspension. CAUTION: When checking the rear alignment on this vehicle, the alignment rack must be equipped with rear skid plates. 1. For either rear wheel needing alignment, loosen the adjusting screw jam nuts on both the front and the rear lateral links. CAUTION: Do not attempt to move the adjusting screws without properly loosening the tam nuts. Note that each adjusting screw has one right handed nut and one left-handed nut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4221 Fig. 8 CAUTION: When setting rear camber and toe on the vehicle, the maximum lengths of the adjustable lateral link at the locations shown must not be exceeded. If these maximum lengths are exceeded, inadequate retention of adjustment link to the inner and outer link may result. 2. Rough-in the rear camber setting as close as possible to the preferred specification by mainly adjusting the rear lateral link adjusting screw. Some adjustment of the forward lateral link adjusting screw will also be required to get the rear camber setting to the preferred specification. 3. Adjust the forward lateral link adjusting screw to set rear toe to the preferred specification. NOTE: Adjusting toe will cause a slight change in the camber setting. If during the setting of toe, camber is no longer at the preferred specification, continue to adjust camber and toe until both are at their preferred specifications. 4. While holding adjustment screws from turning, use a crow foot and torque wrench, and tighten all lateral link adjusting screw jam nuts to a torque of 92 Nm (68 ft. lbs.). This will securely hold the adjusting screws from turning. 5. Proceed to FRONT CASTER AND CAMBER, or FRONT TOE if front caster and camber are within specifications. FRONT CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as NET BUILD. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using a procedure listed here. Before performing the camber adjustment procedure, inspect the suspension components for any signs of damage or bending. CAMBER ADJUSTMENT PROCEDURE Fig. 9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4222 1. Open the hood and mark the position of all four shock assembly mounting bolts on the shock tower on the side of the vehicle requiring front camber adjustment. 2. Raise the vehicle by the frame until the tires and front suspension are not supporting the weight of the vehicle. 3. Loosen the shock assembly mounting bolts on the side marked in step 1. Loosen the bolts enough to allow adequate space for removal of the plastic locating pins that align the upper mounting bracket with the shock tower. 4. Remove and discard both plastic locating pins from the shock assembly upper mounting bracket using a punch or pliers. NOTE: Do not leave the plastic locating pins in the cavity of the shock tower or mount. Objectionable noise may result. 5. Position the shock assembly inboard or outboard as required to adjust the camber. Make sure the fore and aft position is in the same as indicated by the marks made prior to adjustment, and also the forward and rearward bolts are moved equal amounts inward or outward. NOTE: Do not attempt to enlarge any existing holes to increase adjustment range. 6. Torque the upper shock assembly mounting bolts to 90 Nm (68 ft. lbs.) 7. Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. 8. Check and adjust the front camber as necessary. 9. If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure. FRONT TOE 1. Center the steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Fig. 10 2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front toe to the preferred toe specification. 3. Tighten tie rod jam nuts to 61 Nm (45 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4223 Alignment: Service and Repair Curb Height Measurement STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, maximum left-to-right differential is not to exceed 20 mm (0.79 inch). 3. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Page 4229 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Disc Brake Caliper Adapter Bolts 125 ft.lb Tie Rod Nut 45 ft.lb Tie Rod Adjustment Jam Nut 45 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4234 Front Steering Knuckle: Description and Operation DESCRIPTION The steering knuckle is a single casting with legs machined for attachment to the vehicle's upper and lower control arm ball joints. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub and bearing assembly using a nut, nut lock and cotter pin. OPERATION The steering knuckle pots between the upper and lower ball joints. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub and bearing and axle shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4235 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - STEERING The front suspension steering knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4236 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 9 5. Remove nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Fig. 10 6. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB-991113. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4237 Fig. 24 7. Remove the speed sensor cable routing bracket from the steering knuckle. Fig. 25 8. Remove cotter pin and castle nut from the stud of the lower ball joint . CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in step Step 9 below. CAUTION: When striking the steering knuckle, do not hit the heat shield covering the ball joint grease seal. Bending the heat shield against the ball joint grease seal will cause the grease seal to fail. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4238 Fig. 26 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until the steering knuckle separates from the stud of lower ball joint. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate ON joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 23 11. Separate the steering knuckle from the outer C/V joint. Seperate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4239 Fig. 24 12. Remove the cotter pin and nut from the upper ball joint stud to steering knuckle attachment. Fig. 25 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A. 14. Remove steering knuckle from vehicle. 15. The bolt in type front wheel bearing used on the vehicle is transferable to the replacement steering knuckle if bearing is found to be in usable condition. INSTALLATION 1. If required install a hub/bearing assembly into the steering knuckle before installing steering knuckle on vehicle. 2. Install the heat shield for the lower control arm ball joint grease seal before beginning the installation of the steering knuckle on the vehicle. 3. Slide drive shaft; back into front hub/bearing assembly. Then install steering knuckle onto the ball joint stud in lower control arm. 4. Install the steering knuckle to lower ball joint stud castle nut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4240 Fig. 24 5. Install upper ball joint in steering knuckle. Install the steering knuckle to upper ball joint nut. Tighten the upper ball joint castle nut to a torque of 54 Nm (40 ft. lbs.). Then, using a crowfoot and torque wrench, tighten the lower ball joint nut to a torque of 75 Nm (55 ft. lbs.). Install cotter pins in upper and lower ball joint studs. 6. Install the speed sensor cable routing bracket on the steering knuckle and securely tighten the attaching bolt. Fig. 24 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 7. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 8. Install brake rotor, and caliper, shoes and adapter assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 4241 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto driveshaft stub axle. 10. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 Nm (150 ft. lbs.) of torque. 11. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Then tighten to a torque of 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4247 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4248 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4249 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Fill the the indicated level on the side of the reaervoir. The power steering fluid level should be at normal ambient temperature (70°F - 80°F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4252 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4253 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4254 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. The fluid level can be read through the exterior of the power steering fluid reservoir. The reservoir exterior is marked "FILL RANGE" and "ADD." The fluid shows through the reservoir indicating its level. The fluid level should be within the "FILL RANGE" when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Remove the cap and fill as necessary. Do not overfill the power steering system. Use only Mopar Power Steering Fluid, or equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Reservoir Mounting Screw 53 in.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 4258 Power Steering Fluid Reservoir: Description and Operation DESCRIPTION All vehicles use a remote mounted power steering fluid reservoir. The reservoir is mounted to the engine coolant recovery bottle on the right side of the engine compartment. Coolant level is read through the side of the bottle. OPERATION The power steering fluid reservoir stores fluid for the power steering system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 4259 Power Steering Fluid Reservoir: Service and Repair REMOVAL Fig. 10 1. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 2. Remove screw fastening reservoir to engine coolant recovery bottle. 3. Lift reservoir off guide on engine coolant recovery bottle. 4. Remove hose clamps attaching power steering fluid supply hose and return hose to reservoir. 5. Remove power steering fluid supply and return hoses from reservoir and remove reservoir from vehicle. INSTALLATION 1. Install power steering fluid return and supply hoses on power steering fluid reservoir fittings. Be sure both hose clamps are installed on hose past upset bead on power steering reservoir fittings. 2. Slide reservoir down over guide on engine coolant recovery bottle. 3. Install power steering fluid reservoir mounting screw and tighten to 6 Nm (53 inch lbs.). 4. Fill power steering pump fluid reservoir to the proper level. 5. Start the engine and let run for a few seconds, then turn the engine off. 6. Adjust fluid level if necessary. Repeat steps 5 and 6 until the fluid level remains constant after running the engine. If necessary perform Power Steering Pump Initial Operation standard procedure. See: Power Steering Pump/Service and Repair 7. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Hose Tube Nuts 23 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4263 Power Steering Line/Hose: Description and Operation HOSES DESCRIPTION Fig. 10 The power steering fluid hoses connect the components of the power steering system. The power steering fluid supply hose is a special rubber hose that connects the power steering fluid reservoir to the power steering pump. The hose is secured at each end using a standard adjustable clamp. The power steering fluid pressure hose is a high pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting with an O-ring is used at each end to connect it to either the power steering pump or the gear. The power steering fluid return hose is a special rubber hose that connects the power steering gear to the fluid reservoir. It has a special metal tubing section that acts as cooler running in front of the radiator module. A standard tube nut fitting with an O-ring is used to connect it to the power steering gear. The hose is secured to the reservoir using a standard adjustable clamp. OPERATION The power steering fluid hoses transfer fluid from one power steering system component to the next. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4264 Power Steering Line/Hose: Service and Repair REMOVAL- RETURN HOSE WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. The return hose can be serviced as two separate pieces. They are the Return Hose With Tube and the Return Hose To Reservoir. RETURN HOSE WITH TUBE 1. Siphon power steering fluid from power steering fluid reservoir. 2. Remove vehicles front fascia. 3. If not previously lifted, raise vehicle. 4. Remove left front wheel and tire assembly. 5. Remove wheel opening forward splash shield. 6. Remove power steering fluid pressure hose, then return hose from power steering gear. 7. Remove air shield below left end of bumper reinforcement. Fig. 10 8. Remove clamp and return hose (to reservoir) from right end of return hose tube below the bumper reinforcement. 9. Remove tube mounting clips from bumper reinforcement. 10. Remove the return hose tube from routing clips along left frame rail. 11. Move the steering gear end of return hose tube to outside of frame rail. 12. Pull return hose with tube forward, snaking it between ABS ICU and frame rail. Remove return hose from vehicle. RETURN HOSE TO RESERVOIR 1. Siphon power steering fluid from power steering fluid reservoir. 2. Remove screw fastening power steering fluid reservoir to engine coolant recovery bottle. 3. Lift reservoir off guide on engine coolant recovery bottle. 4. Remove hose clamp attaching power steering fluid return hose to reservoir. 5. Remove power steering fluid return hose from reservoir. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4265 6. Remove vehicles front fascia. 7. If not previously lifted, raise vehicle. 8. Remove clamp and return hose (to reservoir) from right end of return hose tube below the bumper reinforcement. 9. Remove the return hose from routing clip on inside of right frame rail. 10. Remove power steering fluid return hose. INSTALLATION - RETURN HOSE WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. The return hose can be serviced as two separate pieces. They are the Return Hose With Tube and the Return Hose To Reservoir. RETURN HOSE WITH TUBE 1. Install hose with tube in vehicle using the reverse of removal. Guide return hose with tube rearward, snaking it between ABS ICU and frame rail. 2. Install the return hose tube into the routing clips along left frame rail. 3. Install tube along bottom of bumper reinforcement using routing clips. 4. Install return hose (to reservoir) on right end of return hose tube below the bumper reinforcement. Install clamp securing hose in place. 5. Install air shield below left end of bumper reinforcement. 6. Using a lint free towel, wipe clean open power steering hose ends and power steering gear port. 7. Install new O-rings on the power steering hose ends to the steering gear. 8. Lubricate O-rings using fresh clean power steering fluid. 9. Install power steering fluid return hose to power steering gear. Tighten tube nut to 31 Nm (275 inch lbs.). 10. Install power steering fluid pressure hose to power steering gear. Tighten tube nut to 31 Nm (275 inch lbs.). 11. Install wheel opening forward splash shield. 12. Install front fascia. 13. Install left front wheel and tire assembly. Progressively tighten all wheel lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.) torque. 14. Lower vehicle. 16. Fill reservoir with fluid and bleed system using Power Steering Pump Initial Operation standard procedure. 16. Check for leaks. RETURN HOSE TO RESERVOIR 1. Install return hose into routing clip on inside of right frame rail. 2. Install return hose (to reservoir) on right end of return hose tube below the bumper reinforcement. Install clamp securing hose in place. 3. Install front fascia. 4. Lower vehicle. 5. Install power steering fluid return hose on power steering fluid reservoir fitting. Be sure hose clamp is installed on hose past upset bead on power steering reservoir fitting. 6. Slide reservoir down over guide on engine coolant recovery bottle. 7. Install power steering fluid reservoir mounting screw. 8. Fill reservoir with fluid and bleed system using Power Steering Pump Initial Operation standard procedure. See: Power Steering Pump/Service and Repair 9. Check for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4270 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4271 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4272 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4273 Power Steering Pump: Specifications Pump Discharge Fitting 55 ft.lb Pump Front Mounting Bolts 40 ft.lb Pump rear Mounting Bolts 40 ft.lb Pump Bracket-to-Engine Mounting Bolts 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4274 Power Steering Pump: Description and Operation DESCRIPTION All vehicles are equipped with power steering. The hydraulic pressure for operation of the power steering gear is provided by a belt driven power steering pump. The pump is a constant flow rate and displacement vane type power steering pump. The power steering pump is mounted on the back side of the engine, above the front suspension crossmember. The power steering pump uses a remote mounted reservoir for storage of the power steering fluid. Because of unique shaft bearings, flow control levels or pump displacements, power steering pumps may be used only on specific vehicle applications. Be sure that the power steering pump is only replaced with a pump that is the correct replacement for that specific application. OPERATION Hydraulic pressure is provided for operation of the power steering gear by the belt driven power steering pump. The power steering pump is connected to the steering gear by a power steering fluid pressure hose, return hose, power steering fluid cooler and remote power steering fluid reservoir. Rectangular pumping vanes in the shaft driven rotor move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump. As the rotor begins to turn, centrifugal force throws the vanes against the inside surface of the cam ring to pick up residual oil. This oil is then forced into the high pressure area. As more oil is picked up by the vanes, the additional oil is forced into the cavities of the thrust plate through two crossover holes in the cam ring and pressure plate. The crossover holes empty into the high pressure area between the pressure plate and the housing Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4275 end cover. As the high pressure area is filled, oil flows under the vanes in the rotor slots, forcing the vanes to follow the inside surface of the cam ring. As the vanes reach the restricted area of the cam ring, oil is forced out from between the vanes. When excess oil flow is generated during high-speed operation, a regulated amount of oil returns to the pump intake side through a flow control valve. The flow control valve reduces the power required to drive the pump and holds down temperature build-up. When steering conditions exceed maximum pressure requirements, such as when the wheels are turned against the stops, the pressure built up in the steering gear exerts pressure on the spring end of the flow control valve inside the pump. The high pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the power steering pump. Under normal power steering pump operating conditions, pressure requirements of the pump are below maximum, causing the pressure relief valve to remain closed. In the event of a power steering pump drive belt failure, manual steering control of the vehicle can still be maintained without pump assistance. However, under these conditions, steering effort will be significantly increased. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Initial Operation STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION CAUTION: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21 - 27 °C (70 - 80 °F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. Removal and Installation REMOVAL - PUMP WARNING: POWER STEERING FLUID, ENGINE COMPONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES, OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. 1. Remove battery cable from (-) negative post on battery and isolate cable. 2. Siphon as much power steering fluid as possible out of the remote power steering fluid reservoir. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4278 3. Remove the power steering fluid supply hose fitting. 4. Raise vehicle. 5. Remove accessory drive splash shield. 6. Remove power steering fluid pressure hose from fitting on power steering pump. 7. Remove oxygen sensor harness and clip from edge of pump heat shield. 8. Completely remove bolt at slot in stamped pump adjuster bracket and remove power steering drive belt. 9. Pivot pump out past full-adjust position. This will allow access to two pump bracket-to-engine mounting bolts. 10. Remove the three bolts fastening the cast power steering pump bracket to the engine. 11. Remove power steering pump, pulley and brackets as an assembly from the engine. Remove the pump through opening between frame rail and right driveshaft. 12. Remove stamped adjuster bracket mounting bolts. Remove bracket from pump. 13. Remove two pivot bolts. Remove cast mounting bracket from pump. 14. For removal of pulley, (Refer to STEERING/PUMP- DISASSEMBLY). INSTALLATION - PUMP 1. If previously removed, install cast mounting bracket on pump using two pivot bolts. Tighten the bolts to a torque of 28 Nm (250 inch lbs.). 2. If previously removed, install stamped adjuster bracket on pump using its mounting bolts. Tighten the bolts to a torque of 28 Nm (250 inch lbs.). 3. Install power steering pump, pulley and brackets as an assembly back in vehicle, using the reverse of the removal procedure. 4. Install the three bolts fastening cast pump mounting bracket to engine. Tighten the bolts to a torque of 28 Nm (250 inch lbs.). 5. Loosely install bolt through the stamped adjuster bracket slot and into the cast bracket. 6. Using a lint free towel, wipe clean all open power steering hose ends, and power steering pump fittings. 7. Install power steering pump drive belt on power steering pump pulley. 8. Install a 1/2 inch breaker bar in the square adjusting hole in the front power steering pump mounting bracket and adjust the belt. 9. When correct drive belt tension is obtained, tighten the adjusting slot bolt to a torque of 28 Nm (250 inch lbs.). 10. Install a new O-ring on end of power steering pressure hose fitting. Lubricate all O-rings using fresh clean power steering fluid. 11. Install the power steering pressure hose on the power steering pump pressure fitting. Tighten the tube nut to a torque of 31 Nm (275 inch lbs.). 12. Install accessory drive splash shield. 13. Lower vehicle. 14. Install power steering fluid supply hose on power steering pump supply fitting. Install hose clamp on hose. Be sure hose clamp is installed on hose past upset bead on power steering fluid reservoir. 15. Connect battery cable back on negative (-) post of battery. 16. Fill power steering reservoir to correct fluid level and perform Power Steering Pump Initial Operation standard procedure. See: Initial Operation 17. Check for leaks at all hose connections and power steering pump. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4279 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL - PUMP (PULLEY) 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount Puller, Special Tool C-4333, on power steering pump pulley. Mount puller (with power steering pump) in a vise. This will keep shaft of power steering pump from turning while removing pulley. 3. Tighten puller and remove pulley from shaft of power steering pump. NOTE: Replace power steering pump pulley if bent, cracked, or loose. INSTALLATION - PUMP (PULLEY) CAUTION: Do not hammer on power steering pump pulley or shaft to install power steering pump pulley. This will damage the pulley and the power steering pump. 1. Place power steering pump pulley squarely on end of power steering pump shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4280 2. Place Installation Spacer, Special Tool 6936, on top of the power steering pump pulley. Fig. 43 3. Mount Installer, Special Tool C-4063, in internal threads of the power steering pump shaft and against Special Tool 6936 on power steering pump pulley. 4. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until Special Tool 6936 is against the end of the power steering pump shaft. When Special Tool 6936 is against the shaft of the power steering pump, Special Tool C-4063 will no longer be able to be turned. 5. Remove Installer from power steering pump. 6. Install power steering pump and mounting bracket back on engine. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 29 On vehicles equipped with a four cylinder engine, a power steering pressure switch is used to improve the vehicle's idle quality when required. When a demand for power assist is put on the power steering system at idle, pump pressure puts additional load on the engine, thus decreasing engine idle speed. The pressure switch improves vehicle idle quality by maintaining the required engine idle speed when the pressure rises in the power steering system. The power steering pressure switch is mounted directly to the power steering gear. OPERATION The pressure switch functions by signaling the powertrain control module that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Page 4285 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 29 1. Disconnect the negative cable from the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove the wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. INSTALLATION CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install wiring harness connector on power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 4290 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection To test the key left in ignition function: - The ignition switch must be in the OFF position with key in ignition. - Driver's door open. - Chime should sound until key is removed from ignition or drivers door is closed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Bearing: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-003-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-003-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NOTE, ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: **This bulletin applies to vehicles built prior to November 10, 2003.** SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4302 SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or TechCONNECT service information for removal and installation procedures. 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.). Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506382AA for JR, p/n 06506112AA for PT, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4303 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft (lower coupling assembly for PT) from the steering column shaft. Install remover/installer, special tool 6831-A, through the center of the roll pin in the intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of remover/installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft.(Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4304 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. (Fig. 2) 21. Install the original steering column shaft, except for vehicles built prior to Oct. 1, 2001 (MDH 1001Xx) install revised shaft p/n 04690852AA, revised wedge, p/n 04690570, and **revised spring, p/n 05057088AA.** 22. Thread the steering wheel bolt into the steering column shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4305 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to a distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4306 NOTE: If the installed dimension is less than 12 mm a binding condition may result. If the installed dimension is greater than 14 mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column assembly into the vehicle. 27. PT VEHICLES - If the airbag retainer clips or foam silencer pads are damaged, they must be replaced. a. Use a large flat tipped screwdriver to pry up on the middle of the driver air bag retaining clip to remove it from the steering wheel armature holes. Refer to (Fig. 5) b. Use a small screwdriver to remove the three (3) existing foam pads from the steering wheel base. c. Insert new clip(s), p/n 05086385AA, in the steering wheel armature holes. The round end of the clip goes in the small hole, open end goes in the larger hole. Put round end in first and press open end with screwdriver as shown in (Fig. 6). d. Install three (3) new foam pads, found in the kit. THE POSITIONING OF THE FOAM PADS IS CRITICAL, AS THE GROUND FOR THE HORN IS AFFECTED BY POSITION OF THE PADS. Two EXTRA pads are included in the kit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4307 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Column Bearing: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-003-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-003-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NOTE, ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: **This bulletin applies to vehicles built prior to November 10, 2003.** SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4313 SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or TechCONNECT service information for removal and installation procedures. 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.). Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506382AA for JR, p/n 06506112AA for PT, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4314 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft (lower coupling assembly for PT) from the steering column shaft. Install remover/installer, special tool 6831-A, through the center of the roll pin in the intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of remover/installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft.(Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4315 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. (Fig. 2) 21. Install the original steering column shaft, except for vehicles built prior to Oct. 1, 2001 (MDH 1001Xx) install revised shaft p/n 04690852AA, revised wedge, p/n 04690570, and **revised spring, p/n 05057088AA.** 22. Thread the steering wheel bolt into the steering column shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4316 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to a distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4317 NOTE: If the installed dimension is less than 12 mm a binding condition may result. If the installed dimension is greater than 14 mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column assembly into the vehicle. 27. PT VEHICLES - If the airbag retainer clips or foam silencer pads are damaged, they must be replaced. a. Use a large flat tipped screwdriver to pry up on the middle of the driver air bag retaining clip to remove it from the steering wheel armature holes. Refer to (Fig. 5) b. Use a small screwdriver to remove the three (3) existing foam pads from the steering wheel base. c. Insert new clip(s), p/n 05086385AA, in the steering wheel armature holes. The round end of the clip goes in the small hole, open end goes in the larger hole. Put round end in first and press open end with screwdriver as shown in (Fig. 6). d. Install three (3) new foam pads, found in the kit. THE POSITIONING OF THE FOAM PADS IS CRITICAL, AS THE GROUND FOR THE HORN IS AFFECTED BY POSITION OF THE PADS. Two EXTRA pads are included in the kit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4318 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls for Steering Gear: > NHTSA00V225002 > Aug > 00 > Recall 00V225002: Steering Gear Vibration/Stiff Steering Gear: Recalls Recall 00V225002: Steering Gear Vibration/Stiff A nut in the steering gear assembly was not properly tightened, resulting in symptoms ranging from steering wheel vibration to stiff steering, and in the worst case, no ability to turn left. A loss of steering control could increase the risk of a crash. Dealers will inspect these vehicles and replace the steering gear assembly if a loose nut connection is found. Owner notification began October 11, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > NHTSA00V225002 > Aug > 00 > Recall 00V225002: Steering Gear Vibration/Stiff Steering Gear: All Technical Service Bulletins Recall 00V225002: Steering Gear Vibration/Stiff A nut in the steering gear assembly was not properly tightened, resulting in symptoms ranging from steering wheel vibration to stiff steering, and in the worst case, no ability to turn left. A loss of steering control could increase the risk of a crash. Dealers will inspect these vehicles and replace the steering gear assembly if a loose nut connection is found. Owner notification began October 11, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4332 Steering Gear: Specifications Gear Mounting Bolts 50 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4333 Steering Gear: Description and Operation DESCRIPTION The steering gear on this vehicle is a rack and pinion unit with power assist. It is mounted on the front suspension crossmember. The steering column connects to the steering gear shaft on top of the gear. The outer tie rod ends of the gear connect to each suspension steering knuckle to steer the vehicle. OPERATION Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs fluid from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. This movement directs fluid behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. The drive tangs on the gear pinion mate loosely with a stub shaft. This is to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation REMOVAL Fig. 5 Fig. 6 1. Remove remote ground cable from ground stud on shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud. 2. Siphon as much power steering fluid as possible from the remote power steering fluid reservoir. 3. Place the steering wheel and front wheels in the STRAIGHT-AHEAD position. Lock the steering wheel in this position using a steering wheel holder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4336 Fig. 3 4. Under the instrument panel, disconnect the intermediate shaft from the steering gear shaft. To do so, remove the pinch bolt from the intermediate shaft coupler, then slide the intermediate shaft up and off the steering gear shaft. 5. Raise vehicle on jack stands or centered on a frame contact type hoist. 6. Remove both front wheel and tire assemblies from the vehicle. Fig. 5 7. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4337 Fig. 10 8. Remove both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-991113. CAUTION: This vehicles is designed and assembled using NET BUILD front suspension alignment settings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in relation to the vehicle body. This process is carried out when building the vehicle, by accurately locating the front suspension crossmember to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer necessary or possible to adjust a vehicles front suspension alignment settings. Consequently, whenever the front suspension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspension Toe settings though are still adjustable by the outer tie rod ends. CAUTION: Before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle. This must be done so front suspension crossmember can be located against body of vehicle, in the same location when it is installed back in vehicle. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assembled, NET BUILD front suspension alignment settings will not be obtained. This may lead to handling and or tire wear problems. NOTE: Use the following procedure to mark the side to side and front to back installed location of the front suspension crossmember to the body of the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4338 Fig. 11 Fig. 12 9. Using an awl, scribe a line on the body and marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle. In and the left side of the vehicle is shown. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4339 Fig. 9 10. Using an awl, scribe a line on the front suspension crossmember marking the side to side installed location where front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at the side of the frame rail bracket where the crossmember is mounted to the vehicle. The locating mark is to be marked the same on each side of the vehicle. In the left side of the vehicle is shown. Fig. 10 11. Remove the stabilizer bar bushing clamp to body attaching bolts only. The sway bar bushing clamp to front suspension crossmember bolts do not need to be removed 12. If vehicle is equipped with antilock brakes, the hydraulic control unit can not hang from the brake tubes when lowering front suspension crossmember. Using wire, tie the antilock brakes hydraulic control unit to the body and engine so the wire will support it when the crossmember is lowered. 13. If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4340 Fig. 15 14. Remove the bolts attaching the shock absorber clevis to the left and right lower control Fig. 12 15. Remove the 2 bolts attaching the under engine support bracket to the front edge of the front suspension crossmember. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4341 Fig. 17 16. Remove the 2 attaching bolts from the rear support bracket at the rear of the front suspension crossmember. Fig. 18 17. Remove bolt attaching engine support bracket to the transaxle mounting bracket. 18. Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4342 Fig. 19 19. From each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle. 20. Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission Jack. Fig. 20 21. Remove power steering fluid, pressure and return hoses from the power steering gear assembly. 22. Remove wiring harness connector, from the power steering fluid pressure switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4343 Fig. 21 Fig. 22 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4344 Fig. 19 23. Remove the 2 bolts, at the isolators and attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracketto the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember 24. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed. INSTALLATION 1. Install steering gear assembly on front suspension crossmember. Install the 2 long steering gear assembly to front crossmember mounting bolts and into the mounting isolators. Then install the 2 short boltsinto the saddle bracket. Tighten the 4 steering gear mounting bolts to a torque of 68 Nm (50 ft. lbs.). 2. Install the power steering fluid pressure and return lines on the ports of the power steering gear. Tighten power steering fluid pressure and return lines to steering gear tube nuts to a torque of 31 Nm (275 inch lbs.). 3. Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle. Tighten the 4 mounting bolts evenly, until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 Nm (20 inch lbs.) to hold front suspension crossmember in position. CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings. 4. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the previously scribed positioning marks on body of vehicle, and. When front suspension crossmember is correctly positioned, torque the 2 rear crossmember mounting bolts to 163 Nm (120 ft. lbs.). Then torque the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.). 5. Install the engine support bracket on the front of the front suspension crossmember. Install the 2 support bracket to suspension crossmember attaching bolts and tighten to a torque of 75 Nm (55 ft. lbs.). 6. Install bolt attaching engine support bracket to transaxle mounting bracket. Tighten bolt to a torque of 75 Nm (55 ft. lbs.). 7. Install the 2 bolts attaching the rear support bracket, for the under engine support bracket, to the rear of the front suspension crossmember. Tighten bolts to a torque of 75 Nm (55 ft. lbs.). 8. Install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch. 9. Install the antilock brakes hydraulic control unit mounting bracket on the front suspension crossmember. Install the 3 mounting bracket to crossmember attaching bolts and tighten to a torque of 28 Nm (250 inch lbs.). 10. Loosely install the 2 shock absorber clevis to lower control arm attaching nuts and bolts. 11. Install tie rod seal boot heat shield on tie rod end. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4345 Fig. 23 12. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 55 Nm (40 ft. lbs.). 13. Install and tighten the 2 stabilizer bar bushing clamp to body attaching bolts. Fig. 25 CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown in. 14. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm. 15. Tighten the shock absorber clevis to lower control arm bushing thru-bolt to a torque of 92 Nm (68 ft. lbs.). 16. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts in proper sequence to a torque of 129 Nm (95 ft. lbs.). CAUTION: Before connecting the steering column intermediate shaft coupler to the steering gear shaft, position the front wheels STRAIGHT-AHEAD. The steering wheel must also be in the centered position. 17. Under the instrument panel, reconnect the intermediate shaft to the steering gear shaft. To do so, align the flats and slide the intermediate shaft onto the steering gear shaft aligning the pinch bolt hole with the notch formed into the steering gear shaft. Install a new pinch bolt in the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4346 intermediate shaft coupler, then tighten the pinch bolt to a torque of 44 Nm (32 ft. lbs.). 18. Remove the steering wheel holder. CAUTION: Do not use automatic transmission fluid in place of power steering fluid. 19. Fill power steering pump fluid reservoir to the proper level and perform Power Steering Pump Initial Operation standard procedure. 20. Check for leaks. 21. Check front alignment and adjust the front toe setting on the vehicle. 22. Tighten tie rod jam nuts to 74 Nm (55 ft. lbs.) torque. 23. Adjust steering gear to tie rod boots at tie rods. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4347 Steering Gear: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Using a screwdriver, pry the sleeve out of the mounting Bolt isolator. 2. Pry the mounting bolt isolator bushing from the steering gear mounting bracket. ASSEMBLY 1. Lubricate replacement mounting bolt isolator bushing using Mopar, Silicone Spray Lube or an equivalent. Fig. 27 2. Install the mounting bolt isolator bushing into the steering gear mounting bracket from the bottom side of the bracket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4348 Fig. 28 3. Install mounting bolt isolator bushing sleeve into isolator bushing by pressing the sleeve into the bushing by hand . Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft: Customer Interest Steering - Steering Column Clicking Sound NUMBER: 19-003-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-003-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NOTE, ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: **This bulletin applies to vehicles built prior to November 10, 2003.** SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4357 SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or TechCONNECT service information for removal and installation procedures. 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.). Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506382AA for JR, p/n 06506112AA for PT, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4358 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft (lower coupling assembly for PT) from the steering column shaft. Install remover/installer, special tool 6831-A, through the center of the roll pin in the intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of remover/installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft.(Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4359 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. (Fig. 2) 21. Install the original steering column shaft, except for vehicles built prior to Oct. 1, 2001 (MDH 1001Xx) install revised shaft p/n 04690852AA, revised wedge, p/n 04690570, and **revised spring, p/n 05057088AA.** 22. Thread the steering wheel bolt into the steering column shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4360 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to a distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4361 NOTE: If the installed dimension is less than 12 mm a binding condition may result. If the installed dimension is greater than 14 mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column assembly into the vehicle. 27. PT VEHICLES - If the airbag retainer clips or foam silencer pads are damaged, they must be replaced. a. Use a large flat tipped screwdriver to pry up on the middle of the driver air bag retaining clip to remove it from the steering wheel armature holes. Refer to (Fig. 5) b. Use a small screwdriver to remove the three (3) existing foam pads from the steering wheel base. c. Insert new clip(s), p/n 05086385AA, in the steering wheel armature holes. The round end of the clip goes in the small hole, open end goes in the larger hole. Put round end in first and press open end with screwdriver as shown in (Fig. 6). d. Install three (3) new foam pads, found in the kit. THE POSITIONING OF THE FOAM PADS IS CRITICAL, AS THE GROUND FOR THE HORN IS AFFECTED BY POSITION OF THE PADS. Two EXTRA pads are included in the kit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4362 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound Steering Shaft: All Technical Service Bulletins Steering - Steering Column Clicking Sound NUMBER: 19-003-04 REV. A GROUP: Steering DATE: August 27, 2004 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL SEPT. 3, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-003-04 DATED APRIL 6, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NOTE, ADDITIONAL PART AND CHANGE TO THE REPAIR PROCEDURE. SUBJECT: Steering Column Click Sound OVERVIEW: This bulletin involves aligning the steering column or removing the steering column and installing a new steering column shaft, revised wedge, **revised spring** and seating the lower bearing. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2004 (PT) Chrysler PT Cruiser NOTE: **This bulletin applies to vehicles built prior to November 10, 2003.** SYMPTOM/CONDITION: A click sound is heard when the steering wheel is turned. PARTS REQUIRED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4368 SPECIAL TOOLS/EQUIPMENT REQUIRED DIAGNOSIS/REPAIR PROCEDURE: NOTE: Refer to the appropriate service manual or TechCONNECT service information for removal and installation procedures. 1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove the steering column shrouds. 2. Turn the steering wheel, listen to hear if the click sound remains. 3. If the click sound is eliminated determine the source interference with the steering column shrouds and correct, the repair is then complete. WARNING: When an undeployed airbag is to be removed from the steering wheel, disconnect and isolate the battery ground cable. Allow system capacitor to discharge for two minutes, then begin airbag removal. NOTE: Be sure to center the steering wheel and have the front tires and wheels straight ahead before removing the steering wheel and disconnecting the lower coupling. Access to the steering column shaft coupler screw is easier if the steering wheel is turned so the screw head is pointing straight down. 4. If a click sound is heard, remove the steering wheel and disconnect the intermediate shaft to steering gear (lower) coupling. NOTE: Turn the steering shaft no more than one revolution in either direction from center. Keep track of the centered position. 5. Turn the steering shaft, listen to see if the click sound remains. 6. If the click sound is eliminated reattach the lower coupling and install the steering wheel, being sure the clock spring/steering wheel travel is centered. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm (40 ft. lbs.). 7. Turn the steering wheel; listen to hear if the click sound remains. 8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering column mounting bracket nuts. 9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the coupling pinch bolt to 29 Nm (21 ft. lbs.). Tighten the 2 lower steering column assembly mounting nuts to hold the steering column in place. Be sure both break-away capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten both steering column mounting nuts, until upper steering column mounting bracket is seated against support bracket. Tighten the 4 steering column bracket to support bracket nuts to 17 Nm (150 in. lbs.). 10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is eliminated, replace the lower coupling pinch bolt, p/n 06506382AA for JR, p/n 06506112AA for PT, torque the coupling pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete. 11. If the click sound remains, remove the clock spring. To avoid damaging the clock spring: a. The clock spring is positioned to the lock housing by two snap latch features at 12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over the lock housing. This will prevent the latch from being broken. b. Care should be taken regarding centering of the steering wheel and clock spring with respect to the front wheels; follow the service manual clock spring centering procedure. Turning the steering wheel when the column is disconnected from the steering gear can damage the clock spring. c. When using the steering wheel puller, hand tighten the puller bolts (no more than five revolutions) and avoid contact between the bolts and the top of the clock spring. d. When removing the airbag inflator connectors, squeeze the sides of the connector, to release it, while pulling it out of the airbag. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4369 12. Disconnect the lower coupling. 13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is eliminated determine the source interference with the clock spring and correct, the repair is then complete. 14. If the click sound remains, remove the steering column from the vehicle. NOTE: The ignition key must be turned to the run position to remove the shifter/ignition interlock cable from the key lock housing. 15. Remove the two screws attaching the multifunction switch and separate the switch from the steering column. 16. Remove the steering column intermediate shaft (lower coupling assembly for PT) from the steering column shaft. Install remover/installer, special tool 6831-A, through the center of the roll pin in the intermediate shaft's universal joint and install knurled nut. While holding hex on end threaded rod, tighten the nut on threaded rod of remover/installer. This will pull the roll pin out of the intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft. 17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it off the end of the steering column shaft.(Fig. 1). 18. Remove the spring, wedge and steering column shaft. 19. Inspect the upper and lower steering column bearings, if damaged replace them/it as necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with notch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4370 20. Stand the steering column on end so the outer race of the upper bearing is supported on a 1-1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed against the lower bearing outer race tap the bearing downward several times with a brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure no clearance exists between the lower casting and the outer race of the lower bearing. (Fig. 2) 21. Install the original steering column shaft, except for vehicles built prior to Oct. 1, 2001 (MDH 1001Xx) install revised shaft p/n 04690852AA, revised wedge, p/n 04690570, and **revised spring, p/n 05057088AA.** 22. Thread the steering wheel bolt into the steering column shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4371 23. Stand the column assembly on the head of the steering wheel bolt, insure the surface is flat. Refer to (Fig. 3). 24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8" deep well socket and small hammer to tap the retainer into place so the installed distance between the lower housing and the outside face of the retainer is 12-14 mm (15/32-17/32 in.). If the retainer is installed to a distance less than 12 mm (15/32 in.) remove the retainer and install a new retainer, repeat as necessary until the installed distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4372 NOTE: If the installed dimension is less than 12 mm a binding condition may result. If the installed dimension is greater than 14 mm a loose condition may result. 25. Verify the click sound has been corrected. If a sound is still present further diagnosis is required. 26. Using the procedures outlined in the appropriate service information, install the steering column assembly into the vehicle. 27. PT VEHICLES - If the airbag retainer clips or foam silencer pads are damaged, they must be replaced. a. Use a large flat tipped screwdriver to pry up on the middle of the driver air bag retaining clip to remove it from the steering wheel armature holes. Refer to (Fig. 5) b. Use a small screwdriver to remove the three (3) existing foam pads from the steering wheel base. c. Insert new clip(s), p/n 05086385AA, in the steering wheel armature holes. The round end of the clip goes in the small hole, open end goes in the larger hole. Put round end in first and press open end with screwdriver as shown in (Fig. 6). d. Install three (3) new foam pads, found in the kit. THE POSITIONING OF THE FOAM PADS IS CRITICAL, AS THE GROUND FOR THE HORN IS AFFECTED BY POSITION OF THE PADS. Two EXTRA pads are included in the kit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-003-04A > Aug > 04 > Steering - Steering Column Clicking Sound > Page 4373 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod Adjustment Jam Nut 45 ft.lb Tie Rod Steering Knuckle Nut 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4378 Tie Rod End: Service and Repair REMOVAL - OUTER TIE ROD 1. Raise vehicle. 2. Remove wheel and tire assembly. Fig. 29 3. Loosen inner tie rod-to-outer tie rod jam nut. Fig. 9 4. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4379 Fig. 10 5. Remove tie rod end stud, from steering knuckle, using Remover, Special Tool MB-991113. 6. Remove outer tie rod end from inner tie rod by unthreading it from the inner tie rod. INSTALLATION - OUTER TIE ROD 1. Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod before installing outer tie rod. Do not tighten jam nut at this time. 2. Install tie rod end seal boot heat shield on the tie rod end. Fig. 24 3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket, torque tie rod end attaching nut to 61 Nm (45 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 4. Tighten tie rod jam nut to 61 Nm (45 ft. lbs.) torque. 5. Install tire and wheel assembly. 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4380 7. Adjust the front wheel alignment toe setting on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications Ball Joint: Specifications Ball Joint Wear Limit Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................................... 0.059" Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications > Page 4386 Ball Joint: Specifications To Knuckle Castle Nut 63 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint Ball Joint: Description and Operation Lower Ball Joint LOWER BALL JOINT DESCRIPTION The ball joint used in the lower control arm of this vehicle is a sealed for life ball joint. The ball joint can not be replaced as a separate component of the lower control arm assembly. If the ball joint is determined to be defective it will require replacement of the complete lower control arm assembly. The lower ball joint connection to the steering knuckle is achieved by an interference fit created by the tapered stud of the ball joint and a tapered hole in the steering knuckle. The ball joint stud is retained in the steering knuckle using a castle nut and a cotter pin. The cotter pin is used for positive retention of the castle nut. The lower ball joint is lubricated for life at the time it is assembled in the lower control arm. 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 to the lower ball joint. OPERATION The ball joint is a pivotal joint that allows the knuckle to move up and down, and turn with ease. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint > Page 4389 Ball Joint: Description and Operation Upper Ball Joint UPPER BALL JOINT DESCRIPTION The ball joint is pressed into the upper control arm and has a tapered stud for attachment to the steering knuckle. The ball joint stud is attached and locked into the steering knuckle using a castle nut and cotter pin. The ball joint is not serviceable as a separate component of the upper control arm. If the ball joint is defective it will require replacement of the entire upper control arm. OPERATION The ball joint is a pivotal joint that allows the knuckle to move up and down and turn with ease. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint DIAGNOSIS AND TESTING - LOWER BALL JOINT 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Install a dial indicator on the vehicle so it is contacting the top surface of the steering knuckle near the lower ball joint stud castle nut. 3. Grab wheel and tire assembly and push it up and down firmly. 4. Record the amount of up and down movement of the steering knuckle recorded on the dial indicator. 5. Replace lower control arm if the movement in the lower control arm exceeds 1.5 mm (0.059 inch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 4392 Ball Joint: Testing and Inspection Upper Ball Joint Front DIAGNOSIS AND TESTING - UPPER BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the grease fitting and with no mechanical assistance or added force, attempt to move the grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of the upper control arm is required. Rear UPPER BALL JOINT DIAGNOSIS AND TESTING - UPPER BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the grease fitting and with no mechanical assistance or added force, attempt to move the grease fitting. If the ball joint is worn, the grease fitting will move easily. If movement is noted, replacement of the ball joint is required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover Ball Joint: Service and Repair Lower Ball Joint Dust Cover BALL JOINT SEAL BOOT (LOWER) REMOVAL CAUTION: The replacement of the lower ball joint seal boot can only be done in the event that the seal boot is damaged while performing a service procedure on the vehicle. CAUTION: Under no circumstances can a lower ball joint seal boot be replaced if it is determined that the vehicle had been driven with the seal boot damaged. If the vehicle has been driven with a damaged seal boot contamination of the ball joint has occurred. When contamination of the ball joint has occurred the lower control arm must be replaced. This is to ensure excessive wear of the ball joint does not occur from the contamination present in the ball joint. CAUTION: Excessive wear in the ball joint can lead to a separation of the ball joint from the lower control arm. CAUTION: The procedure below must be carefully followed when replacing the ball joint seal in the event it is damaged while servicing a vehicle. CAUTION: The ball joint used in the lower control arm of this vehicle is a lubricated for life ball joint. This ball joint does not required any additional lubrication for the life of the vehicle. Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint. If it is determined that the ball joint is lacking proper lubrication, the lower control arm will need to be replaced. 1. Remove lower control arm assembly from vehicle. 2. Wrap a shop towel around the ball joint and seal boot. This is to prevent dirt and cleaning solvent to enter ball joint when cleaning area around ball joint. 3. Using ONLY a solvent such as Mopar Foamy Engine Degreaser or an equivalent, thoroughly clean lower control arm in area around ball joint and seal. Then using a shop towel saturated with the engine degreaser, carefully wipe off the ball joint seal boot. 4. Using 2 screwdrivers remove the ball joint seal retaining ring from the bottom of the ball joint seal. a. Remove ball joint seal from ball joint. INSTALLATION CAUTION: The replacement of the lower ball joint seal boot can only be done in the event that the seal boot is damaged while performing a service procedure on the vehicle. CAUTION: Under no circumstances can a lower ball joint seal boot be replaced if it is determined that the vehicle had been driven with the seal boot damaged. If the vehicle has been driven with a damaged seal boot contamination of the ball joint has occurred. When contamination of the ball joint has occurred the lower control arm must be replaced. This is to ensure excessive wear of the ball joint does not occur from the contamination present in the ball joint. CAUTION: Excessive wear in the ball joint can lead to a separation of the ball joint from the lower control arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover > Page 4395 CAUTION: The procedure below must be carefully followed when replacing the ball joint seal in the event it is damaged while servicing a vehicle. CAUTION: The ball joint used in the lower control arm of this vehicle is a lubricated for life ball joint. This ball joint does not required any additional lubrication for the life of the vehicle. Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint. If it is determined that the ball joint is lacking proper lubrication, the lower control arm will need to be replaced. CAUTION: When replacing ball joint seal, do not use any other type of grease to lubricate ball joint other than the lubricant provided in the Mopar Ball Joint Seal service kit. 1. Apply grease from the ball joint seal kit, to the specified areas of the ball joint stud and seal. Be sure no grease is present on the seal boot installation section of the seal boot or lower control arm. 2. Slide ball joint seal boot with upper seal ring installed, down tapered section of ball joint stud. Seal boot is to be installed on stud of ball joint until seal boot is sitting on seal groove in lower control arm. 3. Carefully position ball joint seal boot in seal retaining groove on lower control arm. After installing seal boot in retaining groove, carefully bleed air out of sealing boot without getting grease pushed into seal boot retaining groove in lower control arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover > Page 4396 4. Place Retaining Ring Installer, Special Tool, 6875-1 over ball joint seal boot. Using adjusting knob, adjust tool so bottom edge of tool is even with top of retaining ring groove in seal boot. 5. Place seal boot retaining ring on Installer, Special Tool, 6875-1. Then place expandable collar from Installer, Special Tool, 6875 over tapered cone of the special tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover > Page 4397 6. Using the expandable collar of Installer, Special Tool, 6875 push the seal boot retaining ring down the cone of Installer, Special Tool, 6875. 7. Continue pushing retaining ring down Installer, Special Tool, 6875 until it is installed in the retaining ring groove of the seal boot 8. Remove Installer, Special Tool, 6875 from the ball joint seal boot. When removing tool from seal boot be careful not to damage the seal boot with the tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover > Page 4398 9. Check retaining ring installation on seal boot to ensure it is fully seated in seal boot groove and the ends are not twisted. Also, make sure upper sealing ring is on seal boot and correctly installed. Check seal boot for damage before installing back on car. 10. Install lower control arm assembly back on vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Dust Cover > Page 4399 Ball Joint: Service and Repair Upper Ball Joint Dust Cover BALL JOINT SEAL BOOT (UPPER) REMOVAL 1. Using a screw driver or other suitable tool, pry seal boot off of the ball joint assembly. INSTALLATION 1. Install a NEW ball joint assembly sealing boot on ball joint assembly. Install sealing boot as far as possible on ball joint assembly. CAUTION: Do not use an arbor press to install the sealing boot on the upper control arm ball joint assembly. Damage to the sealing boot can occur do to excessive pressure applied to sealing boot when being installed. 2. Position Receiving Cup, Special Tool 6758 over sealing boot so it is aligned properly with bottom edge of sealing boot. Apply pressure BY HAND) to special tool 6758, until sealing boot is pressed squarely against surface of upper control arm. 3. Properly lubricate the upper ball joint assembly using only Mopar Multi-Mileage Lube or an equivalent. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Customer Interest: > 02-009-00 > Dec > 00 > Rear Suspension - Popping or Squawking Noises Control Arm: Customer Interest Rear Suspension - Popping or Squawking Noises NUMBER: 02-009-00 GROUP: Suspension DATE: Dec. 29, 2000 SUBJECT: Popping or Squawking Noise From Rear Suspension OVERVIEW: This bulletin involves diagnosing and it necessary replacing rear upper control arms. MODELS: 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible SYMPTOM/CONDITION: Popping or squawking noise from rear suspension while driving vehicle. Noise can be mistaken for a strut or strut mount condition. DIAGNOSIS: Play in the rear suspension upper control arm bushing may be caused by improperly installed bushings (Fig. 1). If the bushing is not visually improperly installed, place a pry bar between the control arm and lip of the bushing. Apply light to moderate force, it there is any movement between the two, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Replace the upper control arm assembly(s) as described on page 2-50 of the 2001 Sebring/Stratus Sedan Service Manual (Pub. No 81-270-1021). POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Customer Interest: > 02-009-00 > Dec > 00 > Rear Suspension - Popping or Squawking Noises > Page 4408 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-009-00 > Dec > 00 > Rear Suspension - Popping or Squawking Noises Control Arm: All Technical Service Bulletins Rear Suspension - Popping or Squawking Noises NUMBER: 02-009-00 GROUP: Suspension DATE: Dec. 29, 2000 SUBJECT: Popping or Squawking Noise From Rear Suspension OVERVIEW: This bulletin involves diagnosing and it necessary replacing rear upper control arms. MODELS: 2001 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible SYMPTOM/CONDITION: Popping or squawking noise from rear suspension while driving vehicle. Noise can be mistaken for a strut or strut mount condition. DIAGNOSIS: Play in the rear suspension upper control arm bushing may be caused by improperly installed bushings (Fig. 1). If the bushing is not visually improperly installed, place a pry bar between the control arm and lip of the bushing. Apply light to moderate force, it there is any movement between the two, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Replace the upper control arm assembly(s) as described on page 2-50 of the 2001 Sebring/Stratus Sedan Service Manual (Pub. No 81-270-1021). POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-009-00 > Dec > 00 > Rear Suspension - Popping or Squawking Noises > Page 4414 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Arm: > NHTSA00V320002 > Oct > 00 > Recall 00V320002: Defective Fuel Return Hose Fuel Return Line: All Technical Service Bulletins Recall 00V320002: Defective Fuel Return Hose The outer layer only of this 3-layer fuel return hose does not contain the desired ozone protection due to a processing error. This hose is considered to be inadequate. Dealers will replace the fuel return hose. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications > Front Control Arm: Specifications Upper Control Arm Ball Joint Stud Castle Nut 40 ft.lb Shock Bracket Bolt 66 ft.lb Lower Control Arm Ball Joint Stud Castle Nut 55 ft.lb Front Pivot Bolt 135 ft.lb Rear Bolt 70 ft.lb Ball Joint Heat Sheild 10 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications > Front > Page 4427 Control Arm: Specifications Upper Control Arm Pivot Bar to Crossmember 80 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front Control Arm: Description and Operation Front Upper Control Arm UPPER CONTROL ARM DESCRIPTION The upper control arm is a high strength steel stamping. The upper control arm uses the 2 rubber bushings of the upper control arm/shock absorber mounting bracket to isolate it from the mounting bracket and the body of the vehicle. The upper control arm is bolted to the top of the steering knuckle through the upper ball joint. If damaged, the upper control arm is serviced only as a complete component. Inspect the upper control arm for any signs of damage. If control arm shows any sign of damage the upper control arm must be replaced. Do not attempt to repair or straighten a broken or bent upper control arm. The only serviceable component of the upper control arm is the ball joint grease seal. No other repair or replacement procedure should be attempted on any component of the upper control arm. Service procedures to replace the serviceable components are detailed in the specific component. OPERATION The upper control arm supports the upper end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel. Lower Control Arm LOWER CONTROL ARM DESCRIPTION The lower control arm is a ductile iron casting using 2 rubber bushings to isolate it from the front suspension crossmember and body of the vehicle. The isolator bushings consist of 2 metal encased rubber isolated pivot bushings. The front of the lower control arm is bolted to the front crossmember using a bolt through the center of the rubber pivot bushing. The rear of the lower control arm is mounted to the front suspension crossmember using a through-bolt. The lower control arms are inter-connected through a linked rubber isolated sway bar. OPERATION The lower control arm supports the lower end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel. It also provides a lower mounting point for the shock assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Front > Page 4430 Control Arm: Description and Operation Rear UPPER CONTROL ARM DESCRIPTION An upper control arm is attached to the top of each rear knuckle, connecting the knuckle to the rear suspension crossmember. The attachment of the upper control arm to the knuckle is achieved through a ball joint in the upper control arm. The upper control arm is bolted to the rear suspension crossmember using a pivot bar which is rubber isolated from the upper control arm. OPERATION The upper control arm supports the upper end of the knuckle and allows for the up and down movement of the suspension under jounce and rebound travel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Description and Operation > Page 4431 Control Arm: Testing and Inspection DIAGNOSIS AND TESTING LOWER CONTROL ARM If damaged, the lower control arm casting is serviced only as a complete component. Inspect lower control arm for signs of damage from contact with the ground or road debris. If lower control arm shows any sign of damage, inspect lower control arm for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. The replaceable components of the lower control arm are: the ball joint grease seal and the control arm bushings. Inspect both control arm bushings for severe deterioration, and replace if required. Inspect the lower ball joint for wear. Use the wear inspection procedure in the diagnosis and testing to determine if the wear is excessive and ball joint (lower control arm) replacement is required. Service procedures to replace these components are detailed in the specific component removal and installation procedure. INSPECTION UPPER CONTROL ARM If damaged, the upper control arm is serviced only as a complete component. Inspect the upper control arm for any signs of damage. If control arm shows any sign of damage the upper control arm must be replaced. Do not attempt to repair or straighten a broken or bent upper control arm. The only serviceable component of the upper control arm is the ball joint grease seal. No other repair or replacement procedure should be attempted on any component of the upper control arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension Control Arm: Service and Repair Front Suspension Removal REMOVAL 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel from the vehicle. NOTE: Removing the tie rod end from the steering knuckle allows the steering knuckle to be turned further. This allows better access to the steering knuckle when striking it to remove the ball joint stud from the steering knuckle. Fig. 31 3. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Fig. 32 4. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB-991113. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4434 Fig. 33 5. Remove cotter pin and castle nut from stud of lower ball joint. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate the lower ball joint from the steering knuckle. The steering knuckle is to be separated from the ball joint only using the procedure as described in step Step 6 below. CAUTION: When striking the steering knuckle, do not hit the heat shield covering the ball joint grease seal. Bending the heat shield against the ball joint grease seal will cause the grease seal to fail. Fig. 34 6. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel opening as possible. Using a hammer, strike steering knuckle boss until steering knuckle separates from the lower ball joint. When striking steering knuckle care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling the steering knuckle outward from the vehicle after releasing it from the ball joint, can separate inner C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4435 Fig. 35 7. Remove the shock absorber clevis to lower control arm bushing, nut and thru-bolt. Separate the clevis from lower control arm. Fig. 36 8. Remove nut attaching the stabilizer bar link to the lower control arm. When removing nut, hold stud of stabilizer bar link from turning by inserting an alien wrench in the end of the stud Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4436 Fig. 37 9. Remove the bolts attaching the one stabilizer bar bushing clamp to the front suspension crossmember and the body of the vehicle. 10. Lower the one side of the stabilizer bar away from the lower control arm and body of vehicle. Fig. 38 11. Remove the nut and bolt attaching the rear of the lower control arm to the front suspension crossmember. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4437 Fig. 39 12. Remove nut and bolt attaching the front of the lower control arm to the front suspension crossmember. CAUTION: When removing lower control arm from crossmember care must be taken to prevent hitting lower ball joint seal against steering knuckle, causing damage to the ball joint seal. 13. Remove the front of the lower control arm from the front suspension crossmember first. 14. Then, remove the rear of the lower control arm from the front suspension crossmember. When removing rear of lower control arm from crossmember, keep control arm as level as possible. This will keep rear bushing from binding on crossmember making it easier to remove control arm from crossmember. Installation INSTALLATION Fig. 38 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4438 Fig. 39 1. Position rear of lower control arm into front suspension crossmember first. Then install front of lower control arm in front suspension crossmember. Install bolts and nuts attaching the front and rear of lower control arm to front suspension crossmember. Do not tighten front attaching bolt at this time. 2. Tighten lower control arm rear attaching nut and bolt to a torque of 95 Nm (70 ft. lbs.). Fig. 33 3. Install the lower control arm ball joint stud into the steering knuckle. Install the steering knuckle to ball joint stud castle nut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4439 Fig. 31 Fig. 47 4. Install the tie rod end into the steering knuckle. Start the tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 5. Tighten the lower control arm ball joint stud castle nut to a torque of 74 Nm (55 ft. lbs.). Install the cotter pin in the ball joint stud. 6. Position sway bar link into its lower control arm mounting hole. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4440 Fig. 37 7. Align sway bar bushing clamp with mounting holes in front suspension crossmember and body of vehicle. Then install and securely tighten the bushing clamp mounting bolts to a torque of 61 Nm (45 ft. lbs.). Fig. 36 8. Install and securely tighten the stabilizer bar link to lower control arm attaching nut to a torque of 102 Nm (75 ft. lbs.). When tightening and torquing attaching nut, hold stud of attaching link from turning with an alien wrench. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4441 Fig. 35 9. Install the clevis on the lower control arm. Loosely install the clevis to bushing thru-bolt. CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown in. 10. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm. CAUTION: When tightening the thru-bolt do not turn the bolt in the clevis. The serrations on the bolt and the hole in the clevis will be damaged. 11. With the vehicle's suspension at curb height, tighten the clevis to lower control arm bushing thru-bolt nut to a torque of 88 Nm (65 ft. lbs.). 12. Tighten front lower control arm nut and bolt to a torque of 182 Nm (135 ft. lbs.). 13. Install wheel and tire assembly. 14. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 15. Remove jack stand from under lower control arm and lower vehicle to the ground. 16. Check the vehicles alignment specifications and set front Toe to preferred specifications. Disassembly DISASSEMBLY - FRONT ISOLATOR BUSHING To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4442 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6602-5 and Bushing Receiver, Special Tool MB-990799 on Special Tool C-4212-F. 3. Install lower control arm on Special Tools assembled for removal of the front isolator bushing. Be sure Special Tool MB-990799 is square on lower control arm and Special Tool 6602-5 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F to press front bushing out of lower control arm. DISASSEMBLY - REAR ISOLATOR BUSHING To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6756 and Bushing Receiver, Special Tool C-4366-2 on Special Tool C-4212-F. 3. Install Special Tools assembled for removal of the rear isolator bushing on the lower control arm. Be sure Special Tool C-4366-2 is square on lower control arm and Special Tool 6756 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F to press rear bushing out of lower control arm. DISASSEMBLY- CLEVIS BUSHING To perform removal and replacement of the lower control arm clevis bushing, the lower control arm must be removed from the vehicle. 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6877 and Bushing Receiver, Special Tool 6876 on Special Tool C-4212-F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4443 3. Install lower control arm on Special Tools assembled for removal of the clevis isolator bushing. Be sure Special Tool 6876 is square on lower control arm and Special Tool 6877 is positioned correctly on clevis bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F to press clevis bushing out of lower control arm. Assembly ASSEMBLY - FRONT ISOLATOR BUSHING To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. 1. Mount Bushing Installer, Special Tool 6876 on screw portion of Remover/Installer Special Tool C-4212-F. 2. Start front bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed in lower control arm from the machined surface side of lower control arm bushing hole. 3. Install lower control arm on Special Tools assembled for installation of front isolator bushing into lower control arm. Be sure Special Tool 6758 is square on lower control arm and Special Tool 6876 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F pressing front bushing into lower control arm. Continue pressing front bushing into lower control arm until bushing is sitting flush on the machined surface of the lower control arm. This will correctly position front bushing in lower control arm. 5. Install lower control arm assembly back on vehicle. ASSEMBLY - REAR ISOLATOR BUSHING To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4444 1. Start rear bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed from the machined surface side of lower control arm bushing hole, with the void in rubber portion of bushing facing away from ball joint. 2. Mount Bushing Installer, Special Tool 6760 on screw portion of Remover/Installer Special Tool C-4212-F. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4445 3. Install Special Tools assembled for installation of rear isolator bushing into lower control arm on the lower control arm. Be sure Special Tool 6766 is square on lower control arm and Special Tool 6760 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F pressing rear bushing into lower control arm. Continue pressing rear bushing into lower control arm until bushing is sitting flush on the machined surface of the lower control arm. This will correctly position rear bushing in lower control arm. 5. Install lower control arm assembly back on vehicle. ASSEMBLY - CLEVIS BUSHING To perform removal and replacement of the lower control arm clevis bushing, the lower control arm must be removed from the vehicle. 1. Start clevis bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed in lower control arm from the machined surface side of lower control arm bushing hole. 2. Mount Bushing Installer, Special Tool 6877 on screw portion of Remover/Installer Special Tool C-4212-F as shown in the image. 3. Install the assembled special tools for installing the clevis bushing into the lower control arm, on the lower control arm and clevis bushing. Be sure Special Tool 6876 is square on lower control arm and Special Tool 6877 is positioned correctly on clevis bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F pressing clevis bushing into lower control arm. Continue pressing clevis bushing into lower control arm until bushing is sitting flush with the machined surface of the lower control arm. This will correctly position the clevis bushing in the lower control arm. 5. Install lower control arm assembly back on vehicle. Upper Control Arm REMOVAL - UPPER CONTROL ARM 1. Remove the front shock assembly from the vehicle. 2. Disassemble the shock assembly until the upper (shock absorber/upper control arm) mounting bracket is removed from the coil spring. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4446 3. Remove the 2 bolts attaching the upper control arm to the bushings in the upper mounting bracket. 4. Remove the upper control arm from the mounting bracket. INSPECTION - UPPER CONTROL ARM If damaged, the upper control arm is serviced only as a complete component. Inspect the upper control arm for any signs of damage. If control arm shows any sign of damage the upper control arm must be replaced. Do not attempt to repair or straighten a broken or bent upper control arm. The only serviceable component of the upper control arm is the ball joint grease seal. No other repair or replacement procedure should be attempted on any component of the upper control arm. INSTALLATION - UPPER CONTROL ARM 1. Install the upper control arm on the upper (shock absorber/upper control arm) mounting bracket. 2. Install the 2 bolts attaching the upper control arm to the bushings in the mounting bracket. The bolts must be installed from center, so the heads are toward the coil spring when it is installed. The bolts MUST be installed so the head of the bolt will be toward the coil spring when the mounting bracket is installed on shock absorber. CAUTION: For clearance reasons the control arm mounting bolts must be installed from center, so the heads are toward the coil spring when it is installed. Otherwise the bolts may rub the coil spring, damaging it. 3. Install the control arm mounting bolt nuts. Position the control arm at a 90° angle to the mounting bracket and tighten the bolts to a torque of 90 Nm (66 ft. lbs.). 4. Reinstall the upper mounting bracket and control arm on the coil spring. Reassemble the front shock assembly. 5. Reinstall the front shock assembly on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4447 Control Arm: Service and Repair Rear Suspension REMOVAL NOTE: The rear control arm, control arm bushings, and pivot bar are serviced as a complete assembly on this vehicle. Do not attempt to disassemble the control arm from the pivot bar to service the rear control arm bushings. The ball joint and ball joint seal are to be replaced with the control arm removed from the vehicle. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove both rear wheel and tire assemblies from the vehicle. Fig. 33 3. Remove the shock absorber clevis bracket to rear knuckle attaching bolt and nut on both sides of the vehicle. Fig. 34 4. Remove muffler support bracket from rear frame rail. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4448 Fig. 35 5. Remove the rear exhaust pipe hanger bracket from the rear suspension crossmember. Let exhaust system drop down as far as possible. 6. On only the side of the vehicle requiring control arm removal, separate the control arm ball joint from the rear knuckle using following procedure. - Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle. Fig. 8 - Remove ball joint stud from knuckle using Puller, Special Tool, CT- 1106. When using puller, install castle nut on ball joint stud to protect threads from damage. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4449 Fig. 37 7. Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal. Fig. 1 8. If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on both upper control arms. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4450 Fig. 39 9. Remove the 4 bolts attaching rear suspension crossmember to rear frame rails. CAUTION: When lowering rear suspension crossmember do not put a strain on the rear brake flex hoses. 10. Lower the rear suspension crossmember far enough to access the upper control arm pivot bar to crossmember attaching bolts. NOTE: One flat washer is used at each upper control arm pivot bar attaching bolt. The flat washer is located between the pivot bar and the rear suspension crossmember. Be sure the washers are not lost when removing the pivot bar attaching bolts from the rear suspension crossmember. Fig. 40 11. Remove the 2 bolts attaching the upper control arm to the rear suspension crossmember. 12. Remove the flat washers and the upper control arm from the rear suspension crossmember. 13. Transfer any required components to the replacement control arm. DISASSEMBLY - UPPER BALL JOINT The rear upper control arm must be removed from the vehicle for replacement of the ball joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4451 Fig. 41 1. Using a screw driver or other suitable tool, pry seal boot up and off of ball joint assembly. Fig. 42 2. Position Receiving Cup, Special Tool 6758 to support control arm when removing ball joint assembly. Install Remover/Installer, Special Tool 6804 on top of ball joint assembly. 3. Using an arbor press, press the ball joint assembly out of the control arm. INSPECTION Inspect the control arm for physical damage. If it is determined that the upper control arm is broken or bent, the upper control arm must be replaced. The rear suspension upper control arm is not a repairable component and no attempt is to be made to repair or to straighten it. The upper control arm must be replaced if found to be damaged in any way. Inspect the control arm pivot bushings for deterioration. If found to need replacement, the upper control arm is to be replaced. The rear control arm, control arm bushings, and pivot bar are serviced as a complete assembly on this vehicle. Do not attempt to disassemble the control arm from the pivot bar to service the rear control arm bushings. The only component on the upper control arm that is serviceable is the rear upper ball joint and its seal. ASSEMBLY - UPPER BALL JOINT 1. By hand, position ball joint assembly into ball joint bore of control arm. Be sure ball joint assembly is not cocked in the bore of the control arm, this will cause binding of the ball joint assembly, when being pressed into lower control arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4452 Fig. 43 2. Position assembly in an arbor press with Receiving Cup, Special Tool 6758 supporting lower control arm. Then install Remover/Installer, Special Tool 6804 on the top of the ball joint assembly. CAUTION: When installing the ball joint in the upper control arm, do not press the ball joint into the control arm all the way. The lip on the ball joint must not touch the surface of the control arm. Refer to Step 3 below when installing the ball joint. 3. Carefully align all pieces. Using the arbor press, press the ball joint into the control arm until a gap of 3 mm (1/8 inch) is between lip on ball joint and surface of lower control arm. 4. Install a NEW ball joint assembly sealing boot on ball joint assembly. CAUTION: Do not use an arbor press to install the sealing boot on the lower control arm ball joint assembly. Damage to the sealing boot can occur due to excessive pressure applied to sealing boot when being installed. Fig. 44 5. Position Receiving Cup, Special Tool 6758 over sealing boot so it is aligned properly with bottom edge of sealing boot. Apply pressure BY HAND to special tool 6768, until sealing boot is pressed squarely against surface of control arm. 6. Reinstall the control arm on the vehicle. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4453 NOTE: The rear control arm, control arm bushings, and pivot bar are serviced as a complete assembly on this vehicle. Do not attempt to disassemble the control am, from the pivot bar to service the rear control arm bushings. The ball joint and ball joint seal are to be replaced with the control arm removed from the vehicle. NOTE: One flat washer is used at each upper control arm pivot bar attaching bolt. The flat washer is located between the pivot bar and the rear suspension crossmember. Be sure 1 flat washer is used at each bolt attaching the pivot bar to the rear suspension crossmember. 1. Align the upper control arm pivot bar with the mounting holes in the rear suspension crossmember. Install the pivot bar attaching bolts and washers. Tighten the 2 pivot bar to crossmember attaching bolts to a torque of 108 Nm (80 ft. lbs.). 2. Using transmission jack, raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts. Fig. 45 3. Position an appropriate size drift into the positioning hole in each side of rear suspension crossmember and crossmember locating holes in frame rails of the vehicle. This is required to properly position rear suspension crossmember in the body of the vehicle. Then tighten the 4 crossmember to frame rail attaching bolts to 108 Nm (80 ft. lbs.). Remove drifts from rear suspension crossmember. 4. Install upper ball joint stud in knuckle. Install and tighten the ball joint stud castle nut to a torque of 85 Nm (63 ft. lbs.). Install cotter pin in ball joint stud. 5. Remove transmission jack supporting rear suspension crossmember. 6. Install muffler support bracket on rear frame rail. Install rear exhaust pipe hanger on rear suspension crossmember. 7. Install the wheel speed sensor cable routing clip on upper control arm mounting bracket. Install and securely tighten attaching bolt. 8. Install the shock absorber clevis brackets on the rear knuckles. Tighten the shock absorber mounting bolts to a torque of 95 Nm (70 ft. lbs.). 9. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 10. Lower vehicle to the ground. 11. Check and reset if required, rear wheel Camber and Toe to preferred specifications. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair FRONT SUSPENSION CROSS-MEMBER REMOVAL 1. Hoist and support vehicle on safety stands. Refer to Vehicle Lifting. 2. Place a suitable lifting device under front suspension crossmember. 3. Remove bolts attaching suspension strut to the lower control arm. 4. Disengage lower ball joints from lower control arms. Fig. 13 5. Remove 3 bolts attaching rear engine mount to crossmember (Fig.13). If equipped, manual transmission bracket will come down when these bolts are removed. It may be necessary to loosen damper mounting bolt at engine structural collar to allow bracket and damper to swing down sufficiently (Fig.13). 6. Remove bolts attaching front of suspension crossmember to frame rails under upper control arms. 7. Loosen bolts attaching rear of suspension cross-member to frame rail torque boxes. 8. Allow the front of the suspension crossmember to swing away from the frame rails. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 4458 Fig. 14 9. Remove bolts attaching steering gear to top of suspension crossmember (Fig. 14). CAUTION: Do not allow steering gear to hang by the pressure or return hoses, damage to hoses can result. 10. Using mechanics wire, tie steering gear to structure above. 11. Raise crossmember back into position. 12. Remove bolts attaching rear of crossmember to frame rail torque boxes. 13. Lower front suspension crossmember away from bottom of vehicle. INSTALLATION 1. Raise front suspension crossmember into position on vehicle. 2. Loosely install bolts attaching rear of cross-member to frame rail torque boxes. 3. Lower crossmember and install bolts attaching steering gear to top of suspension crossmember. 4. Raise crossmember into position. 5. Tighten bolts holding rear of suspension cross-member to frame rail torque boxes. 6. Install bolts attaching front of suspension crossmember to frame rails under upper control arm. 7. Engage lower ball joint to lower control arms. 8. Install 3 bolts attaching rear engine mount to crossmember (Fig. 13). If equipped, make sure manual transmission bracket is positioned in place before installing bolts (Fig. 13). Tighten bolts to 65 N.m (48 ft.lbs.) torque. 9. Install bolts attaching suspension strut to lower control arm. 10. Lower vehicle. 11. After assembly is complete, check front end alignment and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation Rear Cross-Member: Description and Operation REAR SUSPENSION CROSS-MEMBER DESCRIPTION This vehicle is equipped with a bolt in type rear suspension crossmember. The crossmember on this vehicle is the same for all of the optional suspensions that are available on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 4462 Rear Cross-Member: Service and Repair REAR SUSPENSION CROSS-MEMBER REMOVAL 1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Vehicle Lifting. 2. Remove both rear wheel and tire assemblies from the vehicle. Fig. 15 3. Remove the shock absorber clevis bracket to rear knuckle attaching bolt and nut on both sides of the vehicle (Fig.15). Fig. 16 4. Remove muffler support bracket from rear frame rail (Fig.16). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 4463 Fig. 17 5. Remove the rear exhaust pipe hanger from the rear suspension crossmember (Fig.17). Let exhaust system drop down as far as possible. Fig. 18 6. Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal (Fig.18). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 4464 Fig. 19 7. If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on upper control arm (Fig.19). 8. Remove the nuts and bolts on each side of vehicle attaching the 4 lateral links to the knuckles. Fig. 20 9. Disconnect the clips attaching line bundle to crossmember (Fig.20). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 4465 Fig. 21 10. Remove the 4 bolts attaching the rear suspension crossmember to rear frame rails (Fig. 21). Fig. 22 11. Lower the rear suspension crossmember enough to access the upper control arm pivot bar to crossmember attaching bolts (Fig.22). Remove the 4 bolts attaching the upper control arms to the suspension crossmember. Remove the control arms from the crossmember. 12. Lower the rear suspension crossmember, lateral arms and stabilizer bar as far as possible using the transmission jack. Then with the aid of a helper remove rear suspension crossmember from the vehicle. NOTE: When installing the lateral links on the crossmember, the lateral link attaching bolts must be installed as listed below. Install the forward lateral link to crossmember bolts so that the head of the bolt will be toward the front of the vehicle when the crossmember is installed. Install the rear lateral link to crossmember bolts so that the threaded end of the bolt will be facing toward the front of the vehicle when the crossmember is installed. 13. Transfer the lateral links, stabilizer bar mounting brackets and the stabilizer bar and bushings to the replacement crossmember before installing the replacement crossmember in the vehicle. Tighten the stabilizer bar mounting bracket to rear crossmember mounting bolts to 27 N.m (20 ft.lbs.) torque. Tighten the 4 lateral link to crossmember attaching bolts to 95 N.m (80 ft.lbs.) torque. INSTALLATION 1. Install the rear suspension crossmember, lateral arms and rear stabilizer bar back into the vehicle as an assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 4466 2. With the aid of a helper position rear suspension crossmember back in vehicle and support it using the transmission jack. 3. Align the upper control arm pivot bars with the mounting holes in the rear suspension crossmember. Install and tighten the 4 pivot bar to crossmember attaching bolts (Fig.22) to 107 N.m (80 ft.lbs.) torque. CAUTION: While raising crossmember use care not to pinch any lines. 4. Using transmission jack, raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts. 5. Connect line bundle clips to crossmember (Fig.20). Fig. 23 6. Position a drift of the appropriate size into the positioning hole in each side of rear suspension cross-member and locating holes in the frame rail of the body. (Fig. 23). This is required to properly position rear suspension crossmember side-to-side and front-to-rear in the body of the vehicle. Then tighten the 4 crossmember to frame rail attaching bolts to 95 N.m (70 ft.lbs.) torque. Remove drifts from rear suspension crossmember. 7. Align lateral links with knuckles and install the lateral arm to knuckle attaching bolts. Tighten the 4 lateral arm to spindle attaching bolts to 95 N.m (70 ft.lbs.) torque. 8. Remove transmission jack supporting rear suspension crossmember. 9. Install muffler support bracket on rear frame rail (Fig.16). Install rear exhaust pipe hanger on rear suspension crossmember (Fig.17). 10. If vehicle is equipped with antilock brakes, install the wheel speed sensor cable routing clip on upper control arm mounting bracket (Fig.19). Install and securely tighten attaching bolt. 11. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified 129 N.m (95 ft.lbs.) torque. 12. Lower vehicle to the ground. 13. Check and reset if required, rear wheel alignment to meet the preferred specifications. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Disc Brake Caliper Adapter Bolts 125 ft.lb Tie Rod Nut 45 ft.lb Tie Rod Adjustment Jam Nut 45 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4470 Front Steering Knuckle: Description and Operation DESCRIPTION The steering knuckle is a single casting with legs machined for attachment to the vehicle's upper and lower control arm ball joints. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub and bearing assembly using a nut, nut lock and cotter pin. OPERATION The steering knuckle pots between the upper and lower ball joints. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub and bearing and axle shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4471 Front Steering Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - STEERING The front suspension steering knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4472 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 9 5. Remove nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Fig. 10 6. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB-991113. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4473 Fig. 24 7. Remove the speed sensor cable routing bracket from the steering knuckle. Fig. 25 8. Remove cotter pin and castle nut from the stud of the lower ball joint . CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in step Step 9 below. CAUTION: When striking the steering knuckle, do not hit the heat shield covering the ball joint grease seal. Bending the heat shield against the ball joint grease seal will cause the grease seal to fail. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4474 Fig. 26 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until the steering knuckle separates from the stud of lower ball joint. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate ON joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 23 11. Separate the steering knuckle from the outer C/V joint. Seperate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4475 Fig. 24 12. Remove the cotter pin and nut from the upper ball joint stud to steering knuckle attachment. Fig. 25 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A. 14. Remove steering knuckle from vehicle. 15. The bolt in type front wheel bearing used on the vehicle is transferable to the replacement steering knuckle if bearing is found to be in usable condition. INSTALLATION 1. If required install a hub/bearing assembly into the steering knuckle before installing steering knuckle on vehicle. 2. Install the heat shield for the lower control arm ball joint grease seal before beginning the installation of the steering knuckle on the vehicle. 3. Slide drive shaft; back into front hub/bearing assembly. Then install steering knuckle onto the ball joint stud in lower control arm. 4. Install the steering knuckle to lower ball joint stud castle nut. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4476 Fig. 24 5. Install upper ball joint in steering knuckle. Install the steering knuckle to upper ball joint nut. Tighten the upper ball joint castle nut to a torque of 54 Nm (40 ft. lbs.). Then, using a crowfoot and torque wrench, tighten the lower ball joint nut to a torque of 75 Nm (55 ft. lbs.). Install cotter pins in upper and lower ball joint studs. 6. Install the speed sensor cable routing bracket on the steering knuckle and securely tighten the attaching bolt. Fig. 24 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 7. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 8. Install brake rotor, and caliper, shoes and adapter assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 4477 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto driveshaft stub axle. 10. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 Nm (150 ft. lbs.) of torque. 11. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Then tighten to a torque of 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications To Knuckle Nuts 80 ft.lb Jam Nuts 68 ft.lb To Suspension Crossmember Nuts 80 ft.lb Shaft Nuts (Front and rear) 73 ft.lb Bracket To Body Mounting Bolts 25 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4481 Lateral Stabilizer Rod: Description and Operation LATERAL LINK DESCRIPTION The lateral links connect the lower front and rear of the knuckle to the rear crossmember. They have rubber isolator bushings at each end to isolate suspension noise from the body of the vehicle. The forward link allows for stabilizer bar attachment through stabilizer bar attachment links. OPERATION The lateral movement of the rear knuckle is controlled by the lateral links connecting the front and rear of the knuckle to the rear suspension crossmember. The metal sleeves of the links are adjustable for setting rear wheel alignment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4482 Lateral Stabilizer Rod: Testing and Inspection DIAGNOSIS AND TESTING - LATERAL LINKS Inspect the lateral link isolator bushings and sleeves for signs of damage or deterioration. If the lateral link isolator bushings or sleeves are damaged or are deteriorated, replacement of the lateral link assembly will be required. The isolator bushings are not serviceable as a separate component of the lateral link assembly. Inspect the lateral links for signs of contact with the ground or road debris which has bent or caused other damage to the lateral link. If the lateral link is bent or damaged, the lateral link will require replacement. Do not attempt to repair or straighten a lateral links CAUTION: Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4483 Lateral Stabilizer Rod: Service and Repair REMOVAL The rear suspension lateral links are only serviced as complete assemblies. The isolator bushings used in the lateral links are not serviced as separate components. CAUTION: Do not attempt to straighten or repair a lateral link. Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. FORWARD LATERAL LINK 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. Fig. 14 3. Remove the rear stabilizer bar attaching link from the forward lateral link. 4. Remove the nut, bolt and washer attaching the forward lateral link to the knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4484 Fig. 15 5. Remove the nut and bolt attaching the lateral link to the rear suspension crossmember. 6. Remove the forward lateral link from the vehicle. REAR LATERAL LINK 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. Fig. 16 3. Remove the nut, bolt and washer attaching the lateral link to the knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4485 Fig. 17 4. Remove the boltand nut attaching the lateral link to the rear suspension crossmember. 5. Remove rear lateral link from vehicle. INSTALLATION The rear suspension lateral linksare only serviced as complete assemblies. The isolator bushings used in the lateral links are not serviced as separate components. CAUTION: Do not attempt to straighten or repair a lateral link. Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. FORWARD LATERAL LINK 1. Install the lateral link and the attaching nut and bolt at rear suspension crossmember. The forward lateral link is to be installed with the cup in cast portion facing down and toward rear knuckle. 2. Install the lateral link and attaching nut, bolt and washer at rear knuckle. 3. Torque both lateral link attaching bolts to 108 Nm (80 ft. lbs.). 4. Install the rear stabilizer bar attaching link, isolator bushings and attaching nut on the forward lateral link. Tighten the attaching nut to a torque of 35 Nm (26 ft. lbs.). 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Lower vehicle to the ground. 7. Check and reset rear wheel Camber and Toe to specifications if required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 4486 REAR LATERAL LINK 1. Install the lateral link and the attaching nut and bolt at rear suspension crossmember. The rear lateral link is to be installed with the adjusting screw toward rear knuckle not rear suspension crossmember. 2. Install the lateral link and the attaching nut, bolt and washer at rear knuckle. 3. Torque both lateral link attaching bolts to 108 Nm (80 ft. lbs.). 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 5. Lower vehicle to the ground. 6. Check and reset rear wheel Camber and Toe to specifications if required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications Rear Knuckle: Specifications Brake Adapter Mounting Bolts 45 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4490 Rear Knuckle: Description and Operation KNUCKLE DESCRIPTION A cast iron rear knuckle is attached to each side of the vehicle through the upper control arm and ball joint, the rear shock assembly, the lateral links and the trailing link. The knuckle serves as a mounting point for the rear hub and bearing, tire and wheel, and rear brakes. OPERATION The knuckle moves up and down with the tire and wheel under jounce and rebound conditions while acting as a mount for the rear hub and bearing, tire and wheel, and rear brakes. The lateral movement of the rear knuckle is controlled using two lateral arms attached to the bottom of the knuckle and by the upper control arm attached to the top of the knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4491 Rear Knuckle: Testing and Inspection DIAGNOSIS AND TESTING - KNUCKLE Inspect the knuckle for physical damage. If it is determined that the knuckle is cracked, bent or broken when servicing the vehicle, no attempt is to be made to repair or to straighten the knuckle. The rear knuckle is not a repairable component of the rear suspension and must be replaced if found to be damaged in any way. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4492 Rear Knuckle: Service and Repair REMOVAL 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the vehicle. 3. Remove rear brake drum from rear hub and bearing assembly. Fig. 1 4. If vehicle is equipped with antilock brakes remove the rear wheel speed sensor from the brake support plate and brake flex hose routing bracket. Fig. 2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4493 Fig. 3 5. Remove the park brake cable from the park brake actuating lever. Then remove the park brake cable from the rear brake support plate. Park brake cable is removed from brake support plate using this procedure. Position a 1/2 inch box end wrench over cable retainer to collapse retaining tabs. Then pull bear brake cable from brake support plate. Fig. 4 6. Remove the rear hub/bearing assembly retaining nut. Then remove the washer and the hub/bearing assembly from the knuckle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4494 Fig. 5 Fig. 6 7. Remove the 4 bolts attaching rear brake support plate to knuckle. Then remove brake support plate, brake shoes and wheel cylinder as an assembly from rear knuckle. It is not necessary to remove brake flex hose from wheel cylinder when removing support plate. Brake support plate when removed, must be supported using mechanics wire as shown in the image. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4495 Fig. 7 8. Remove the nuts and bolts attaching the forward and rear lateral links to the rear knuckle. 9. Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle. Fig. 8 10. Remove ball joint stud from knuckle using Puller, Special Tool, CT-1106. When using puller, install castle nut on ball joint stud to protect threads from damage. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4496 Fig. 9 11. Remove the nut and washer attaching the trailing link to the rear knuckle. Use a wrench on the flat of the trailing link to keep it from turning when removing nut. Fig. 10 12. Remove the shock absorber clevis bracket to knuckle attaching nut and bolt. 13. Remove the knuckle assembly from the vehicle. INSTALLATION 1. Install knuckle on clevis bracket of rear shock absorber. Then install clevis bracket to shock absorber attaching bolt with head of bolt facing rear of vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4497 Fig. 11 CAUTION: When installing trailing link bushing retainers, retainers must be installed with cupped side of retainer facing away from bushing and knuckle. 2. Install knuckle on trailing link. Install the trailing link outer bushing, gold bushing retainer and retaining nut on trailing link. Using a large adjustable wrench, to keep trailing link from rotating securely tighten the trailing link retaining nut to a torque of 99 Nm (73 ft. lbs.). 3. Install the upper ball joint stud in the knuckle. Install and tighten the ball joint stud castle nut to a torque of 85 Nm (63 ft. lbs.). Install cotter pin in ball joint stud. 4. Install the front and rear lateral links and attaching nuts and bolts on the knuckle. Tighten the lateral links to knuckle attaching bolts and nuts to 108 Nm (80 ft. lbs.). 5. Install rear brake support plate assembly onto the knuckle. Install the 4 bolts attaching rear brake support plate to rear knuckle. Tighten the attaching bolts to a torque of 61 Nm (45 ft. lbs.). Fig. 12 6. If vehicle is equipped with ABS brakes, install speed sensor head into rear brake support plate. Torque speed sensor head mounting bolt to 7 Nm Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Page 4498 (60 inch lbs.). 7. Attach routing bracket for speed sensor cable to brake flex hose bracket and securely tighten attaching bolt. 8. Install park brake cable into brake support plate. Ensure cable retainer is securely holding cable to support plate. Then connect park brake cable to park brake lever on brake shoe. 9. Install rear hub and bearing assembly on knuckle and install hub and bearing assembly retaining nut. Tighten retaining nut to a torque of 250 Nm (185 ft. lbs.). 10. Install the brake drum on the hub/bearing assembly. 11. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. Check and reset rear wheel alignment to specifications if required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair REMOVAL - STABILIZER BAR BUSHING (FRONT) 1. Bend back the 4 crimp locations on the stabilizer bar bushing retainer. 2. Separate the stabilizer bar bushing retainer. 3. Stabilizer bar bushings are removed by opening slit and peeling bushing off stabilizer bar. INSTALLATION - STABILIZER BAR BUSHING 1. Install new stabilizer bar bushings on the stabilizer bar. Bushings must be installed on sway bar with slit in bushing facing front of vehicle when sway bar is installed. 2. Install bushing retainers back on stabilizer bar bushings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension Clunk/Pop Sound From Vehicle Front Strut / Shock Tower: Customer Interest Body/Suspension - Clunk/Pop Sound From Vehicle Front NUMBER: 23-039-04 GROUP: Body DATE: September 24, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-03, DATED May 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR. SUBJECT: Pop/Clunk Sound From Front Of Vehicle OVERVIEW: This bulletin involves installing two rivets in each front shock tower/wheel well area. MODELS: 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Vehicle produces an intermittent front end popping or clunk type sound while driving over road inputs that cause the body to come under a twisting load. This sound may also be produced when in park & idle by turning the steering wheel quickly, 90 degrees, to the left and back to the right. DIAGNOSIS: If the vehicle operator describes the above Symptom, turn the steering wheel quickly, 90 degrees, to the left and back to the right while the transmission is in park and the engine is at idle. If a popping or clunk type sound is heard, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove both front tire/wheel assemblies. 3. Remove wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension Clunk/Pop Sound From Vehicle Front > Page 4511 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension Clunk/Pop Sound From Vehicle Front > Page 4512 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front Strut / Shock Tower: All Technical Service Bulletins Body/Suspension - Clunk/Pop Sound From Vehicle Front NUMBER: 23-039-04 GROUP: Body DATE: September 24, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-03, DATED May 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR. SUBJECT: Pop/Clunk Sound From Front Of Vehicle OVERVIEW: This bulletin involves installing two rivets in each front shock tower/wheel well area. MODELS: 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Vehicle produces an intermittent front end popping or clunk type sound while driving over road inputs that cause the body to come under a twisting load. This sound may also be produced when in park & idle by turning the steering wheel quickly, 90 degrees, to the left and back to the right. DIAGNOSIS: If the vehicle operator describes the above Symptom, turn the steering wheel quickly, 90 degrees, to the left and back to the right while the transmission is in park and the engine is at idle. If a popping or clunk type sound is heard, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove both front tire/wheel assemblies. 3. Remove wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 4518 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 4519 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Body Mounting Bolts 40 ft.lb Knuckle Bolt/Nut 70 ft.lb Rod to Upper Mount Nut 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 4524 Suspension Strut / Shock Absorber: Specifications Clevis Pinch Bolt 65 ft.lb Shock Tower Bolts 75 ft.lb Clevis to Control Arm Bolt 65 ft.lb Rod to Upper Mount Nut 40 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front DESCRIPTION - SHOCK ASSEMBLY The front shock assembly and suspension of the vehicle is supported by coil springs positioned around shock absorbers. The springs are contained between an upper seat located in the upper mounting bracket and a lower spring seat on the shock absorber. The top of each shock absorber is bolted to a cast shock absorber/upper control arm bracket which is bolted to the shock tower of the vehicle using 4 mounting bolts. The bottom of the shock absorber attaches to a clevis bracket using a pinch bolt. The clevis bracket attaches to the lower control arm of the vehicle using a through-bolt and prevailing torque nut. A coil spring is housed within each shock assembly. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If the coil springs require replacement, be sure that the springs needing replacement, are replaced with springs meeting the correct load rating and spring rate for the vehicle and its specific options. The components of the shock assembly listed below are serviceable if found to be defective: - Upper mounting bracket - Upper spring isolator - Dust shield - Cup - Jounce bumper - Coil spring - Shock absorber - Lower spring isolator The shock absorber/upper control arm mounting bracket also provides a pivotal mounting point for the upper control arm. OPERATION - SHOCK ASSEMBLY Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 4527 The shock absorber assembly cushions the ride of the vehicle, controlling vibration, and jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting bracket and shock absorber. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The shock absorber dampens jounce and rebound motions of the coil spring and suspension. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 4528 Suspension Strut / Shock Absorber: Description and Operation Rear SHOCK DESCRIPTION - SHOCK ASSEMBLY The rear shock absorber assemblies support the weight of the vehicle using coil springs positioned around the shock absorbers. The coil springs are contained between the upper mount of the shock absorber and a lower spring seat on the body of the shock absorber. The top of each shock absorber assembly is bolted to the top of the inner fender through a rubber isolated mount. The bottom of the shock absorber assembly attaches to the rear knuckle using a through-bolt. The rear coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. Coil springs come in a various rates; be sure the correct spring is in use. The components of the shock assembly listed below are serviceable: Shock rod nut - Shock mount - Shock rod bushings - Upper spring isolator - Dust shield - Cup - Jounce bumper - Lower spring isolator - Coil spring - Strut OPERATION - SHOCK ASSEMBLY The shock absorber assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains ride height. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce. The shock absorber dampens jounce and rebound motions of the coil spring and suspension. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut / Shock Absorber: Testing and Inspection Front DIAGNOSIS AND TESTING - SHOCK ASSEMBLY (FRONT) 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged shock absorber dust boots. 3. Lift the dust boot and inspect the shock absorber for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off the lower end of the shock absorber). A slight amount of seepage between the shock absorber rod and the seal is not unusual and does not affect performance of the shock absorber. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 4531 Suspension Strut / Shock Absorber: Testing and Inspection Rear DIAGNOSIS AND TESTING - SHOCK ASSEMBLY 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged shock absorber dust shield. 3. Inspect for damaged lower spring isolator. 4. Lift dust boot and inspect shock absorber for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the shock absorber rod and shock absorber rod seal is not unusual and does not affect performance of the shock absorber. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL - SHOCK ASSEMBLY NOTE: Before proceeding, Refer to Suspension, Service Precautions; Vehicle Damage Warnings. 1. Loosen wheel nuts. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove the wheel and tire from the location on front of vehicle requiring shock removal. 4. If both shock assemblies are removed, mark the shock assemblies right and left according to which side of the vehicle they were removed from. 5. Remove the wheel speed sensor cable routing bracket from the steering knuckle. 6. Remove the cotter pin and castle nut . Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4534 7. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A. Pull steering knuckle outward and position toward the rear of the front wheel opening. 8. Remove pinch bolt attaching shock absorber clevis to shock absorber. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4535 9. Remove the nut and thru-bolt attaching the shock absorber clevis to the lower control arm. 10. Remove the clevis from the shock absorber by carefully tapping the clevis off the shock absorber using a soft (brass) drift. 11. Remove the 4 bolts attaching the shock absorber/upper control arm mounting bracket to the shock tower of the vehicle. 12. Remove the shock assembly from the vehicle. The shock assembly is removed out through the front area of the front wheel well. 13. For disassembly and assembly of the shock assembly, Refer to SHOCK- DISASSEMBLY. DISASSEMBLY - SHOCK ASSEMBLY The shock assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. 1. If both shocks are being serviced at the same time, mark the coil spring and shock assembly according to which side of the vehicle the shock was removed from, and which shock the coil spring was removed from. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4536 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4537 2. Position the shock assembly in the strut coil spring compressor following the manufacturer's instructions. Set the lower hooks and install the clamp on the lower end of the coil spring, so the shock is held in place once the shock shaft nut is removed. Rotate the shock assembly so the upper control arm ball joint sits directly below the front upper hook as shown. Position the upper hooks on top of the upper mounting bracket. WARNING: DO NOT REMOVE THE SHOCK ROD NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNTING BRACKET BEFORE THE ROD NUT IS REMOVED. 3. Compress the coil spring until all coil spring tension is removed from the upper mounting bracket. 4. Hold the shock rod from rotating using special socket Snap-On A136), or an equivalent, and remove the retainer nut. 5. Remove the upper bushing retainer washer from the shock absorber rod. 6. Remove the clamp from the bottom of the coil spring and remove the shock absorber, lower spring isolator, jounce bumper, cup, dust boot, and lower bushing retainer washer out through the bottom of the coil spring. NOTE: If the coil spring, upper mounting bracket, rod bushings, upper coil spring isolator, or upper control arm need to be serviced, proceed with the next step, otherwise, proceed with step 11. NOTE: Before removing the coil spring from the spring compressor, note the position of the lower coil spring end to the spring compressor. The coil spring will need to be in this position on reassembly for proper coil spring-to-shock absorber and upper mounting bracket orientation. 7. Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper mounting bracket and upper control arm from the coil spring. 8. Note the position of the coil spring in the spring compressor as listed in the above note before removal. This is necessary for proper alignment of the shock assembly components when reassembly is made. Remove the coil spring from the spring compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4538 9. Remove the shock absorber rod upper isolator bushing from the upper (shock absorber/upper control arm) mounting bracket. 10. Remove the shock absorber rod lower isolator bushing and sleeve from the upper (shock absorber/upper control arm) mounting bracket. Remove upper coil spring isolator from mounting bracket. NOTE: If removal of the upper control arm is necessary, Refer to UPPER CONTROL ARM REMOVAL. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4539 11. Remove the lower shock rod bushing retainer washer from the shock absorber rod. 12. Remove the dust shield and cup as an assembly from the shock absorber rod by pulling both straight up and off the shock rod. The jounce bumper may come off at the same time. Remove the jounce bumper and metal collar. 13. Remove the lower spring isolator from the lower spring seat on the shock absorber. 14. Inspect the shock assembly components for the following and replace as necessary: - Inspect the shock for any condition of rod binding over the full stroke of the shaft. - Check the upper mounting bracket for cracks, distortion and any sign of damage. - Inspect the upper mounting bracket-upper control bushings for deterioration of the rubber. - Check the upper and lower shock rod isolator bushings for severe deterioration of the rubber. - Check the upper and lower spring isolators for severe deterioration of the rubber. - Inspect the dust shield for rips and deterioration. - Inspect the jounce bumper for cracks and signs of deterioration. - Inspect the coil spring for any sign of damage to the coating. ASSEMBLY - SHOCK ASSEMBLY For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. NOTE: If the coil spring, upper mounting bracket, rod bushings, upper coil spring isolator, and upper control arm have been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 7. NOTE: If installation of the upper control arm on the upper mounting bracket is necessary, Refer to UPPER CONTROL ARM -REMOVAL. 1. Install the upper coil spring isolator on the upper (shock absorber/upper control arm) mounting bracket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4540 CAUTION: The top and bottom shock absorber rod isolator bushings are unique to the position which they are installed on the rod. When installing the bushings on the rod, attention must be paid to their location so they are installed correctly. 2. Install the sleeve into the lower shock absorber rod isolator bushing. Install the shock absorber rod lower isolator bushing and sleeve in the bottom of the upper (shock absorber/upper control arm) mounting bracket as shown. From the top, install the shock absorber rod upper isolator bushing into the center of the upper mounting bracket over the sleeve protruding from the lower isolator bushing. The smaller end of each bushing is to face away from the upper mounting bracket once installed. 3. Place the lower end (smaller diameter) of the coil spring in the spring compressor supported by the lower hooks, following the manufacturer's instructions. Position the coil spring lower end tip at the position it was at before coil spring removal from the compressor as noted in Step 8 of DISASSEMBLY. Proper orientation of the spring in the compressor is necessary for proper alignment of all shock assembly components. 4. Install the upper (shock absorber/upper control arm) mounting bracket on top of the coil spring matching the coil spring to its isolator on the upper mounting bracket. Position the upper control arm ball joint so it lies directly below the front upper hook as shown. 5. Position the upper hooks on top of the upper mounting bracket as shown. 6. Compress the coil spring. 7. Install the lower spring isolator on the lower spring seat of the shock absorber. When installing the spring isolator, be sure the isolator sets in the notch made for the lower coil spring end. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4541 8. Install the jounce bumper on the shock rod. Install the jounce bumper with the pointed end pointing downward. 9. Install the collar, undercut side facing down, on the rod of the shock absorber. Be sure the collar is positioned squarely on the step of the shock absorber rod. 10. Install the dust shield and cup onto the shock rod until the cup contacts the collar just installed. The dust boot will snap over the jounce bumper. Install the lower shock rod bushing retainer washer. 11. Install the shock through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The lower coil spring end should set into the notch of the shock absorber lower seat and isolator. Install the clamp temporarily securing the shock absorber to the coil spring. 12. Install the upper shock rod bushing retainer washer. Make sure the concave side is facing up. 13. Install the shock assembly retainer nut. Hold the shock rod from rotating using special socket Snap-On A136), or an equivalent, and tighten the retainer nut using a crow foot wrench (on the end of a torque wrench and extension) to a torque of 55 Nm (40 ft. lbs.). 14. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mounting bracket, isolator, and coil spring align properly. Remove the clamp from the lower end of the coil spring and shock. Push back the spring compressor upper and lower hooks, then remove the shock assembly from the spring compressor. 15. Install shock assembly on the vehicle. INSTALLATION - STRUT ASSEMBLY NOTE: Before proceeding, Refer to Service Precaution. 1. Install the shock assembly, with the clevis removed, into shock tower. Aligning the 2 locating pins and the 4 mounting holes on the upper control arm shock absorber mount with the 4 holes in shock tower. Install the 4 upper control arm mount to shock tower mounting bolts. Tighten the 4 bolts to a torque of 95 Nm (70 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4542 2. Install the clevis on the shock absorber. Clevis is installed by tapping it onto the fluid reservoir of the shock absorber using a soft (brass) drift until fully seated against locating tab on shock absorber. Orientation tab on locating tab must be positioned in the split of the clevis. 3. Install the pinch bolt retaining the shock clevis to the shock absorber. Tighten the pinch bolt to a torque of 88 Nm (65 ft. lbs.) 4. Install the clevis bracket to lower control arm thru-bolt. Do not tighten or torque the thru-bolt at this time. 5. Install upper ball joint into steering knuckle. Install castle nut on ball joint stud. Tighten castle nut to a torque of 54 Nm (40 ft. lbs.). Install cotter pin in stud of ball joint. 6. Install the routing bracket for the speed control cable on the steering knuckle. Install and securely tighten the routing bracket attaching bolt. CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm as shown. 7. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm. 8. Tighten the shock absorber clevis to lower control arm bushing thru-bolt nut to a torque of 88 Nm (65 ft. lbs.). 9. Raise the vehicle, then remove the jack stand. 10. Install the tire and wheel assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 11. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4543 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL - SHOCK ASSEMBLY NOTE: Access for the nuts attaching the rear shock assembly upper mount to the vehicle is through the inside of the trunk. 1. Roll back carpeting on top of the rear shock tower to access shock mounting nuts. 2. Remove plastic cover from the top of the shock assembly. 3. Remove 2 nuts attaching the shock assembly upper mount/spring seat to the shock tower. 4. Raise vehicle on jackstands or centered on a frame contact type hoist. 5. Remove the rear wheel and tire assembly from the vehicle. 6. Remove two fasteners holding the splash shield to the shock assembly upper mount. Fig. 19 7. Remove bolt attaching shock absorber to rear knuckle . 8. Remove the shock absorber from the rear knuckle first when removing the shock absorber from vehicle by pushing down on the rear suspension. 9. Move shock assembly downward and tilt top of shock outward, then remove shock assembly from vehicle through top of wheel opening. DISASSEMBLY - SHOCK ASSEMBLY The shock assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: DO NOT REMOVE THE SHOCK ROD NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNTING BRACKET BEFORE THE ROD NUT IS REMOVED. 1. If both shocks are being serviced at the same time, mark the coil spring and shock assembly according to which side of the vehicle the shock was removed from, and which shock the coil spring was removed from. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4544 Fig. 20 2. Position the shock assembly in the strut coil spring compressor following the manufacturer's instructions. Set the lower hooks and install the clamp on the lower end of the coil spring, so the shock is held in place once the shock shaft nut is removed. Lower the upper hooks and position them on the coil spring near the top. 3. Compress the coil spring until all coil spring tension is removed from the upper mounting bracket. 4. Hold the shock rod from rotating using special socket Snap-On A136, or equivalent, and remove the retainer nut. 5. Remove the upper shock rod bushing retainer washer from the shock rod. 6. Remove the upper shock mount and the rod isolator bushings as an assembly from the rod of the shock absorber. 7. Remove the upper coil spring isolator from the top of the coil spring. 8. Remove the lower shock rod bushing washer from the top of the dust boot and shock absorber rod. 9. Remove the dust shield and cup as an assembly from the shock absorber rod by pulling both straight up and off the shock rod. 10. Remove the clamp from the bottom of the coil spring and remove the shock absorber, lower spring isolator, jounce bumper, and collar out through the bottom of the coil spring. Fig. 21 11. Remove the jounce bumper and the collar from the rod of the shock absorber. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4545 Fig. 22 12. Remove the lower coil spring isolator from the lower spring seat on the shock absorber. 13. Remove the upper shock rod isolator bushing and sleeve from the upper shock mount. 14. Remove the lower shock rod isolator bushing from the upper shock mount. 15. Inspect the shock assembly components for the following and replace as necessary: - Inspect the shock for any condition of rod binding over the full stroke of the shaft. - Check the upper shock mount for cracks and distortion, and locating studs for any sign of damage. - Check the upper and lower shock rod isolator bushings for severe deterioration of the rubber. - Check the upper and lower coil spring isolators for severe deterioration of the rubber. - Inspect the dust shield for rips and deterioration. - Inspect the jounce bumper for cracks and signs of deterioration. - Inspect the coil spring for any sign of damage to the coating. 16. If the coil spring needs to be serviced, release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the coil spring from the compressor. ASSEMBLY - SHOCK ASSEMBLY For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. 1. If the coil spring has been removed from the compressor, place the lower end (smaller diameter) of the coil spring in the spring compressor supported by the lower hooks at the same position as in disassembly, following the manufacturer's instructions. 2. Position the upper hooks of the spring compressor on the coil spring near the top as in disassembly. 3. Compress the coil spring enough to reinstall the shock absorber and upper mount. 4. Install the lower shock rod isolator bushing in the bottom of the upper shock mount. The smaller end is to be pointed away from the mount when installed. 5. Install the upper shock rod isolator bushing and sleeve in the upper shock mount until seated into lower bushing. The smaller end of the bushing is to be pointed away from the mount when installed. 6. Install the lower coil spring isolator on the lower spring seat of the shock absorber. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4546 Fig. 23 7. Install the jounce bumper as shown on the rod of the shock absorber. Fig. 24 8. Install the collar on the rod of the shock absorber assembly with the undercut side of sleeve facing down. Push the collar down until seated on the step of the shock absorber rod. 9. Install the shock through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. Install the clamp temporarily securing the shock absorber to the coil spring. 10. Install dust shield and cup over the jounce bumper and onto the rod of the shock absorber. 11. Install the lower shock rod bushing retainer washer on the shock absorber rod. 12. Install the upper spring isolator on the top of the coil spring. The bottom of the isolator is contoured to fit around the inside diameter of the coil spring. 13. Install the upper shock mount bracket and rod isolator bushings as an assembly on the top of the rod of the shock absorber. 14. Install the upper shock rod bushing retainer washer. Make sure the concave side is facing up. 15. Install the shock assembly retainer nut. Hold the shock rod from rotating using special socket Snap-On A136, or equivalent, and tighten the retainer nut using a crow foot wrench (on the end of a torque wrench and extension) to a torque of 55 Nm (40 ft. lbs.). 16. Position the upper shock mount so it's studs are in line with the bolt hole in the shock absorber lower bracket. 17. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, isolator, and coil spring align properly. Remove the clamp from the lower end of the coil spring and shock. Push back the spring compressor upper and lower hooks, then remove the shock assembly from the spring compressor. 18. Install shock assembly on the vehicle. INSTALLATION - SHOCK ASSEMBLY 1. Install shock assembly back in vehicle using the reverse sequence of removal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4547 2. Install upper shock mount into the mounting holes in rear shock tower . 3. Push down on rear knuckle to obtain clearance and then install shock absorber clevis bracket on rear knuckle. 4. Align clevis bracket on shock absorber with bushing in knuckle. Install and tighten bolt to a torque of 95 Nm (70 ft. lbs.). 5. Lower vehicle far enough to gain access to the trunk. 6. Install and tighten the 2 shock assembly upper mounting nuts to a torque of 54 Nm (40 ft. lbs.). 7. Install plastic cover on shock assembly. 8. Install carpeting back on shock tower. 9. Install fasteners securing splash shield to shock mount. 10. Install wheel and tire assembly on vehicle. Install all wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Repeat tightening sequence to full specified torque of 135 Nm (100 ft. lbs.). 11. Lower vehicle to the ground. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Description and Operation Trailing Arm: Description and Operation TRAILING LINK DESCRIPTION The trailing link on each side of the vehicle bolts to the bottom of the knuckle and to a bracket attached to the floor pan of the vehicle. The trailing link is steel and has rubber isolator bushings, retainer washers and nuts at each end to isolate suspension noise from the body of the vehicle. OPERATION Fore and aft movement of the knuckle is controlled by a trailing link. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Description and Operation > Page 4551 Trailing Arm: Testing and Inspection DIAGNOSIS AND TESTING - TRAILING LINK Inspect the trailing link bushings and retainers for signs of deterioration or damage. If the trailing link bushings are deteriorated or the retainers are damaged, replacement of the trailing link bushings and or the retainers will be required. The bushings and retainers are serviceable as separate components of the trailing link. Inspect the trailing link for signs of contact with the ground or road debris which has bent or caused other damage to the trailing link. If the trailing link is bent or damaged the trailing link will require replacement. Do not ever attempt to repair or straighten a trailing link. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Description and Operation > Page 4552 Trailing Arm: Service and Repair REMOVAL 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly from the vehicle. Fig. 28 3. At the knuckle, remove the nut, bushing retainer and outer trailing link bushing from the trailing link. Fig. 29 4. Remove the 4 bolts attaching the trailing link hanger bracket to the floor pan and frame rail. 5. Remove the trailing link and mounting bracket as an assembly from the vehicle. CAUTION: The installation position of the bushings and retainers on the trailing link is important. When separating the trailing link from the hanger bracket, note the position and orientation on the bushings and retainers to ensure they are re-installed correctly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Description and Operation > Page 4553 Fig. 30 6. Separate the trailing link from the hanger bracket. To separate trailing link from hanger bracket, use a large adjustable wrench on flat of trailing link to turn link while holding nut stationary. INSTALLATION CAUTION: The inner and outer trailing link to hanger bracket bushings and retainers must be installed in their correct position on the trailing link. Do not reverse the position of the inner and outer trailing link bushing or retainers on the trailing link. NOTE: When installing trailing link into hanger bracket, the flat on the trailing link must be positioned at the hanger bracket. Fig. 31 1. Install the (black) inner bushing retainer, and inner bushing on the trailing link. Install the trailing link, retainer and bushing on the hanger bracket. Then install the outer bushing, (gold) outer bushing retainer and nut on the trailing link. Using a large adjustable wrench on flat of trailing link to Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Description and Operation > Page 4554 keep it from rotating, tighten the trailing link retaining nut to a torque of 99 Nm (73 ft. lbs.). 2. Install the (black) inner bushing retainer, and inner bushing on the trailing link. 3. Install knuckle end of trailing link in rear knuckle. CAUTION: It is important that the following procedure be done when installing the trailing arm hanger bracket to the body of the vehicle. This procedure will ensure that the hanger bracket is installed in the correct position on the vehicle. Fig. 32 4. Install trailing link hanger bracket on vehicle and loosely install the 4 attaching bolts. Then install 2 drift pins of appropriate size in positioning holes on hanger bracket and into locating holes in body. With hanger bracket correctly positioned on vehicle tighten the 4 hanger bracket mounting bolts to a torque of 34 Nm (25 ft. lbs.). CAUTION: When installing trailing link bushing retainers, the retainers must be installed with cupped side of retainer facing away from bushing and knuckle. 5. At the knuckle, install the outer trailing link bushing, (gold) outer bushing retainer and retaining nut on trailing link. Using a large adjustable wrench on flat of trailing link to keep it from rotating tighten the trailing link retaining nut to a torque of 99 Nm (73 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Hub Nut 150 ft.lb Wheel Stud Lug Nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4559 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB / BEARING - FRONT DESCRIPTION The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The hub and bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub and bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective. 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. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front > Page 4562 Wheel Bearing: Description and Operation Rear HUB / BEARING - REAR DESCRIPTION The hub and bearing is a combined rear wheel hub and wheel bearing unit. All vehicles are equipped with permanently lubricated and sealed for life rear hub and bearing assemblies. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing is mounted to the rear knuckle's spindle using a retaining nut. The tire and wheel assembly, and rear brake drum or disc attaches to the studs protruding from the hub flange with wheel mounting studs. OPERATION The hub and bearing has internal bearings that allow it to rotate with the tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING - FRONT The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4565 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING - REAR The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT SUSPENSION REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 12 5. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a socket while loosening and removing nut with wrench. Fig. 13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4568 6. Remove the tie rod end from the steering knuckle arm, using Remover, Special Tool MB-991113. Fig. 14 7. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Fig. 15 8. Remove cotter pin and castle nut from the stud of the lower ball joint. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 9 below. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4569 Fig. 16 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 17 11. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4570 Fig. 18 12. Remove the cotter pin and nutfrom the upper ball joint stud to steering knuckle attachment. Fig. 19 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C3894-A. 14. Remove steering knuckle from vehicle. 15. Mount steering knuckle securely in a vise. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4571 Fig. 20 16. Remove the 3 boltsattaching the hub/bearing assembly to the steering knuckle. 17. Remove the hub and bearing assembly out from the front of the steering knuckle. NOTE: If bearing will not come out of steering knuckle, it can be tapped out using a soft faced hammer. INSTALLATION 1. Thoroughly clean all hub and bearing assembly mounting surfaces on steering knuckle. 2. Install the replacement hub and bearing assembly in steering knuckle aligning bolt boles in bearing flange with holes in steering knuckle. 3. Install the 3 mounting boltsand tighten evenly to ensure bearing is square to face of steering knuckle. The tighten the 3 mounting boltsto a torque of 110 Nm (80 ft. lbs.). 4. Slide drive shaft back into front hub and bearing assembly. 5. Install the steering knuckle on the lower control arm ball joint. 6. Install the steering knuckle to lower ball joint castle nut. 7. Install upper ball joint stud in steering knuckle. 8. Install the steering knuckle to upper ball joint stud castle nut. 9. Using a crow foot and torque wrench, tighten the upper and lower ball joint castle nuts to the following torque specifications. - Lower ball joint castle nut 74 Nm (56 ft. lbs.). - Upper ball joint castle nut 62 Nm (45 ft. lbs.). 10. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4572 Fig. 21 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 11. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding the stud of the tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 12. Install brake rotor, and caliper, shoes and adapter assembly. 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto the driveshaft stub axle. 14. With vehicle brakes applied to keep stub axle from turning, tighten hub nut to a torque of 203 Nm (150 ft. lbs.) of torque. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Tighten nuts to a torque of 135 Nm (100 ft. lbs.). 16. Lower vehicle. 17. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4573 Wheel Bearing: Service and Repair Rear REAR SUSPENSION REMOVAL - HUB AND BEARING 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the rear brake caliper and rotor. Remove the brake rotor by pulling the rotor straight off the wheel mounting studs. 4. Remove dust cap from rear hub and bearing assembly by prying it off. 5. Remove hub and bearing retaining nut. 6. Remove rear hub and bearing from the spindle by pulling it straight off the spindle by hand. INSTALLATION - HUB AND BEARING 1. Install the hub and bearing assembly on the knuckle spindle. Install a NEW retaining nut. Tighten the retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install the hub and bearing dust cap using a soft faced hammer. 3. Install the brake rotor on the hub and bearing. 4. Install the disc brake caliper. 5. Install the rear tire and wheel assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half the specified torque. Repeat pattern, fully tightening the stud nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION - SPARE TIRE (TEMPORARY) The compact temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the temporary spare tire. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 4583 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4584 Wheels: Specifications Specifications Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4585 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Fig. 1 All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the rim flange of the wheel and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4586 Wheels: Testing and Inspection DIAGNOSIS AND TESTING - WHEEL INSPECTION Inspect wheels for: Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. WARNING: REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4587 Wheels: Service and Repair CLEANING - ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Any of the "DO NOT USE" items listed below WILL damage chrome plated and painted aluminum wheels. DO NOT USE: any abrasive metal cleaner - any abrasive cleaning pad or brush - any cleaner that contains an acid (this will immediately react with and discolor the chromium surface) - chrome polish (unless it is buffed off immediately after application) - oven cleaner - a car wash that uses carbide-tipped wheel cleaning brushes Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Hub Nut 150 ft.lb Wheel Stud Lug Nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4592 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB / BEARING - FRONT DESCRIPTION The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The hub and bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible from the back of the steering knuckle. The hub and bearing unit is not serviceable and must be replaced as an assembly if the bearing or the hub is determined to be defective. 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. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 4595 Wheel Bearing: Description and Operation Rear HUB / BEARING - REAR DESCRIPTION The hub and bearing is a combined rear wheel hub and wheel bearing unit. All vehicles are equipped with permanently lubricated and sealed for life rear hub and bearing assemblies. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing is mounted to the rear knuckle's spindle using a retaining nut. The tire and wheel assembly, and rear brake drum or disc attaches to the studs protruding from the hub flange with wheel mounting studs. OPERATION The hub and bearing has internal bearings that allow it to rotate with the tire and wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING - FRONT The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. The bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4598 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING - REAR The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front FRONT SUSPENSION REMOVAL 1. Raise vehicle. 2. Remove front tire and wheel assembly from the hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 3. Loosen hub nut with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 4. Remove the disc brake caliper, adapter, shoes and rotor from the steering knuckle. Fig. 12 5. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a socket while loosening and removing nut with wrench. Fig. 13 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4601 6. Remove the tie rod end from the steering knuckle arm, using Remover, Special Tool MB-991113. Fig. 14 7. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Fig. 15 8. Remove cotter pin and castle nut from the stud of the lower ball joint. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 9 below. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4602 Fig. 16 9. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. 10. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. Fig. 17 11. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4603 Fig. 18 12. Remove the cotter pin and nutfrom the upper ball joint stud to steering knuckle attachment. Fig. 19 13. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C3894-A. 14. Remove steering knuckle from vehicle. 15. Mount steering knuckle securely in a vise. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4604 Fig. 20 16. Remove the 3 boltsattaching the hub/bearing assembly to the steering knuckle. 17. Remove the hub and bearing assembly out from the front of the steering knuckle. NOTE: If bearing will not come out of steering knuckle, it can be tapped out using a soft faced hammer. INSTALLATION 1. Thoroughly clean all hub and bearing assembly mounting surfaces on steering knuckle. 2. Install the replacement hub and bearing assembly in steering knuckle aligning bolt boles in bearing flange with holes in steering knuckle. 3. Install the 3 mounting boltsand tighten evenly to ensure bearing is square to face of steering knuckle. The tighten the 3 mounting boltsto a torque of 110 Nm (80 ft. lbs.). 4. Slide drive shaft back into front hub and bearing assembly. 5. Install the steering knuckle on the lower control arm ball joint. 6. Install the steering knuckle to lower ball joint castle nut. 7. Install upper ball joint stud in steering knuckle. 8. Install the steering knuckle to upper ball joint stud castle nut. 9. Using a crow foot and torque wrench, tighten the upper and lower ball joint castle nuts to the following torque specifications. - Lower ball joint castle nut 74 Nm (56 ft. lbs.). - Upper ball joint castle nut 62 Nm (45 ft. lbs.). 10. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten attaching bolt. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4605 Fig. 21 CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. 11. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding the stud of the tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). 12. Install brake rotor, and caliper, shoes and adapter assembly. 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto the driveshaft stub axle. 14. With vehicle brakes applied to keep stub axle from turning, tighten hub nut to a torque of 203 Nm (150 ft. lbs.) of torque. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Tighten nuts to a torque of 135 Nm (100 ft. lbs.). 16. Lower vehicle. 17. Set front toe on vehicle to required specification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4606 Wheel Bearing: Service and Repair Rear REAR SUSPENSION REMOVAL - HUB AND BEARING 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the rear brake caliper and rotor. Remove the brake rotor by pulling the rotor straight off the wheel mounting studs. 4. Remove dust cap from rear hub and bearing assembly by prying it off. 5. Remove hub and bearing retaining nut. 6. Remove rear hub and bearing from the spindle by pulling it straight off the spindle by hand. INSTALLATION - HUB AND BEARING 1. Install the hub and bearing assembly on the knuckle spindle. Install a NEW retaining nut. Tighten the retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install the hub and bearing dust cap using a soft faced hammer. 3. Install the brake rotor on the hub and bearing. 4. Install the disc brake caliper. 5. Install the rear tire and wheel assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half the specified torque. Repeat pattern, fully tightening the stud nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 4611 Wheel Fastener: Specifications Wheel Mounting Lug Nut Hex Size 19mm Wheel Mounting Stud Size M12 x 1.5mm Wheel Mounting Lug nut 100 ft.lb Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS FRONT REMOVAL CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly, DO NOT hammer the studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper and adapter as an assembly. 4. Remove any retainer clips, then remove brake rotor form hub. 5. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150 on hub and bearing assembly flange 6. Tighten down on special tool, this will push the wheel stud out of the hub and bearing flange. INSTALLATION CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly, DO NOT hammer the studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4614 1. Install replacement wheel stud into Range of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install brake rotor on front hub. 4. Install disc brake caliper and adapter as an assembly on knuckle. 5. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 6. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4615 Wheel Fastener: Service and Repair Rear WHEEL MOUNTING STUDS REAR REMOVAL CAUTION: DO NOT hammer studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. 1. Remove the hub and bearing from the vehicle. CAUTION: Take care to keep hub and bearing assembly from falling during stud removal. Damage to the hub and bearing could result. 2. Position the hub and bearing assembly under a hydraulic press ram, supported by a 21 mm deepwell impact socket under the stud to be replaced 3. Press the stud out of the hub flange and into the socket well. 4. Remove the hub and bearing assembly from the press. 5. Remove the stud from the socket. INSTALLATION CAUTION: DO NOT hammer studs into the hub flange. If a stud is installed in such a manner, damage to the hub and bearing assembly may occur leading to premature bearing failure. 1. Install wheel stud into stud hole in hub and bearing assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4616 2. Position the hub and bearing assembly face down with stud pointing down into the well of the 21 mm socket. The hydraulic press ram must line up with the stud. 3. Press the stud into the hub flange until it bottoms. 4. Remove the hub and bearing assembly from the press. 6. Install the hub and bearing on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Blend Door Actuator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Blend Door Actuator > Page 4623 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Blend Door Actuator > Page 4624 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator Blend Door Actuator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator > Page 4627 Recirculation Door Actuator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator > Page 4628 Mode Door Actuator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator Air Door Actuator / Motor: Description and Operation Blend Door Actuator The blend door actuator is an electric motor which mechanically positions the blend door. The actuator is mounted to the the bottom of the HVAC housing in the center. A potentiometer in the actuator allows the BCM (for both manual and ATC systems) to know the exact position of the blend door at all times. The blend door actuator is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 4631 Air Door Actuator / Motor: Description and Operation Fresh Air/Recirculation Actuator The recirculation door actuator is an electric motor. It mechanically positions the recirculation door. The actuator is mounted to the right side of the HVAC housing. A potentiometer in the actuator allows the BCM (for both manual and ATC systems) to know the exact position of the door at all times. The actuator is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 4632 Air Door Actuator / Motor: Description and Operation Mode Door Actuator MODE DOOR ACTUATOR The mode door actuator is an electric motor. It mechanically positions the panel/bi-level door and the heat/defrost door. The actuator is mounted to the bottom of the HVAC housing on the left side. A potentiometer in the actuator allows the BCM (for both manual and ATC systems) to know the exact position of the doors at all times. The actuator is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement REMOVAL NOTE: Prior to part replacement, re-calibration the HVAC actuator. Disconnecting negative battery cable for 60 seconds. This will automatically initiate the software calibration procedure. 1. Disconnect negative battery cable. 2. Remove the floor console. 3. Remove rear heat ducts. 4. Remove HVAC housing. 5. Disconnect the electrical connection. Fig.23 Blend Door Actuator 6. Remove actuator retaining screws and pull actuator straight down. Note actuator shaft position for installation reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 4635 Fig.24 Blend Actuator Spline INSTALLATION 1. Install blend door actuator on the housing, making sure the shaft spline is positioned properly with the cam. 2. Install tighten the actuator mounting. 3. Connect wire harness connector to the actuator. 4. Install HVAC housing. 5. Install rear heat ducts. 6. Install the floor console. 7. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 4636 Air Door Actuator / Motor: Service and Repair Fresh Air/Recirculation Actuator Replacement REMOVAL NOTE: Prior to part replacement, re-calibration the HVAC actuator. Disconnecting negative battery cable for 60 seconds. This will automatically initiate the software calibration procedure. 1. Disconnect negative battery cable. 2. Remove the instrument panel. Fig.27 Recirculation Actuator 3. Remove actuator retaining screws and pull actuator straight off. Note actuator shaft position for installation reference. 4. Disconnect the electrical connection. INSTALLATION 1. Connect wire harness connector to the recirculation door actuator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 4637 Fig.28 Recirculation Door Gear 2. Install recirculation door actuator on the housing, making sure shaft spline is positioned properly with the gear. 3. Install and tighten actuator mounting screws. 4. Install the instrument panel. 5. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 4638 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement REMOVAL NOTE: Prior to part replacement, re-calibration the HVAC actuator. Disconnecting negative battery cable for 60 seconds. This will automatically initiate the software calibration procedure. 1. Disconnect battery negative cable. 2. Remove left silencer panel. 3. Remove wiring connection from actuator. Fig.25 Actuators 4. Remove mode actuator mounting screws and pull actuator straight down. Note actuator shaft position for installation reference. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 4639 Fig.26 Mode Actuator Spline INSTALLATION 1. Install mode door actuator on the housing, make sure spline shaft is positioned properly with the cam. 2. Install and tighten the mounting screws. 3. Connect actuator wiring harness to the actuator. 4. Install console left side panel. 5. Install left silencer panel. 6. Connect the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Description and Operation Air Door Position Sensor / Switch: Description and Operation BLEND SWITCH The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient air temperature sensor is located on the inside of front bumper beam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4646 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4647 Ambient Temperature Sensor / Switch HVAC: Description and Operation Fig.21 Ambient Temp Sensor The ambient air temperature sensor is located on the inside of front bumper beam. This sensor informs the ATC system of the ambient temperature outside vehicle. The ambient temp sensor is used by the ATC system to adjust blower speed, temperature offsets, evaporator temperatures and mode control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4648 Ambient Temperature Sensor / Switch HVAC: Service and Repair Fig.22 Ambient Temp Sensor REMOVAL 1. Remove sensor mounting push pin. 2. Disconnect sensor wiring connector. INSTALLATION 1. Connect the sensor wiring harness connector. 2. Install the sensor fastener push pin. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4657 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4658 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4664 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4665 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Blower Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Blower Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Blower Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 4688 Blower Motor: Description and Operation BLOWER MOTOR POWER MODULE The blower motor power module is mounted to the right side of the heater-A/C housing in the passenger compartment. The module provides the ground path to change the blower motor speeds. The blower motor power module cannot be repaired and must be replaced if faulty. With the blower motor switch in the lowest speed position the ground path for the motor is applied through the module. Each higher speed selected the module applies a increase in ground which, increases the blower motor speed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 4689 Blower Motor: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove lower right silencer panel. 3. Remove right sill plate and kick panel. 4. Fold back right upper corner of the carpet. 5. Remove blower motor connector. 6. Remove the three blower motor mounting screws. Fig.1 Blower Motor 7. Remover blower motor from housing. INSTALLATION 1. Install blower motor into the housing. 2. Install the three blower motor mounting screws. 3. Connect blower motor wiring harness. 4. Install right kick panel and sill plate. 5. Install silencer panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor Resistor: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4698 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4699 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor Resistor: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4705 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4706 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4707 Blower Motor Resistor: Locations The blower motor resistor is located in the passenger compartment on the lower side of the heater-A/C housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4708 Blower Motor Resistor Block (MTC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4709 Blower Motor Resistor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4710 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR BLOCK The blower motor resistor is mounted to the lower right side of the heater-A/C housing in the passenger compartment, where it can be accessed for service. The blower motor resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. With the blower motor switch in the lowest speed position the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the switch is in the highest speed position, blower motor resistor is bypassed and the blower motor receives a direct path to ground. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4711 Blower Motor Resistor: Testing and Inspection The blower motor resistor is located in the passenger compartment on the lower side of the heater-A/C housing. The blower motor resistor can be tested without removing it from its mounting position. For circuit descriptions and diagrams, refer to appropriate wiring diagram. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4712 Blower Motor Resistor: Service and Repair REMOVAL 1. Remove lower right silencer panel. Fig.29 Resistor Block 2. Disconnect wiring connector from resistor. 3. Remove blower resistor mounting screws. 4. Pull blower motor resistor out of HVAC housing. INSTALLATION 1. Install blower resistor into HVAC housing. 2. Install and tighten the two resistor mounting screws. 3. Connect resistor wiring harness. 4. Install right silencer panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER SWITCH The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ............................. 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4723 A/C Compressor Clutch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4724 Compressor Clutch: Description and Operation The compressor clutch components provide a way to drive the compressor. The compressor clutch assembly consists of a stationary electromagnetic coil, hub bearing and pulley assembly and a clutch plate. The compressor clutch and coil assembly are the only serviced parts on the compressor. When clutch engages the compressor is then driven by the engine serpentine drive belt. The clutch engagement is controlled the heater-A/C mode control switch, a/c pressure transducer, evaporator probe, thermal limiter switch, compressor clutch relay and Powertrain Control Module (PCM). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4725 Compressor Clutch: Service and Repair REMOVAL NOTE: Refrigerant does not have to be reclaimed for compressor clutch, pulley or coil replacement. The compressor clutch can be serviced in the vehicle. 1. Disconnect and isolate negative battery cable. 2. Remove serpentine drive belt. 3. Unplug the compressor clutch coil wire harness connector. 4. Remove four compressor mounting bolts. 5. Remove compressor from mounting bracket and support compressor while servicing the clutch. Fig.1 Clutch Nut 6. Insert two pins of the Spanner Wrench C-4489 into the holes of the clutch plate. Hold the clutch plate stationary and remove nut. Fig.2 Clutch Plate 7. Remove clutch plate with a Puller C-6461. 8. Remove compressor shaft key and clutch shims. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4726 Fig.3 External Snap Ring 9. Remove external front housing snap ring with snap ring pliers. Fig.4 Shaft Protector And Puller 10. Install lip of the Rotor Puller C-6141-1 into the external snap ring groove and install Shaft Protector C-6141-2. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4727 Fig.5 Puller Plate 11. Install Puller Bolts C-6461 through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free. Fig.6 Clutch Coil Lead Wire Harness 12. Remove screw and retainer from clutch coil wire harness on the front of the compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4728 Fig.7 Clutch Field Coil Snap Ring 13. Remove snap ring from compressor hub and remove clutch field coil. Slide clutch field coil off of the compressor hub. INSTALLATION 1. Install clutch field coil and snap ring. 2. Install clutch coil wire harness retaining clip on the front of the compressor and tighten the screw. 3. Align rotor assembly squarely on the front compressor housing hub. Fig.8 Clutch Pulley Install 4. Install pulley bearing assembly with Installer C-6871. Thread installer on the shaft, then turn the nut until the pulley assembly is seated. 5. Install external snap ring with the bevel side of the snap ring facing outward. Verify snap ring is seated. CAUTION: If snap ring is not seated in the groove it will vibrate out and cause clutch failure and severe compressor damage will occur. 6. Install compressor shaft key and the original clutch shims on the compressor shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 4729 Fig.9 Clutch Plate Driver 7. Install clutch plate with Driver C-6463. Install the shaft nut and tighten to 14.4 Nm (10.5 ft. lbs.). Fig.10 Check Clutch Air Gap 8. Check clutch air gap with a feeler gauge. If air gap does not meet specification 0.41 - 0.79 mm (0.016 - 0.031 in.) add or subtract shims as required. NOTE: If air gap is not consistent around the clutch, lightly pry up at the minimum variations and lightly tap down at the maximum variation point. - When installing a new clutch onto a compressor that previously did not have a clutch, use the shims 1.0, 0.50, and 0.13 mm (0.040, 0.020, and 0.005 in.) provided with the new clutch. 9. Position compressor on the mounting bracket and install bolts. Tighten bolts to 41 Nm (30 ft. lbs.). 10. Plug in compressor clutch harness. 11. Install serpintine drive belt. 12. Install Negative battery cable. 13. Start engine, set system to A/C mode, run engine at 1500-2000 rpm, and blower speed on high. Cycle the new A/C clutch 20 times (5 seconds ON and 5 seconds OFF). NOTE: This procedure will seat (burnishing) friction surfaces and provide a higher clutch torque capability. This is only necessary on a NEW clutch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation Compressor Clutch Coil: Description and Operation The compressor clutch coil is an electromagnetic and provides a way to engage the compressor clutch plate. The electromagnetic coil unit, hub bearing and pulley assembly are retained on the compressor front housing with snap rings. The compressor clutch and coil assembly are the only serviced parts on the compressor. The coil is controlled by the heater-A/C mode control switch, a/c pressure transducer, evaporator probe, thermal limiter switch, compressor clutch relay and Powertrain Control Module (PCM). When the clutch coil is energized, it magnetically draws the clutch plate into contact with the pulley. When the coil is not energized the pulley freewheels on the clutch hub bearing, which is part of the pulley. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 4733 Compressor Clutch Coil: Testing and Inspection 1. Verify battery state of charge. 2. Connect an ammeter (0 - 10 ampere scale) in series with the clutch coil terminal. Use a volt meter (0 - 20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. 3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. 4. The A/C clutch should engage immediately and the clutch voltage should be within 2 volts of the battery voltage. If the A/C clutch does not engage, test the fusible link. 5. The A/C clutch coil is acceptable if the current draw is 2.0 to 4.15 amperes at 11.5 to 12.5 volts at clutch coil. This is with the work area temperature at 21 °C (70 °F). If voltage is more than 12.5 volts, add electrical loads by turning ON electrical accessories until voltage reads below 12.5 volts. 6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 5 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center (PDC) A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4737 Compressor Clutch Relay: Diagrams Power Distribution Center (PDC) A/C Compressor Clutch Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4738 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The A/C compressor clutch relay is a electromechanical device that switches battery current to the A/C compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C heater control (Manual Temperature Control, or Automatic Temperature Control) , the Body Control Module (BCM), and the a/c pressure transducer. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4739 Compressor Clutch Relay: Testing and Inspection Fig.11 A/C Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4740 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations Condenser HVAC: Locations The condenser is located in front of the vehicles radiator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations > Page 4744 Condenser HVAC: Description and Operation The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. The condenser is located in front of the vehicles radiator. When air passes through the condenser fins the refrigerant gives up its heat. The refrigerant then condenses as it leaves the condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical for proper air conditioning performance. It is important that there are no objects placed in front of the radiator grille openings or foreign material on the condenser fins that might obstruct proper air flow. The condenser cannot be repaired and if faulty or damaged must be replaced. All factory-installed air seals or shrouds must he installed following service to maintain proper air flow. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations > Page 4745 Condenser HVAC: Service and Repair REMOVAL 1. Recover refrigerant from A/C system with an R134a refrigerant recovery machine. 2. Remove front fascia. 3. Remove upper radiator support cross-member. 4. Remove transmission cooler lines. Fig.3 Air Conditioning Lines 5. Remove A/C lines. NOTE: Cap lines while system is open to prevent moisture from entering system. 6. Remove two condenser mounting bolts. 7. Lift condenser up out of the vehicle. INSTALLATION 1. Lower condenser into vehicle. 2. Install condenser mounting bolts. 3. Install new 0-rings and install A/C lines. 4. Install transmission cooler lines. 5. Install upper radiator support. 6. Install front fascia. 7. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Control Assembly: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Control Assembly: Connector Views A/C-Heater Control C1 A/C-Heater Control C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 A/C Heater Control Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4770 Control Assembly: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table A/C Heater Control .............................................................................................................................. ..................................................................... 37 A/C Heater ISO Symbols .......................................... ............................................................................................................................................. LED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4771 Control Assembly: Testing and Inspection CONTROL MODULE The control switch and timer circuit are tested in the vehicle with DRB scan tool. Refer to the Body Diagnostic Procedures. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4772 Control Assembly: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Carefully pull out the control bezel and control from the instrument panel. Fig.12 Control Harness 3. Disconnect the control wiring harness. Fig.13 Control Mounting Screws 4. Remove control mounting screws. INSTALLATION 1. Install control on bezel and install mounting screws. 2. Connect control harness to control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4773 Fig.14 Control Bezel 3. Align bezel with instrument panel and push bezel and control into place. CAUTION: Do not push on control knobs, control could be damage. 4. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Control Module HVAC: Customer Interest A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 4782 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 4788 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 4789 Control Module HVAC: Service and Repair BLOWER MOTOR POWER MODULE REPLACEMENT REMOVAL 1. Remove the HVAC housing. Fig. 30 Blower Power Module 2. Disconnect blower motor power module wiring connectors. 3. Remove the module mounting screws and remove module. INSTALLATION 1. Install module onto the housing and install mounting screws. 2. Plug in wiring connectors. 3. Install HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4798 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4799 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4800 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4801 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4802 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4803 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4804 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4805 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4806 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4807 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4808 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4809 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4815 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4816 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4817 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4818 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4819 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4820 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4821 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4822 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4823 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4824 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4825 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 4826 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4827 Evaporator Core: Locations The evaporator coil is located in the heater-A/C housing on the passenger side of the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4828 Evaporator Core: Description and Operation Fig.6 Evaporator Coil The evaporator coil is located in the heater-A/C housing on the passenger side of the vehicle. The evaporator coil is positioned in the housing so all the air entering the housing passes over the evaporator fins then through the system ducts and outlets. Air passing over the evaporator fins will only be conditioned when the A/C system is ON. The evaporator coil cannot be repaired and must be replaced if faulty or damaged. Refrigerant enters the evaporator from the expansion valve as a low-temperature low-pressure mixture of liquid and gas. As air flows over the evaporator fins, humidity in the air condenses on the fins and heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas before it leaves the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4829 Evaporator Core: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove HVAC housing from the vehicle. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Fig.7 Recirculation Motor 3. Disconnect connector from recirculation motor. Fig.8 HVAC Harness 4. Remove wiring harness connector from the top of the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4830 Fig.9 Evaporator Seal 5. Remove seal around evaporator coil inlet(outlet. 6. Remove retaining screw from the top of the housing. Fig.10 HVAC Housing 7. Separate the upper from the housing from the lower. 8. Remove evaporator temperature sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 4831 Fig.11 Evaporator Coil 9. Lift evaporator out of bottom housing. 10. Remove styrofoam seal around evaporator. INSTALLATION 1. Install evaporator coil into lower housing. 2. Install evaporator temperature sensor. 3. Install upper housing onto lower housing and install screws. 4. Connect recirculation motor connector. 5. Install evaporator seal. 6. Install HVAC harness on upper housing. 7. Install HVAC housing in vehicle. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is located at the coldest point on the face of the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor / Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Evaporator Temperature Sensor / Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 A/C Evaporator Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 HVAC Actuators & EVAP Temperature Senser Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 4857 Evaporator Temperature Sensor / Switch: Description and Operation Fig.15 Evaporator Temperature Sensor The evaporator temperature sensor is located at the coldest point on the face of the evaporator. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The sensor is used to switch the clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the Body Control Module. The clutch is switched OFF when the sensor temperature reaches 1.1 °C (34 °F). The clutch is switched back ON when the sensor temperature reaches 2.2 °C (36 °F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 4858 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Lower glove compartment door. Fig.16 Evaporator Probe Wiring 3. Reach through glove compartment door opening and disconnect evaporator temperature sensor wiring connector. Fig.17 Evaporator Probe 4. Using a flat blade pry tool, pull back on the locking tab. Twist access plate clockwise one-quarter turn and pushed inside the A/C housing. Then orientated the plate in such a way that it can be removed from the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 4859 Fig.18 Remove Probe 5. Pull probe out of evaporator core. INSTALLATION 1. Install new sensor into the evaporator. NOTE: The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Install glove compartment door. 5. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-010-01 > Aug > 01 > A/C - `Honk' or `Fog Horn' Sound Expansion Valve: Customer Interest A/C - `Honk' or `Fog Horn' Sound NUMBER: 24-010-01 GROUP: Heating & A/C DATE: Aug. 31, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-008-00, DATED NOV. 10, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 2000 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-170-00001). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND A CLARIFICATION OF THE SYMPTOM/CONDITION. SUBJECT: A/C **Honk** Or Fog Horn Sound OVERVIEW: This bulletin involves replacing the A/C expansion valve. MODELS: 2001 - **2002** (JR) **Sebring Convertible**/Sedan/Stratus Sedan SYMPTOM/CONDITION: **Honk** or "fog horn" sound coming from the A/C expansion valve within a few seconds of A/C clutch engagement, or immediately after A/C clutch disengagement. This sound lasts anywhere from one to three seconds and can be confused with the sound a vehicle braking system makes as the vehicle is allowed to creep forward while at curb idle. Vibration from **the honk condition can sometimes** be felt in the passenger compartment, especially in the steering wheel and seats. **Performing this TSB will not improve any vehicle noise conditions that last longer than three seconds.** DIAGNOSIS: Due to the random occurrence of this sound, it is not always possible to successfully test for this condition. Therefore, the complaint must be carefully reviewed with the customer to avoid replacing an A/C expansion valve unnecessarily. PARTS REQUIRED: NOTE: THE MOPAR REPLACEMENT A/C EXPANSION VALVE MUST HAVE A DATE OF OCTOBER 2000 OR LATER PRINTED ON THE BOX TO BE USED FOR THIS REPAIR. REPAIR PROCEDURE: 1. Replace A/C expansion valve as described in the appropriate service manual. NOTE: REPLENISH THE SYSTEM WITH 5D15 PAG OIL MATCHING THE AMOUNT THAT WAS REMOVED DURING REFRIGERANT RECOVERY, AND RECHARGE THE SYSTEM WITH R134A REFRIGERANT TO THE QUANTITY LISTED ON THE A/C SYSTEM UNDERHOOD WARNING LABEL. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 24-010-01 > Aug > 01 > A/C - `Honk' or `Fog Horn' Sound > Page 4868 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-010-01 > Aug > 01 > A/C - `Honk' or `Fog Horn' Sound Expansion Valve: All Technical Service Bulletins A/C - `Honk' or `Fog Horn' Sound NUMBER: 24-010-01 GROUP: Heating & A/C DATE: Aug. 31, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-008-00, DATED NOV. 10, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 2000 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-170-00001). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND A CLARIFICATION OF THE SYMPTOM/CONDITION. SUBJECT: A/C **Honk** Or Fog Horn Sound OVERVIEW: This bulletin involves replacing the A/C expansion valve. MODELS: 2001 - **2002** (JR) **Sebring Convertible**/Sedan/Stratus Sedan SYMPTOM/CONDITION: **Honk** or "fog horn" sound coming from the A/C expansion valve within a few seconds of A/C clutch engagement, or immediately after A/C clutch disengagement. This sound lasts anywhere from one to three seconds and can be confused with the sound a vehicle braking system makes as the vehicle is allowed to creep forward while at curb idle. Vibration from **the honk condition can sometimes** be felt in the passenger compartment, especially in the steering wheel and seats. **Performing this TSB will not improve any vehicle noise conditions that last longer than three seconds.** DIAGNOSIS: Due to the random occurrence of this sound, it is not always possible to successfully test for this condition. Therefore, the complaint must be carefully reviewed with the customer to avoid replacing an A/C expansion valve unnecessarily. PARTS REQUIRED: NOTE: THE MOPAR REPLACEMENT A/C EXPANSION VALVE MUST HAVE A DATE OF OCTOBER 2000 OR LATER PRINTED ON THE BOX TO BE USED FOR THIS REPAIR. REPAIR PROCEDURE: 1. Replace A/C expansion valve as described in the appropriate service manual. NOTE: REPLENISH THE SYSTEM WITH 5D15 PAG OIL MATCHING THE AMOUNT THAT WAS REMOVED DURING REFRIGERANT RECOVERY, AND RECHARGE THE SYSTEM WITH R134A REFRIGERANT TO THE QUANTITY LISTED ON THE A/C SYSTEM UNDERHOOD WARNING LABEL. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 24-010-01 > Aug > 01 > A/C - `Honk' or `Fog Horn' Sound > Page 4874 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4875 Expansion Valve: Locations The "H" valve-type Thermal Expansion Valve (TXV) is located in front of the heater-A/C housing between the liquid and suction lines and the evaporator coil. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4876 Expansion Valve: Description and Operation Fig.4 Expansion Valve The "H" valve-type Thermal Expansion Valve (TXV) is located in front of the heater-A/C housing between the liquid and suction lines and the evaporator coil. The expansion valve is a calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. High pressure high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice. The refrigerant is converted into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. A temperature sensor in the expansion valve control head monitors refrigerant temperature leaving the evaporator coil through the suction line. The valve adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil. Controlling refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is in a liquid state, which could damage the compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4877 Expansion Valve: Testing and Inspection The expansion valve is located on the engine side of the dash panel, near the right shock tower. The expansion valve can fail in three different positions (open, closed or restricted). In an Open Position: this will result in a noisy compressor or no cooling. The cause can be a broken spring, broken ball or excessive moisture in the A/C system. If the spring or ball are found to be defective, replace the expansion valve. If excessive moisture is found in the A/C system, recycle the refrigerant. In a Closed Position: There will be low suction pressure and no cooling. This may be caused by a failed power dome or excessive moisture in the A/C system. If the power dome on the expansion valve is found to be defective replace the expansion valve. If excessive moisture is found recycle the refrigerant. A Restricted Orifice: There will be low suction pressure and no cooling. This may be caused by debris in the refrigerant system. If debris is believed to be the cause, recycle the refrigerant and replace the expansion valve and receiver/drier. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 4878 Expansion Valve: Service and Repair REMOVAL 1. Recover refrigerant from the A/C system with a refrigerant recovery machine. 2. Disconnect clips from expansion valve lines. 3. Disconnect quick connectors on expansion valve with Quick Connector Kit 7193. 4. Remove lines at expansion valve. NOTE: Cap lines while system is open to prevent moisture from entering system. Fig.5 Expansion Valve 5. Remove two retaining bolts from expansion valve and remove valve. 6. Remove expansion valve. 7. Remove expansion valve gasket. INSTALLATION 1. Install a new gasket and install valve on evaporator. 2. Install expansion valve bolts and tighten to 11 Nm (100 in. lbs.). 3. Install new 0-rings and install A/C lines on expansion valve. 4. Install quick connector clips. 5. Evacuate and charge system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 4882 Heater Core: Description and Operation Fig.17 Heater Core The heater core is located in the HVAC housing. The core is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core. As coolant flows through the heater core, heat is transferred to the heater core fins and tubes. Air directed through the heater core fins, picks up the heat. The temperature control door controls heater output air temperature by controlling the air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if damaged. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 4883 Heater Core: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Remove HVAC housing from the vehicle. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Fig.18 Recirculation Motor 3. Disconnect connector from recirculation motor. Fig.19 HVAC Harness 4. Remove wiring harness connector from the top of the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 4884 Fig.20 Evaporator Seal 5. Remove seal around evaporator coil inlet/outlet. 6. Remove retaining screw from the top of the housing. Fig.21 HVAC Housing 7. Separate the upper from the housing from the lower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 4885 Fig.22 Heater Core 8. Lift heater core out of lower housing. INSTALLATION 1. Install new heater core into lower housing. 2. Install upper housing onto lower housing and install screws. 3. Install evaporator seal 4. Install HVAC harness on upper housing 5. Connect recirculation motor connector. 6. Install HVAC housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line The discharge line is made from reinforced rubber with a nylon liner on the inner walls. The line has a light weight aluminum fittings at the compressor and condenser end. The O-rings used to seal the connections are made from a special type of rubber not affected by R-134a refrigerant. O-rings must replaced whenever the line is removed and installed. CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 4891 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line The suction line is made from reinforced rubber with a nylon liner on the inner walls. The line has a light weight aluminum fitting at the compressor end and a quick connect fitting at the expansion valve end. The quick connect has two O-rings to seal the connection made from a special type of rubber not affected by R-134a refrigerant. The O-rings must be replaced whenever the line is removed and installed. CAUTION: Use only O-rings specified for the vehicle. Failure to use correct O-ring will cause the connection to leak. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover refrigerant from A/C system with R134a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. Fig.12 Air Conditioning Lines 3. Remove discharge line from A/C condenser. Fig.13 Discharge Line 4. Remove discharge line from A/C compressor. NOTE: Cap compressor and condenser while system is open to prevent moisture from entering system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4894 Fig.14 Discharge Line INSTALLATION 1. Install discharge line on the compressor with new O-ring and tighten bolt to 22 Nm (200 in. lbs.). 2. Install discharge line on the condenser with new O-ring and tighten nut to 22 Nm (200 in. lbs.). 3. Connect pressure transducer wiring harness. 4. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4895 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Recover refrigerant from A/C system with R134a refrigerant recovery machine. 2. Remove suction line from the compressor. 3. Remove clip from the line at the expansion valve. 4. Disconnect quick connector on expansion valve with Quick Connector Kit 7193. Fig.15 Suction Line 5. Remove suction line from expansion valve. NOTE: Cap compressor and expansion valve while system is open to prevent moisture from entering system. INSTALLATION 1. Install suction line to expansion valve with new O-rings. 2. Install clip on the line quick connect at the expansion valve. 3. Install suction line to compressor with new O-ring and tighten bolt to 22 Nm (200 in. lbs.). 4. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 4896 Hose/Line HVAC: Service and Repair Tubing and Fittings Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. CAUTION: - The system must be completely empty before opening any fitting or connection in the refrigeration system. Open fittings with caution even after the system has been emptied. If any pressure is noticed as a fitting is loosened, retighten fitting and evacuate the system again. - A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. - The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. - When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. - All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Housing Assembly HVAC: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4905 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4906 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation Housing Assembly HVAC: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation > Page 4912 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation > Page 4913 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Chrysler does not provide any images related to this service procedure REMOVAL 1. Remove negative battery cable. 2. Recover refrigerant from A/C system with R134a refrigerant recovery machine. 3. Drain the engine cooling system. 4. Remove heater hoses from heater core. NOTE: Plug core tubes to prevents antifreeze from spilling on vehicle interior during removal. 5. Remove quick connect clips from A/C lines at the expansion valve. 6. Remove A/C lines from expansion valve with Quick Connectors Tool Kit 7193. 7. Remove expansion valve mounting bolts and remove valve. NOTE: Cap the A/C lines and evaporator to prevent moisture from entering the refrigerant system. 8. Remove floor console. 9. Remove rear heat ducts. 10. Remove nuts securing HVAC housing to dash panel under the hood. 11. Remove the instrument panel and HVAC housing as an assembly. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 12. Disconnect HVAC wiring connect from left side of the housing. 13. Remove nuts mounting HVAC housing INSTALLATION 1. Align HVAC housing with instrument panel and install mounting nuts. 2. Connect HVAC wiring harness 3. Install instrument panel and HVAC housing assembly. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 4. Install nuts securing HVAC housing to dash panel under the hood. 5. Install rear heat ducts. 6. Install console. 7. Install expansion valve and tighten mounting bolts. 8. Install A/C lines to expansion valve with new 0-rings. 9. Install quick connect clips to A/C lines. 10. Install heater hoses to heater core. 11. Install negative battery cable. 12. Fill engine cooling system. 13. Evacuate and charge A/C system with R134a refrigerant recovery machine. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4916 Housing Assembly HVAC: Overhaul DISASSEMBLY 1. Disconnect recirculation actuator wiring connector. 2. Remove recirculation housing mounting screws from the HVAC housing. 3. Remove recirculation housing from HVAC housing. Fig. 2 Recirculation Actuator 4. Remove recirculation actuator mounting screws and remove actuator. Fig. 3 Recirculation Door Gear 5. Remove recirculation actuator gear mounting screw and remove gear. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4917 Fig.5 Recirculation Door 6. With a small screw driver depress recirculation door gear release and remove gear. 7. Tilt the gear end of the recirculation door up and pull the door out of the housing. 8. Remove blower motor wiring connector. 9. Remove blower motor mounting screws and remove motor. Fig.5 HVAC Harness 10. Remove HVAC harness connector from the top of the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4918 Fig.6 Evaporator Seal 11. Remove seal from evaporator coil inlet(outlet. 12. Remove retaining screws from the top of the housing. Fig.7 HVAC Housing 13. Separate the top housing from the bottom housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4919 Fig.8 Evaporator Temperature Sensor 14. Remove evaporator temperature sensor. Fig.9 Evaporator Coil 15. Lift evaporator out of the bottom housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4920 Fig.10 Heater Core 16. Lift heater core out of the bottom housing. 17. Disconnect blower resistor wiring connector/ATC blower motor power module wiring connectors. Fig.11 Resistor Block Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4921 Fig.12 Blower Power Module 18. Remove blower resistor mounting screws/ATC blower motor power module mounting screws. 19. Remove resistor from the bottom of the housing or ATC module from the side of the housing if equipped. Fig.13 Lower Heater Duct 20. Remove lower heater duct screws and remove duct from the bottom housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4922 Fig.14 Actuators 21. Disconnect mode door actuator and blend door actuator wiring connectors. 22. Remove mode door actuator mounting screws and remove actuator. Fig.15 Mode Actuator Cam 23. Remove mode door actuator cam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4923 Fig.16 Defroster Door Lever 24. Remove heat/defrost door lever mounting screw. Fig.17 Heat/Defrost Door Assembly 25. Remove heat/defrost door lever, link and door assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4924 Fig.18 Panel/Bi-Level Door Lever 26. Pull panel/bi-level door lever off door. Fig.19 Panel/Bi-Level Door Assembly 27. Remove panel/bi-level door and air deflector from the bottom housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4925 Fig.20 Blend Door Actuator 28. Remove blend door actuator mounting screws and remove actuator. 29. Remove blend door actuator cam. Fig.21 Blend Door Actuator Cam NOTE: The cam must be in the correct position for removal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4926 Fig.22 Blend Door Release 30. With a small screw driver, depress blend door release and remove lever and door. 31. Pull other blend door lever off and remove lever and door. ASSEMBLY 1. Install blend doors and levers into the bottom housing. Fig.23 Blend Cam Followers 2. Align blend actuator cam and lever followers and install cam. NOTE: Rotate cam until it drops into the housing. The cam must be in the correct position to install. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4927 Fig.24 Blend Actuator Spline 3. Align blend actuator spline with cam spline and install actuator. 4. Install blend actuator mounting screws and plug in wiring connector. Fig.25 Panel Bi-Level Door And Air Deflector 5. Install panel/bi-level door and air deflector into the housing. NOTE: Center vain of the air deflector must seat in the bottom housing locating tabs. 6. Install panel/bi-level door lever into bottom of the door shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4928 Fig.26 Mode Door Levers 7. Install heat/defrost door, link and lever. Fig.27 Mode Cam Followers 8. Align mode door cam with lever followers and install cam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4929 Fig.28 Mode Actuator Spline 9. Align mode actuator spline with cam spline and install actuator. 10. Install mode actuator mounting screws and plug in wiring connector. Fig.29 Blower Motor 11. Install blower motor into the bottom housing. 12. Install blower mounting screws and plug in wiring connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4930 Fig.30 Resistor Block 13. Install blower resistor into the bottom of the housing or ATC blower motor power onto the side of the housing. 14. Install blower resistor/blower motor power module mounting screws and plug in wiring connector/connectors. Fig.31 Lower Heater Duct 15. Install lower heat duct and mounting screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4931 Fig.32 Evaporator Coil 16. Install evaporator coil into the bottom housing. 17. Install evaporator temperature sensor. Fig.33 Heater Core 18. Install heater core into the bottom housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4932 Fig.34 Door Shafts 19. Install and align the top of the housing with the door shafts. 20. Install top housing mounting screws. Fig.35 Evaporator Seal 21. Install evaporator inlet/outlet seal. 22. Install recirculation door into the recirculation housing. 23. Install recirculation door gear onto the door shaft. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 4933 Fig.36 Recirculation Door Gear 24. Align and install recirculation actuator gear with the door gear and install retaining screw. NOTE: Gears must be align properly to operate. Fig.37 Recirculation Actuator 25. Align recirculation actuator spline with the actuator gear spline and install actuator. 26. Install recirculation actuator mounting screws. 27. Install recirculation housing onto the top housing and install mounting screws. 28. Plug in recirculation actuator wiring connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation The receiver/drier is mounted on the right side of the engine compartment. It is part of the liquid line, between the condenser outlet and evaporator inlet. High-pressure liquid refrigerant from the condenser flows into the receiver/drier. The receiver/drier filters the refrigerant to prevent foreign material from contaminating the expansion valve. A desiccant bag inside absorbs any moisture which may have become trapped in refrigerant system. In periods of high demand air conditioner operation, it acts as a reservoir to store surplus refrigerant. If the receiver/drier is faulty, damaged, contaminated or the system has been left open to the atmosphere for an undetermined period, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 4937 Receiver Dryer: Service and Repair REMOVAL 1. Remove recover refrigerant from A/C system with a refrigerant recovery machine. 2. Remove liquid line from condenser. 3. Remove clip from the line at the expansion valve. 4. Disconnect quick connector on expansion valve with Quick Connector Kit 7193. 5. Remove liquid line from expansion valve. Fig.16 Receiver/Driver 6. Remove receiver/drier bracket bolt at base of receiver/drier and remove the receiver/drier and line. NOTE: Cap condenser and evaporator while system is open to prevent moisture from entering system. INSTALLATION 1. Install receiver/drier in bracket and tighten mounting bolt. 2. Install liquid line to expansion valve with new O-rings. 3. Install clip on the line quick connect at the expansion valve. 4. Install liquid line to condenser with new O-rings and tighten nut to 22 Nm (200 in. lbs.). 5. Evacuate and charge A/C system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant ............................................................................................................................... ..................................................... (27 oz. or 1.69 lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 4942 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 4943 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 4944 http://www.macsw.org/ Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 4945 Refrigerant: Description and Operation REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-Hammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped with R-134a. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ............................................................. 150 ml (5 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator ........................................................................................................................................... ............................................................... 59 ml (2 oz.) Receiver-Drier ..................................................................................................................................... ............................................................... 30 ml (1 oz.) Refrigerant Lines ................................................................................................................................. ............................................................ 44 ml (1.5 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 4950 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ............................................................... SP-15 PAG Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 4951 Refrigerant Oil: Description and Operation REFRIGERANT OIL - DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The TRS9O compressor used in this vehicle is designed to use an SP-15 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. Recap the oil container immediately after use to prevent moisture contamination. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 4952 Refrigerant Oil: Testing and Inspection REFRIGERANT OIL - TESTING It is important to have the correct amount of lubricant in the A/C system to ensure proper lubrication of the compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkylene glycol PAG lubricant. Only PAG refrigerant lubricant approved for use with R-134a should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It is not necessary to check or add lubricant unless it has been lost. Lubricant loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. A/C Component Refrigerant Oil Capacities Refrigerant Oil Level When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with (R-134a) refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser and receiver/drier will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities table. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The receiver/drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On an A/C system, the evaporator retains 60 ml (2 oz.) of oil. The condenser retains 30 ml (1 oz.) of oil, and system capacity may be 150 ml (5.00 oz.) of oil. 150 ml minus 90 ml equals 60 ml (2.00 oz.). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is SP-15 PAG (polyalkylene glycol). Verify Refrigerant Lubricant Level 1. Discharge refrigerant system using a recycling/reclaiming equipment if a charge is present. 2. Disconnect refrigerant lines from A/C compressor. Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction and discharge ports on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Refer to the A/C Component Refrigerant Oil Capacities chart above. Add lubricant through the suction and discharge ports on compressor. This is not to exceed 150 ml (5.00 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. 7. Most reclaim/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4956 A/C Pressure Transducer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4957 Refrigerant Pressure Sensor / Switch: Description and Operation A/C PRESSURE TRANSDUCER The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. This switch prevents compressor operation when the discharge line pressure approaches extreme levels. The transducer is a factory-calibrated unit and cannot be adjusted or repaired. If faulty or damaged, it must be replaced. When discharge line pressure rises above 2971 kPa (431 psi) the switch contacts open and interrupt the A/C clutch relay signal from the PCM. The switch contacts also open when pressure drops below 206 kPa (30 psi). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4958 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. 1. Disconnect the wire harness connector from the A/C pressure transducer 2. Remove transducer with a 14 mm open-end wrench. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. INSTALLATION NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. 1. Thread pressure transducer on to discharge line. 2. Tighten pressure transducer to 6 Nm (50 in. lbs.). 3. Connected wire connector to transducer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center (PDC) A/C Compressor Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4963 Compressor Clutch Relay: Diagrams Power Distribution Center (PDC) A/C Compressor Clutch Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4964 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The A/C compressor clutch relay is a electromechanical device that switches battery current to the A/C compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C heater control (Manual Temperature Control, or Automatic Temperature Control) , the Body Control Module (BCM), and the a/c pressure transducer. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4965 Compressor Clutch Relay: Testing and Inspection Fig.11 A/C Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 4966 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Control Module HVAC: Customer Interest A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 4975 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Erratic Operation/Poor Performance NUMBER: 24-002-04 REV. A GROUP: Heating & A/C DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-002-04, DATED MARCH 30, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEAR. SUBJECT: A/C and Heater Performance OVERVIEW: This bulletin provides diagnostic information for A/C and heater performance complaints. MODELS: 1998 - 2004 (LH) LHS/300M/Concorde/Intrepid 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: Perform Customer Satisfaction Notification no. 857, reprogram Powertrain Control Module (PCM), for 2000 model year LH-vehicles built prior to August 30, 1999 (MDH 0830XX). SYMPTOM/CONDITION: Erratic operation of the A/C and heater systems including: ^ Lack of cold air ^ Lack of hot air ^ Unrequested mode change - Automatic Temperature Control (ATC) only) ^ No control of mode or temperature control ^ Tapping noise from blend door The above Symptoms may be accompanied by the following Diagnostic Trouble Codes (DTCs): ^ Blend door feedback ^ Blend door stall ^ A/C control mode door input shorted to battery ^ Mode door stall ^ In car temp sensor failure ATC messages not received DIAGNOSIS: ^ Do not attempt to remove A/C control until after this entire Diagnosis and Repair Procedure has been performed. ^ Verify customer reported symptom(s) if possible. ^ Check for the presence of DTCs with the scan tool (DRBIII(R)) and record on the repair order. If a DRBIII(R) is not available reference the appropriate Service Manual - Heating and Air Conditioning "Self Diagnostics" procedure and record any present DTCs on the repair order. If Symptoms and/or DTCs other than those listed above are present, repair as necessary. If a Symptom(s) and/or DTC(s) listed above is present, perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-002-04A > Jul > 04 > A/C - Erratic Operation/Poor Performance > Page 4981 REPAIR PROCEDURE: 1. With the vehicle at room temperature 10° - 27° C. (50° to 80° F.), remove the M-1 circuit fuse for ten minutes to erase DTCs. 2. Install the M-1 fuse and start the vehicle, this will initiate the HVAC system calibration. Allow approximately five minutes for the calibration to complete. 3. Operate the vehicle and HVAC system to verify that Symptoms and/or DTCs are gone. If tapping noise or Blend Stall/Feedback DTCs re-occur, additional diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 4982 Control Module HVAC: Service and Repair BLOWER MOTOR POWER MODULE REPLACEMENT REMOVAL 1. Remove the HVAC housing. Fig. 30 Blower Power Module 2. Disconnect blower motor power module wiring connectors. 3. Remove the module mounting screws and remove module. INSTALLATION 1. Install module onto the housing and install mounting screws. 2. Plug in wiring connectors. 3. Install HVAC housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Description and Operation Air Door Position Sensor / Switch: Description and Operation BLEND SWITCH The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations The ambient air temperature sensor is located on the inside of front bumper beam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4990 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor Ambient Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4991 Ambient Temperature Sensor / Switch HVAC: Description and Operation Fig.21 Ambient Temp Sensor The ambient air temperature sensor is located on the inside of front bumper beam. This sensor informs the ATC system of the ambient temperature outside vehicle. The ambient temp sensor is used by the ATC system to adjust blower speed, temperature offsets, evaporator temperatures and mode control. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 4992 Ambient Temperature Sensor / Switch HVAC: Service and Repair Fig.22 Ambient Temp Sensor REMOVAL 1. Remove sensor mounting push pin. 2. Disconnect sensor wiring connector. INSTALLATION 1. Connect the sensor wiring harness connector. 2. Install the sensor fastener push pin. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation BLOWER SWITCH The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations The evaporator temperature sensor is located at the coldest point on the face of the evaporator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor / Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Evaporator Temperature Sensor / Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 A/C Evaporator Temperature Sensor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 HVAC Actuators & EVAP Temperature Senser Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 5021 Evaporator Temperature Sensor / Switch: Description and Operation Fig.15 Evaporator Temperature Sensor The evaporator temperature sensor is located at the coldest point on the face of the evaporator. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator temperature sensor prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow. The sensor is used to switch the clutch OFF before evaporator freeze-up occurs. Output from the probe is sampled by the Body Control Module. The clutch is switched OFF when the sensor temperature reaches 1.1 °C (34 °F). The clutch is switched back ON when the sensor temperature reaches 2.2 °C (36 °F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 5022 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Lower glove compartment door. Fig.16 Evaporator Probe Wiring 3. Reach through glove compartment door opening and disconnect evaporator temperature sensor wiring connector. Fig.17 Evaporator Probe 4. Using a flat blade pry tool, pull back on the locking tab. Twist access plate clockwise one-quarter turn and pushed inside the A/C housing. Then orientated the plate in such a way that it can be removed from the housing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 5023 Fig.18 Remove Probe 5. Pull probe out of evaporator core. INSTALLATION 1. Install new sensor into the evaporator. NOTE: The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Install glove compartment door. 5. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5027 A/C Pressure Transducer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5028 Refrigerant Pressure Sensor / Switch: Description and Operation A/C PRESSURE TRANSDUCER The A/C pressure transducer is located on the discharge line near the condenser and functions as a refrigerant system pressure sensor. This switch prevents compressor operation when the discharge line pressure approaches extreme levels. The transducer is a factory-calibrated unit and cannot be adjusted or repaired. If faulty or damaged, it must be replaced. When discharge line pressure rises above 2971 kPa (431 psi) the switch contacts open and interrupt the A/C clutch relay signal from the PCM. The switch contacts also open when pressure drops below 206 kPa (30 psi). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5029 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. 1. Disconnect the wire harness connector from the A/C pressure transducer 2. Remove transducer with a 14 mm open-end wrench. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. INSTALLATION NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. 1. Thread pressure transducer on to discharge line. 2. Tighten pressure transducer to 6 Nm (50 in. lbs.). 3. Connected wire connector to transducer. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 5033 Sun Sensor (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 5034 Solar Sensor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 5035 Solar Sensor: Description and Operation Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. The sun sensor is not a thermistor type sensor but rather a photo diode. For this reason the sun sensor responds to sun light intensity rather than temperature. It is used to aid in determining proper mode door position, temperature door position and blower speed. The sun sensor is also used to sense day/night conditions for automatic headlight control if so equipped, and has an LED indicator for the vehicle security system. The sun sensor is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 5036 Solar Sensor: Testing and Inspection SUN SENSOR TEST WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The sun sensor is located so the sun hits the sensor in the same way that it hits the driver and the passenger. It is important that the area in front of the sensor be unobstructed. Check that the following items are not in the way of the sun sensor. - Windshield wipers that are adjusted too high. - Stickers on the windshield that are directly in front of the sensor. - Top cover installed not properly. Sun sensor should be 1/4 inch. above the top cover. - Caps or papers which might cover the sensor. Some ATC equipped vehicles may exhibit a lack of passenger comfort in sunny weather such as in the early afternoon. Verify that the ATC system is functioning properly. Inspect the location of the sun sensor. The sun sensor must protrude approximately 1/4 inch above the instrument panel top cover to insure proper operation. If the sensor does not protrude 1/4 inch, perform the following procedure: - Confirm that the top cover is properly installed - Remove the top cover - Remove fasteners from sun sensor - Install one 1/4-20 nut per fastener under the sun sensor so that it is shimmed higher - Reinstall the sun sensor. Do not overtighten screw. If a longer screw is required, use 8-15x1 inch. Refer to the proper Diagnostic Information for the electrical test. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 5037 Solar Sensor: Service and Repair SUN SENSOR REPLACEMENT REMOVAL 1. Disconnect negative battery cable. 2. Remove instrument panel top cover. Refer to Instrument Panel for the procedures. Fig.20 Sun Sensor 3. Remove two Sun Sensor mounting screws. 4. Lift sensor off the instrument panel and disconnect the wiring. 5. Remove the sensor from the vehicle. INSTALLATION 1. Connect wiring connector to sensor and position on instrument panel. 2. Install the two sensor fasteners. 3. Install instrument panel top cover. Refer to Instrument Panel System for the procedures. NOTE: Sun sensor must protrude approximately 1/4 inch above instrument panel top cover to ensure proper operation. 4. Connect negative battery Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the discharge line between the compressor and the condenser over the cooling fans, near the front of the engine compartment. The low pressure service port is located on the suction line, near the right strut tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5041 Service Port HVAC: Description and Operation SERVICE PORT VALVE CORE The high pressure service port is located on the discharge line between the compressor and the condenser over the cooling fans, near the front of the engine compartment. The low pressure service port is located on the suction line, near the right strut tower. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. The two refrigerant system service ports are used to charge/recover/recycle/evacuate and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system to ensure the refrigerant system is not accidentally contaminated with R-12 refrigerant or refrigerant system service equipment. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 5045 Sun Sensor (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 5046 Solar Sensor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 5047 Solar Sensor: Description and Operation Fig.19 ATC Sun Sensor SUN SENSOR The sun sensor is only used on vehicles equipped with Automatic Temperature Control (ATC). The sensor is mounted on the top of the instrument panel below the instrument panel top cover. The sun sensor is not a thermistor type sensor but rather a photo diode. For this reason the sun sensor responds to sun light intensity rather than temperature. It is used to aid in determining proper mode door position, temperature door position and blower speed. The sun sensor is also used to sense day/night conditions for automatic headlight control if so equipped, and has an LED indicator for the vehicle security system. The sun sensor is not serviceable and must be replaced if found to be defective. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 5048 Solar Sensor: Testing and Inspection SUN SENSOR TEST WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The sun sensor is located so the sun hits the sensor in the same way that it hits the driver and the passenger. It is important that the area in front of the sensor be unobstructed. Check that the following items are not in the way of the sun sensor. - Windshield wipers that are adjusted too high. - Stickers on the windshield that are directly in front of the sensor. - Top cover installed not properly. Sun sensor should be 1/4 inch. above the top cover. - Caps or papers which might cover the sensor. Some ATC equipped vehicles may exhibit a lack of passenger comfort in sunny weather such as in the early afternoon. Verify that the ATC system is functioning properly. Inspect the location of the sun sensor. The sun sensor must protrude approximately 1/4 inch above the instrument panel top cover to insure proper operation. If the sensor does not protrude 1/4 inch, perform the following procedure: - Confirm that the top cover is properly installed - Remove the top cover - Remove fasteners from sun sensor - Install one 1/4-20 nut per fastener under the sun sensor so that it is shimmed higher - Reinstall the sun sensor. Do not overtighten screw. If a longer screw is required, use 8-15x1 inch. Refer to the proper Diagnostic Information for the electrical test. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 5049 Solar Sensor: Service and Repair SUN SENSOR REPLACEMENT REMOVAL 1. Disconnect negative battery cable. 2. Remove instrument panel top cover. Refer to Instrument Panel for the procedures. Fig.20 Sun Sensor 3. Remove two Sun Sensor mounting screws. 4. Lift sensor off the instrument panel and disconnect the wiring. 5. Remove the sensor from the vehicle. INSTALLATION 1. Connect wiring connector to sensor and position on instrument panel. 2. Install the two sensor fasteners. 3. Install instrument panel top cover. Refer to Instrument Panel System for the procedures. NOTE: Sun sensor must protrude approximately 1/4 inch above instrument panel top cover to ensure proper operation. 4. Connect negative battery Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Description and Operation Thermal Limiting Fuse: Description and Operation THERMAL LIMITER SWITCH The thermal limiter switch measures compressor surface temperature. If compressor surface temperature is excessive, the switch cuts battery feed to the compressor clutch coil. The switch reset itself, once compressor surface temperature returns to normal. The switch is not adjustable or serviceable, if faulty the compressor must be replaced. The thermal limiter switch interrupts battery feed to the compressor clutch coil when temperature reaches 122 - 128 °C (250 - 260 °F). The switch restores clutch coil battery feed when the temperature drops to 104 - 116 °C (220 - 240 °F). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Description and Operation > Page 5053 Thermal Limiting Fuse: Testing and Inspection 1. Unplug Thermal Limiter connector. 2. With an ohmmeter, check for continuity between the two terminals. If no continuity is present replace compressor. 3. The Thermal Limiter is calibrated to open and close at: - Open circuit (no continuity) Temperature: 122 - 128 °C (252 - 262 °F) - Close circuit (continuity) Temperature: 106 - 116 °C (225 - 235 °F) NOTE: The thermal limiter switch is not serviceable. If the switch falls, the compressor must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System SERVICE OF DEPLOYED AIRBAG DRIVER AIRBAG After a Driver Airbag has been deployed: - Driver Airbag - Steering Wheel - Clock Spring - Steering Column assembly The component above must be replaced because they cannot be reused. Replace any other driver airbag system components if damaged. PASSENGER AIRBAG After a Passenger Airbag has been deployed: - Passenger Airbag - Instrument Panel and Pad Assembly The components above must be replaced because of visible or non visible structural damage. The glove box, top cover, cluster hood, steering column cover, right trim bezel and/or end cap, or any other components should be checked and replaced if damaged. CLEAN UP Roll or fold the Airbag towards the instrument panel surface or steering wheel and tape the door shut or the bag to the steering wheel. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Work from the outside in to avoid kneeling or sitting in a contaminated area. Vacuum the heater and A/C outlets as well. If the heater or air conditioner was in RECIRC mode at time of airbag deployment, operate blower motor on low speed and vacuum powder residue expelled from the heater and A/C outlets. Multiple vacuum cleaning may to necessary to decontaminate the interior of the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5059 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5064 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V306000 > Oct > 00 > Recall 00V306000: Possible Separated Air Bag Door Air Bag: Recalls Recall 00V306000: Possible Separated Air Bag Door Passenger air bags were built with suspect aluminum extrusion sections which may not retain the air bag door during an air bag deployment event. A separated air bag door could injure a vehicle occupant. Dealers will replace the passenger side air bag. Owner notification began October 19, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement Technical Service Bulletin # 898 Date: 001001 Recall - Passenger Airbag Replacement October 2000 Dealer Service Instructions for: Safety Recall No. 898 -- Passenger Airbag Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This recall applies only to the above vehicles built from September 12, 2000 through September 15, 2000 (MDH 091220 through 091512). IMPORTANT: Most of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The passenger airbag door on about 400 of the above vehicles may separate from the airbag during a deployment. Although airbag performance is not affected by this condition, a separated airbag door could injure a vehicle occupant. Repair: The passenger airbag must be replaced on all involved vehicles. Parts Information: Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address) , will receive enough Passenger Airbags to service 100% of those vehicles. Dealers should determine which airbag is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate passenger airbag for the vehicle to be serviced may be determined by: Using the part code in the third column of the VIN list along with the above table (involved dealers); Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Entering the VIN to DIAL System VIP Function (sales code information) along with the above table (all dealers). Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowances shown. Add the cost of the airbag plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5077 Removed passenger airbags must be returned to the airbag manufacturer, TRW. Dealers must contact the TRW Product Return Center at 1-800-879-7145 to obtain airbag shipping materials and instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicle have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD898". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Daimlerchrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Open and lower the glove box fully to gain access to the passenger airbag attaching screws. Glove box removal is not required. 3. Disconnect the passenger airbag electrical connector. 4. Remove the four (4) nuts and two (2) screws that attach the passenger airbag to the instrument panel collar. 5. Remove the passenger airbag and set it aside for return to the airbag supplier. 6. Install the new passenger airbag. 7. Install the four (4) nuts and two (2) screws that attach the passenger airbag to the instrument panel collar. Tighten the nuts to 100 in-lbs (11 Nm) . Tighten the screws to 20 in-lbs (2 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5078 8. Connect the passenger airbag electrical connector. 9. Close the glove box 10. Turn the ignition switch to the ON position and exit the vehicle. 11. Connect the negative battery cable. 12. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 13. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5079 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service Air Bag: All Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service > Page 5085 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5090 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA00V306000 > Oct > 00 > Recall 00V306000: Possible Separated Air Bag Door Air Bag: All Technical Service Bulletins Recall 00V306000: Possible Separated Air Bag Door Passenger air bags were built with suspect aluminum extrusion sections which may not retain the air bag door during an air bag deployment event. A separated air bag door could injure a vehicle occupant. Dealers will replace the passenger side air bag. Owner notification began October 19, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement Technical Service Bulletin # 898 Date: 001001 Recall - Passenger Airbag Replacement October 2000 Dealer Service Instructions for: Safety Recall No. 898 -- Passenger Airbag Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This recall applies only to the above vehicles built from September 12, 2000 through September 15, 2000 (MDH 091220 through 091512). IMPORTANT: Most of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The passenger airbag door on about 400 of the above vehicles may separate from the airbag during a deployment. Although airbag performance is not affected by this condition, a separated airbag door could injure a vehicle occupant. Repair: The passenger airbag must be replaced on all involved vehicles. Parts Information: Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address) , will receive enough Passenger Airbags to service 100% of those vehicles. Dealers should determine which airbag is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate passenger airbag for the vehicle to be serviced may be determined by: Using the part code in the third column of the VIN list along with the above table (involved dealers); Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Entering the VIN to DIAL System VIP Function (sales code information) along with the above table (all dealers). Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowances shown. Add the cost of the airbag plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5099 Removed passenger airbags must be returned to the airbag manufacturer, TRW. Dealers must contact the TRW Product Return Center at 1-800-879-7145 to obtain airbag shipping materials and instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicle have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD898". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Daimlerchrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect the negative battery cable. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Open and lower the glove box fully to gain access to the passenger airbag attaching screws. Glove box removal is not required. 3. Disconnect the passenger airbag electrical connector. 4. Remove the four (4) nuts and two (2) screws that attach the passenger airbag to the instrument panel collar. 5. Remove the passenger airbag and set it aside for return to the airbag supplier. 6. Install the new passenger airbag. 7. Install the four (4) nuts and two (2) screws that attach the passenger airbag to the instrument panel collar. Tighten the nuts to 100 in-lbs (11 Nm) . Tighten the screws to 20 in-lbs (2 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5100 8. Connect the passenger airbag electrical connector. 9. Close the glove box 10. Turn the ignition switch to the ON position and exit the vehicle. 11. Connect the negative battery cable. 12. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 13. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 898 > Oct > 00 > Recall - Passenger Airbag Replacement > Page 5101 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service Air Bag: All Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service > Page 5107 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5112 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Curtain Airbag Modules Air Bag: Locations Curtain Airbag Modules 4-Door Models The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Curtain Airbag Modules > Page 5115 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5116 Air Bag: Diagrams Driver Airbag Squib Driver Airbag Squib No. 1 Driver Airbag Squib No. 2 Left Curtain Airbag (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5117 Passenger Airbag Right Curtain Airbag (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5118 Air Bag: Service Precautions WARNING: - THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. - THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. - THE DRIVER AIRBAG TRIM COVER AND HORN SWITCH ASSEMBLY ARE THE ONLY SERVICEABLE PARTS OF THE DRIVER AIRBAG. DO NOT DISASSEMBLE OTHER PARTS WITHIN AS THEY ARE NOT SERVICEABLE. - NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAGS, THERE ARE NO SERVICEABLE PARTS WITHIN. - WHEN REPLACING A DEPLOYED DRIVER AIRBAG, THE CLOCK SPRING MUST ALSO BE REPLACED. REFER TO ELECTRICAL, RESTRAINTS, CLOCK SPRING, REMOVAL, AND INSTALLATION. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5119 Air Bag: Description and Operation DRIVER AIRBAG WARNING: THE DRIVER AIRBAG TRIM COVER AND HORN SWITCH ASSEMBLY ARE THE ONLY SERVICEABLE PARTS OF THE DRIVER AIRBAG. DO NOT DISASSEMBLE OTHER PARTS WITHIN AS THEY ARE NOT SERVICEABLE. The Driver Airbag located in the center of the steering wheel is the most visible part of the system. It contains the airbag inflator, cushion, cover assembly, and their supporting components. The airbag utilizes a dual stage inflator and two initiator wire connections. The trim cover assembly, consisting of cover and horn switch, is the only serviceable part of the airbag. The cushion, inflator, and inflator adaptor are covered with a wrap so the cushion does not unfold when servicing the trim cover and horn switch assembly WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAGS, THERE ARE NO SERVICEABLE PARTS WITHIN. The driver side inflator assembly is mounted from the back of the airbag housing. When supplied with the proper electrical signal from the Occupant Restraint Controller (ORC), the inflator assembly produces a gas and discharges it directly into the cushion. A protective cover is fitted to the front of the Driver Airbag and forms a decorative cover in the center of the steering wheel. The Driver Airbag is mounted directly to the steering wheel. The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5120 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Active DTC........................................................................................................................................... ................................................... Squib Status Driver squib 1 open..................................................... .....................................................................................................Status of Airbag is Unknown. Driver squib 2 open PASSENGER AIRBAG WARNING: NEVER DISASSEMBLE THE PASSENGER AIRBAG, THERE ARE NO SERVICEABLE PARTS WITHIN. The Passenger Airbag is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger airbag is mounted to the instrument panel and pad assembly. The passenger inflator assembly is within the airbag housing. The airbag is mounted to the instrument panel retainer and support structure. The Passenger Airbag consists of: Dual Initiator Inflator Assembly - Reaction Canister - Airbag Pillow When supplied with the proper electrical signal from the ORC, the inflator produces gas and discharges it directly into the pillow. The airbag will deploy and the pillow will fully inflate. The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5121 Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Active DTC........................................................................................................................................... ................................................... Squib Status Passenger squib 1 open............................................. ......................................................................................................Status of Airbag is Unknown. Passenger squib 2 open CURTAIN AIRBAGS Vehicles equipped with the Side Impact Airbag System utilize two Curtain Airbags mounted in each respective side of the headliner, stretching from the middle of the A-pillar at the instrument panel along the roof line to the C-pillar at the rear shelf panel. This system is designed to protect occupants in the event of a side impact collision. The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. The Side Impact Airbag Control Module (SIACM) controls the curtain airbags. If the SIACM determines the impact is severe enough, the appropriate SIACM will send a message to inflate the respective curtain airbag. The appropriate airbag will inflate, dropping down from the ceiling between the headliner and windows/pillars, protecting the passengers. Once a curtain airbag has been deployed, the complete curtain airbag, headliner, upper A, B, and C-pillar trim panel, and all damaged parts must be replaced. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag REMOVAL 1. Open hood and disconnect the negative battery cable remote terminal from the remote battery post. Wait two minutes for the capacitor to discharge. 2. Remove speed control switch screws from steering wheel back cover, remove switches and disconnect the wires. 3. Remove two bolts retaining Driver Airbag. 4. Lift airbag and disconnect two airbag inflator and horn switch wire connectors. 5. Remove Driver Airbag from vehicle. WARNING: WHEN REPLACING A DEPLOYED DRIVER AIRBAG, THE CLOCK SPRING MUST ALSO BE REPLACED. REFER TO ELECTRICAL, RESTRAINTS, CLOCK SPRING, REMOVAL, AND INSTALLATION. INSTALLATION 1. With the battery disconnected, connect the lead wire from the clock spring to the horn switch and both airbag initiator connectors. The airbag initiator connectors are color-coded. The grey connector from the clock spring goes to the grey connector on the airbag, and the black connector goes to the black connector on the airbag. 2. Install the two torx bolts holding the driver airbag. torque to 9.6 ± 1 Nm (85 ± 10 in. lbs.). 3. Connect the wire connectors to the speed control switches and install switches. Torque the speed control switch mounting screws to 1.5 Nm (13 in. lbs). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5124 Air Bag: Service and Repair Driver Airbag Cover REMOVAL The horn switch is integral to the driver airbag trim cover If either component is faulty or damaged, the driver airbag trim cover and horn switch unit must be replaced. 1. Disconnect and isolate the battery negative remote cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag. Refer to Electrical, Restraints, Driver Airbag, Removal. 3. Disconnect the horn switch ground wire (black) connector from the airbag mounting plate tab. 4. Disconnect the horn switch feed wire (red) connector from the airbag mounting plate tab. 5. Remove the four hex nuts that secure the airbag mounting plate to the airbag. 6. Remove the airbag mounting plate form the airbag. 7. Remove the airbag trim cover from the airbag inflator adaptor by rotating the trim cover mounting flaps off of the mounting studs and disengaging the three tab and slot details. NOTE: The folded cushion will remain intact by the bag wrap. Do not remove the bag wrap when servicing the airbag trim cover. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the driver airbag in the trim cover. Be certain that the horn switch wires are routed properly in the notches adjacent to the trim cover upper mounting flap. Rotate the upper and lower trim cover mounting flaps over the four airbag studs. Ensure that the airbag inflator adapter tabs pass through the mating trim cover slots. 2. Install the airbag mounting plate to the airbag. Be certain that the four studs pass through the mounting plate holes. Ensure that the mounting plate side flanges are positioned outside the trim cover ribbing. 3. Install the four nuts on the airbag. Torque nuts to 9 ± 1 Nm (80 ± 10 in. lbs.). 4. Secure the horn switch feed wire (red) connector to the airbag mounting plate. 5. Secure the horn switch ground (black) connector to the airbag mounting plate tab. 6. Install the driver airbag. Refer to Electrical, Restraints, Driver Airbag, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5125 Air Bag: Service and Repair Passenger Airbag REMOVAL If the airbag has been deployed, the instrument panel and pad assembly must be replaced. 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. Fig.1 Passenger Airbag 2. Open and lower glove box fully to gain access to Passenger Airbag attaching screws inside of the glove box. Glove box removal not required. 3. Disconnect wire connector from the Passenger Airbag. 4. Remove the four nuts and two screws attaching airbag assembly to the instrument panel collar. 5. Disengage airbag door tabs from the instrument panel retainer and lift the Passenger Airbag up and out of panel cavity. INSTALLATION If replacing Passenger Airbag due to a deployment, use a new instrument panel and pad assembly. Transfer all of the components. 1. With the battery disconnected, place the Passenger Airbag into the panel cavity. Press the airbag door tabs down to engage on the instrument panel retainer. 2. Install the four nuts and two screws attaching airbag assembly to the instrument panel collar and torque nuts and screws to 7.5 ± 1 Nm (66 in. lbs.) . 3. Connect Passenger Airbag wire connector. 4. Pinch in on sides of the glove box and raise it up into the instrument panel opening. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5126 Air Bag: Service and Repair Side Curtain Airbag REMOVAL 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. 2. Remove the Headliner. Refer to Body, Interior, Headliner, Removal. 3. Remove the retaining bolt to the front tether at the instrument panel on the A-pillar. 4. Remove the five short retaining bolts along the roof line. 5. Remove the four long retaining bolts to the rear along the roof line and at the C-pillar. 6. Remove all push fasteners and discard. Make sure they are completely removed. 7. Disconnect the wire harness connector from the rear of the inflator. 8. Remove the curtain airbag from the vehicle. INSTALLATION If replacing curtain airbag because of an airbag deployment, the inflator pan (quarter trim upper support at C-pillar) must be inspected, especially if the vehicle is equipped with a sunroof. The sunroof drain is connected to the inflator pan, and if cracked, could result in leaks. Also, the headliner must be replaced due to crease lines occurring during the airbag deployment. 1. Install the curtain airbag into the vehicle. There is blue stripe along the rear edge of the curtain airbag. The stripe should be visible and continuous after installation. The blue stripe is a visual aid so that caution is taken not to twist the airbag upon installation. Make sure the airbag is not twisted upon installation. 2. Connect the wire harness connector to the rear of the inflator. 3. Install all push fasteners. 4. Install the long retaining bolts at the C-pillar to attach inflator. Torque bolts to 11 ± 1 Nm (97.36 ± 10 in. lbs.). 5. Install the remaining two retaining bolts to attach the curtain airbag. Torque bolts to 6 ± 1 Nm (97.36 ± 10 in. lbs.). 6. Install the five short retaining bolts along the roof line. Torque bolts to 6 ± 1 Nm (53.11 ± 10 in. lbs.). 7. Install the short retaining bolt to the front tether at the instrument panel on the A-pillar. Torque bolts to 6 ± 1 Nm (53.11 ± 10 in. lbs.). Make sure the tether is not twisted. If twisted, the airbag may deploy incorrectly, causing vehicle occupant injury. 8. Install the Headliner. Refer to Body, Interior, Headliner, Installation. Use a new headliner if curtain airbag was deployed on either side of the vehicle. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller > Page 5131 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) 4-Door Models SIACM are located on the left and right "B" post, just above the seat belt retractor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5132 Air Bag Control Module: Diagrams Left Side Impact Airbag Control Module (JR-41) Occupant Restraint Controller Right Side Impact Airbag Control Module (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5133 Air Bag Control Module: Service Precautions WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > System Description Air Bag Control Module: Description and Operation System Description AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) Supplemental driver and passenger curtain airbags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity # 5 of the SIACM connector. If cavity # 5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 5136 The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds then goes OFF, there is usually an intermittent problem in the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 5137 Air Bag Control Module: Description and Operation Component Description OCCUPANT RESTRAINT CONTROLLER The Occupant Restraint Controller (ORC) contains the impact sensor and energy reserve capacitor. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ORC monitors the system to determine the system readiness. The ORC stores sufficient energy to deploy the airbags in case battery power is lost prior to impact. The ORC contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few seconds every time the vehicle is started. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Page 5138 Air Bag Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. 2. For a manual transmission, remove shifter knob and boot. 3. For automatic transmission models, remove shifter knob and unsnap shift indicator bezel. 4. Remove the four attaching screws to floor console. 5. Remove parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Removal. 6. Remove three mounting nuts to ORC. 7. Disconnect wire harness connectors and remove ORC from mounting studs. INSTALLATION CAUTION: Use supplied nuts only. 1. With the battery disconnected, position the ORC (arrow pointing forward) on center tunnel area mounting studs. 2. Connect wire harness connector. 3. Attach the three mounting nuts and tighten to 10 to 14 Nm (85 to 125 in. lbs.) torque. 4. Install the parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Installation. 5. Install the floor console. 6. Install the four attaching screws to floor console. 7. For automatic transmission models, install the shift indicator bezel and shifter knob. 8. For a manual transmission, install the shifter boot and knob. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5143 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5144 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5145 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5146 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5147 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5148 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5153 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5154 Clockspring Assembly / Spiral Cable: Locations The clockspring is mounted on the steering column behind the steering wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5155 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5156 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: - IF THE ROTATING TAPE WITHIN THE CLOCK SPRING IS NOT POSITIONED PROPERLY WITH THE STEERING WHEEL AND THE FRONT WHEELS, THE CLOCK SPRING MAY FAIL DURING USE. THE CLOCK SPRING IS CENTERED WHEN YELLOW APPEARS IN THE CENTERING WINDOW AND THE ARROW ON THE LABEL POINTS TO THE DRIVE PIN. IF THE CLOCK SPRING IS NOT CENTERED, THIS PROCEDURE MUST BE USED TO CENTER THE CLOCK SPRING. - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST . Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5157 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring assembly is mounted near the top of the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the fixed instrument panel wire harness connector on the steering column and several electrical components that rotate with the steering wheel. The rotating components include the driver airbag, the horn switch, and the vehicle speed control switches. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring assembly consists of a plastic case which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds like a clock spring with the steering wheel rotation. The electrically conductive tape consists of several fine gauge copper wire leads sandwiched between two narrow strips of plastic film. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear allowing the clockspring tape to change position relative to the other steering components, it must be re-centered following completion of the service or it may be damaged. Refer to Electrical, Restraints, Clockspring, Standard Procedure - Clockspring Centering. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5158 Clockspring Assembly / Spiral Cable: Adjustments WARNING: IF THE ROTATING TAPE WITHIN THE CLOCK SPRING IS NOT POSITIONED PROPERLY WITH THE STEERING WHEEL AND THE FRONT WHEELS, THE CLOCK SPRING MAY FAIL DURING USE. THE CLOCK SPRING IS CENTERED WHEN YELLOW APPEARS IN THE CENTERING WINDOW AND THE ARROW ON THE LABEL POINTS TO THE DRIVE PIN. IF THE CLOCK SPRING IS NOT CENTERED, THIS PROCEDURE MUST BE USED TO CENTER THE CLOCK SPRING. 1. Adjust the steering wheel so that the tires are in a straight ahead position. 2. Remove Driver Airbag from steering wheel. 3. Disconnect wire connectors from back of airbag. 4. Remove steering wheel. 5. Depress the plastic drive pin to disengage lock mechanism. 6. With lock mechanism disengaged, rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive force. 7. From the end of travel, rotate the rotor three turns counterclockwise. The wires should end up at the top. Release drive pin to engage clockspring lock mechanism. 8. Install steering wheel and airbag. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5159 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. 2. Remove the steering wheel. Refer to Steering, Column, Steering Wheel, Removal. Carefully feed all wires through the steering wheel armature to avoid damaging wires. When replacing a deployed Driver Airbag, a new clockspring must be installed. 3. Remove multi-function switch. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal. 4. Remove the clockspring by lifting the top lock housing latches up slightly to guide it over the lock housing. The clock spring cannot be serviced and must be replaced if defective, damaged, or the vehicle has sustained an impact where the front airbags were deployed. INSTALLATION If reinstalling a clock spring, make sure the clock spring is centered by performing the clock spring centering procedure. Refer to Electrical, Restraints, Clockspring, Standard Procedure - Clockspring Centering. 1. Align the top locking tab with the slot on the lock housing. Gently push into place. 2. Install the multi-function switch and tighten to 1.5 to 2.5 Nm (14 to 22 in. lbs.) torque. Refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Installation. 3. Carefully route the wires through the hole in the steering wheel armature and install the steering wheel. 4. Route the speed control wires through guides located inside the steering wheel back cover. Connect the speed control wires to switches and install switches. 5. Connect horn lead to the airbag mounting bracket. 6. Connect the two yellow airbag leads (black and grey connectors) to the Driver Airbag and push secondary latch into place. Ensure the wires do not get pinched during installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Application and ID Malfunction Lamp / Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Airbag .................................................................................................................................................. ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller > Page 5168 Air Bag Control Module: Locations Side Impact Airbag Control Module (SIACM) 4-Door Models SIACM are located on the left and right "B" post, just above the seat belt retractor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5169 Air Bag Control Module: Diagrams Left Side Impact Airbag Control Module (JR-41) Occupant Restraint Controller Right Side Impact Airbag Control Module (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5170 Air Bag Control Module: Service Precautions WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description Air Bag Control Module: Description and Operation System Description AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) Supplemental driver and passenger curtain airbags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity # 5 of the SIACM connector. If cavity # 5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 5173 The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6 - 8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes ON and stays ON for a period longer than 6 - 8 seconds then goes OFF, there is usually an intermittent problem in the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > System Description > Page 5174 Air Bag Control Module: Description and Operation Component Description OCCUPANT RESTRAINT CONTROLLER The Occupant Restraint Controller (ORC) contains the impact sensor and energy reserve capacitor. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ORC monitors the system to determine the system readiness. The ORC stores sufficient energy to deploy the airbags in case battery power is lost prior to impact. The ORC contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few seconds every time the vehicle is started. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Page 5175 Air Bag Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. Wait two minutes for the capacitor to discharge. 2. For a manual transmission, remove shifter knob and boot. 3. For automatic transmission models, remove shifter knob and unsnap shift indicator bezel. 4. Remove the four attaching screws to floor console. 5. Remove parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Removal. 6. Remove three mounting nuts to ORC. 7. Disconnect wire harness connectors and remove ORC from mounting studs. INSTALLATION CAUTION: Use supplied nuts only. 1. With the battery disconnected, position the ORC (arrow pointing forward) on center tunnel area mounting studs. 2. Connect wire harness connector. 3. Attach the three mounting nuts and tighten to 10 to 14 Nm (85 to 125 in. lbs.) torque. 4. Install the parking brake lever. Refer to Brakes, Parking Brake, Parking Brake Lever, Installation. 5. Install the floor console. 6. Install the four attaching screws to floor console. 7. For automatic transmission models, install the shift indicator bezel and shifter knob. 8. For a manual transmission, install the shifter boot and knob. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5180 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Tether Cup Child Seat Tether Attachment: Service and Repair Child Tether Cup REMOVAL 1. Remove the rear shelf trim panel from vehicle. 2. Turn the shelf panel over so that the bottom side is upward to access the Child Tether Cup locks. 3. With a trim stick (special tool #C-4733) or equivalent, push attachment locks toward the center of the cup to release the Child Tether Cup from the rear shelf panel. 4. Remove the Child Tether Cup. INSTALLATION 1. Place the Child Tether Cup into position on top of the rear shelf trim panel. 2. Press rearward until cup engages into the rear shelf trim panel. 3. Push the front of cup down into the rear shelf trim panel. 4. Install the rear shelf panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Tether Cup > Page 5186 Child Seat Tether Attachment: Service and Repair Child Tether Cup Cover REMOVAL 1. Open the Child Tether Cup Cover to the full open position. 2. Push cover towards the rear of the vehicle until the cover detaches from the cup. INSTALLATION 1. Place the Child Tether Cup cover into position on top of the rear shelf trim panel. 2. Push downward on the Child Tether Cup Cover until it locks into position (you will hear it click into place). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 5191 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Technician Safety Information Seat Belt: Technician Safety Information WARNING: - INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. - THE REAR SEAT BACK RETAINING NUT ALSO SERVES AS THE CENTER SEAT BELT ANCHOR. BE CERTAIN TO TORQUE THIS NUT TO 40 Nm (30 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Technician Safety Information > Page 5194 Seat Belt: Vehicle Damage Warnings CAUTION: Do not reuse the bolts attaching the seat belt retractor to the seat frame. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Page 5195 Seat Belt: Description and Operation SEAT BELT & RETRACTOR - FRONT OUTBOARD The seat belt system incorporates Tensioner Modules. They are integral to the front seat belt retractors and cannot be serviced. If found defective they must be replaced. In the event of an impact, the retractor assembly must be replaced regardless of belt condition. The tensioner is a one time pyrotechnic device. At the onset of an impact event, each tensioner uses a pyrotechnic device which is triggered simultaneously with the front airbags to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbags, the seat belt tensioner assembly must be replaced. The Occupant Restraint Controller (ORC) monitors the seat belt tensioner circuit resistance and reports active and stored Diagnostic Trouble Codes (DTC's) if any problem is found. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Page 5196 Seat Belt: Testing and Inspection To test, the ignition switch must be in the OFF position before testing the fasten seat belts. Turn the ignition switch to the ON position with the driver's seat belt unbuckled. The seat belt warning lamp should light for 5 to 7 seconds and the chime should sound 5 to 7 seconds. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt - Rear Inboard Seat Belt: Service and Repair Seat Belt - Rear Inboard REMOVAL 1. Remove rear seat cushion Fig.2 Seat Belt - Rear Inboard 2. Remove nut attaching seat belt to floor. 3. Remove seat belt from vehicle. INSTALLATION 1. Place seat belt in position. 2. Install nut attaching seat belt to floor. Tighten nut to 61 ± 5 Nm (83 ± 5 ft lbs) torque. 3. Install rear seat cushion. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt - Rear Inboard > Page 5199 Seat Belt: Service and Repair Seat Belt - Rear Outboard REMOVAL 1. Remove rear seat cushion. 2. Remove bolt attaching seat belt anchor to floor pan. 3. Remove upper and lower quarter trim panel. 4. Remove bolt attaching rear D-ring to quarter upper panel. 5. Remove bolt attaching rear seat belt retractor to inner quarter panel. 6. Remove retractor and belt from vehicle. INSTALLATION 1. Place retractor and belt into position. 2. Install bolt attaching rear seat belt retractor to inner quarter panel. Torque bolt to 40 Nm (29.5 ft. lbs.). 3. Route seat belt webbing and D-ring through upper trim panel. Install bolt attaching D-ring to quarter panel. Torque bolt to 40 Nm (29.5 ft. lbs.). 4. Install upper quarter trim panel. 5. Install bolt attaching seat belt anchor to floor pan. Torque bolt to 40 .m (29.5 ft. lbs.). 6. Install rear seat cushion. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt - Rear Inboard > Page 5200 Seat Belt: Service and Repair Seat Belt and Retractor - Front Seat REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove adjuster knob and turning loop cover. 3. Remove bolt that attaches the turning loop to the height adjuster. 4. Remove upper B-pillar trim panel. 5. Remove the lower B-pillar trim panel. 6. Disconnect the wire harness connector from the B-pillar retractor. 7. Remove the bolt attaching the seat belt retractor (and lower anchor) to the base of the B-pillar. 8. Remove retractor and belt from vehicle. INSTALLATION 1. Place retractor and belt into position. 2. Install bolt attaching seat belt retractor and lower anchor to the base of the B-pillar. Torque bolt to 55 ± 5 Nm (40.5 ft. lbs.). 3. Connect retractor wire harness connector to the B-pillar. 4. Route belt and install the lower B-pillar trim panel. 5. Install the upper B-pillar trim and bolt that attaches the turning loop to the height adjuster. Torque bolt to 55 ± 5 Nm (40.5 ft. lbs.). 6. Install the turning loop cover and adjuster knob. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt - Rear Inboard > Page 5201 Seat Belt: Service and Repair Seat Belt and Retractor - Rear Center REMOVAL 1. Remove the rear shelf trim panel. Refer to Body, Interior, Rear Shelf Trim Panel, Removal. 2. Remove the nut attaching the center rear seat belt retractor to the rear shelf. 3. Remove rear seat cushion. 4. Remove nut attaching center rear seat belt anchor to floor pan. 5. Remove the center rear seat belt retractor assembly from the vehicle. INSTALLATION WARNING: INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. 1. Install the center rear seat belt retractor assembly on the rear shelf. Torque the bolt to 40 Nm (30 ft. lbs.). 2. Route webbing and bezel through rear shelf trim panel. 3. Install the rear shelf trim panel. Refer to Body, Interior, Rear Shelf Trim Panel, Installation. 4. Install the nut attaching the center rear seat belt anchor to the floor pan stud. Be certain the rear seat belts are properly routed to avoid twisted or tangled belts and/or buckles. Torque nut to 40 Nm (30 ft. lbs.). 5. Install the rear seat cushion. WARNING: THE REAR SEAT BACK RETAINING NUT ALSO SERVES AS THE CENTER SEAT BELT ANCHOR. BE CERTAIN TO TORQUE THIS NUT TO 40 Nm (30 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Driver Seat Belt Switch (JR-41) (Except Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair REMOVAL 1. Remove adjuster knob and turning loop cover. 2. Remove bolt attaching turning loop to belt height adjuster. 3. Remove upper B-pillar trim panel. 4. Remove bolt attaching seat belt height adjuster to B-pillar. 5. Remove seat belt height adjuster from vehicle. INSTALLATION 1. Place seat belt height adjuster into position. 2. Install two bolts attaching seat belt height adjuster to B-pillar. Torque bolts to 55 ± 5 Nm (40.5 ± 5 ft. lbs.). 3. Install upper B-pillar trim panel. 4. Install the bolt attaching the turning loop to the height adjuster. Torque bolt to 55 ± 5 Nm (40.5 ± 5 ft. lbs.). 5. Install turning loop cover and adjuster knob. TAPPING PLATE REPAIR The Tapping Plate used to mount the seat belt height adjuster is designed to deform outboard during certain significant vehicle crash events. Should a deformed tapping plate be found on a damaged vehicle that is to be repaired, the following procedure can be used to reposition the tapping plate relative to the B-pillar, thus enabling replacement of the seat belt height adjuster. 1. Using a large diameter screw socket as a spacer, hand start a three inch 7/16-20 bolt and washer into the threaded tapping plate hole. 2. Continue to apply bolt torque and deform the tapping plate back flush with the B-pillar inner. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Seat Belt .............................................................................................................................................. ........................................................... Red LED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Technician Safety Information Seat Belt Retractor: Technician Safety Information WARNING: - INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. - THE REAR SEAT BACK RETAINING NUT ALSO SERVES AS THE CENTER SEAT BELT ANCHOR. BE CERTAIN TO TORQUE THIS NUT TO 40 Nm (30 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Technician Safety Information > Page 5215 Seat Belt Retractor: Vehicle Damage Warnings CAUTION: - Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. - Do not reuse the bolts attaching the seat belt retractor to the seat frame. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Page 5216 Seat Belt Retractor: Description and Operation SEAT BELT & RETRACTOR - FRONT OUTBOARD The seat belt system incorporates Tensioner Modules. They are integral to the front seat belt retractors and cannot be serviced. If found defective they must be replaced. In the event of an impact, the retractor assembly must be replaced regardless of belt condition. The tensioner is a one time pyrotechnic device. At the onset of an impact event, each tensioner uses a pyrotechnic device which is triggered simultaneously with the front airbags to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbags, the seat belt tensioner assembly must be replaced. The Occupant Restraint Controller (ORC) monitors the seat belt tensioner circuit resistance and reports active and stored Diagnostic Trouble Codes (DTC's) if any problem is found. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove adjuster knob and turning loop cover. 3. Remove bolt that attaches the turning loop to the height adjuster. 4. Remove upper B-pillar trim panel. 5. Remove the lower B-pillar trim panel. 6. Disconnect the wire harness connector from the B-pillar retractor. 7. Remove the bolt attaching the seat belt retractor (and lower anchor) to the base of the B-pillar. 8. Remove retractor and belt from vehicle. INSTALLATION 1. Place retractor and belt into position. 2. Install bolt attaching seat belt retractor and lower anchor to the base of the B-pillar. Torque bolt to 55 ± 5 Nm (40.5 ft. lbs.). 3. Connect retractor wire harness connector to the B-pillar. 4. Route belt and install the lower B-pillar trim panel. 5. Install the upper B-pillar trim and bolt that attaches the turning loop to the height adjuster. Torque bolt to 55 ± 5 Nm (40.5 ft. lbs.). 6. Install the turning loop cover and adjuster knob. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5219 Seat Belt Retractor: Service and Repair Rear REMOVAL 1. Remove the rear shelf trim panel. Refer to Body, Interior, Rear Shelf Trim Panel, Removal. 2. Remove the nut attaching the center rear seat belt retractor to the rear shelf. 3. Remove rear seat cushion. 4. Remove nut attaching center rear seat belt anchor to floor pan. 5. Remove the center rear seat belt retractor assembly from the vehicle. INSTALLATION WARNING: INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. 1. Install the center rear seat belt retractor assembly on the rear shelf. Torque the bolt to 40 Nm (30 ft. lbs.). 2. Route webbing and bezel through rear shelf trim panel. 3. Install the rear shelf trim panel. Refer to Body, Interior, Rear Shelf Trim Panel, Installation. 4. Install the nut attaching the center rear seat belt anchor to the floor pan stud. Be certain the rear seat belts are properly routed to avoid twisted or tangled belts and/or buckles. Torque nut to 40 Nm (30 ft. lbs.). 5. Install the rear seat cushion. WARNING: THE REAR SEAT BACK RETAINING NUT ALSO SERVES AS THE CENTER SEAT BELT ANCHOR. BE CERTAIN TO TORQUE THIS NUT TO 40 Nm (30 ft. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Seat Belt Tensioner: Locations 4-Door Models The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 5223 Seat Belt Tensioner: Diagrams C304 (JR-41) C304 JR-41 Left Seat Belt Tensioner (JR-41) Right Seat Belt Tensioner (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 5224 Seat Belt Tensioner: Description and Operation The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5230 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5231 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5232 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5233 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5234 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5235 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Driver Seat Belt Switch (JR-41) (Except Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Service and Repair Antenna Mast: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the right side trunk liner aside. 3. Remove antenna mast by unscrewing mast from antenna body. 4. Remove screw from mounting bracket. 5. Pull antenna body down through the rubber grommet. 6. Unplug antenna lead from base of antenna body. INSTALLATION 1. Insert antenna lead to base of antenna body. 2. Push antenna body up through the rubber grommet. 3. Install screw into mounting bracket. Tighten screw to 12 Nm (106 in. lbs.). 4. Install antenna mast. 5. Install trunk liner. 6. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5248 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5249 Alarm Module: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS, WARNINGS, BEFORE ATTEMPTING COMPONENT. DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5250 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it. The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the Body Control Module (BCM), and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the assembly plant tester. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the BCM to operate the light. This is the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5251 Alarm Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative remote cable. 2. Remove knee bolster. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM module to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION 1. If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE) Sentry Key Immobilizer Module Initialization. 2. Carefully position the SKIM, the mounting bracket and the antenna ring onto the steering column. 3. Install the two retaining screws. 4. Connect the wire harness connector. 5. Install the steering column upper and lower shrouds. 6. Install the knee bolster. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Sentry Key Immobilizer Transponder TRANSPONDER KEY The Sentry Key Immobilizer System (SKIS) uses a transponder chip that is integral to each ignition key to communicate with the Sentry Key Immobilizer Module (SKIM). Ignition keys are supplied with the vehicle when it is shipped from the factory. The transponder chip is undermolded within the head of the key. This undermold is hidden beneath an overmolded rubber cap. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique "Secret Key" code programmed into it by the manufacturer as well. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the "Secret Key" code from the SKIM. Once the Sentry Key learns the "Secret Key" code of the SKIM, it is also permanently programmed into the transponder's memory. Therefore, blank keys for the SKIS must be programmed by the SKIM in addition to being cut to match the mechanical coding of the ignition lock cylinder. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming. The Sentry Key's transponder is within the range of the SKIM's transceiver antenna ring when it is inserted into the ignition lock cylinder. When the ignition switch is turned to the ON position, the SKIM communicates with the Sentry Key via a radio frequency (RF) signal. The SKIM determines if a valid key is present based on the information it receives from the Sentry Key. If a valid key is detected, that fact is communicated to the PCM via the PCI bus and the vehicle is allowed to continue running. If an invalid key is received by the PCM or no status at all is communicated, the vehicle will stall after two (2) seconds of running. The indicator light will be flashing at this point. The Sentry Key's transponder can not be repaired. If it is faulty or damaged, it must be replaced. Common communication problems: - Two transponder keys too close together. - Speed Pass too close to transponder key. Solid indicator that there is a system failure. - Loss of PCM communication. Failed antenna circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 5255 Alarm System Transponder: Service and Repair USING A DRB III SCAN TOOL All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory The Sentry Key Immobilizer Module (SKIM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder the key must first be cut to match the ignition lock cylinder of the vehicle for which it will be used. The vehicle's four digit PIN code will be required to complete this task since you will need it to enter the Secured Access Mode in the SKIM. The following steps must be completed using a DRB III scan tool: 1. Insert the blank key into the ignition and turn it to the RUN position. 2. Using a DRB III scan tool, select "Theft Alarm," "SKIM," "Miscellaneous," and then "Program New Key." 3. Enter the four digit PIN code using the DRB III scan tool. When programming is completed, the SKIM will exit Secured Access Mode and the DRB III scan tool will display the results of your attempt to program the key. One of five distinct results may be displayed. All five are listed below: "Programming Successful" is displayed if the Sentry Key programming is successful. - "Learned Key in Ignition" is displayed if the key in the ignition has already been programmed into that vehicle's SKIM. - "Eight Keys Already Learned (At The Maximum) Programming Not Done" is displayed if eight keys have already been programmed into the SKIM. In this case, if a new key needs to be added due to a lost or defective key, the "Erase All Keys" command (which requires entering the Secured Access Mode) has to be performed. Following the "Erase All Keys" command, all keys that will be used to operate the vehicle MUST be reprogrammed to the SKIM. - "Programming Not Attempted" is displayed after an "Erase All Keys" function is executed. - "Programming Key Failed" is displayed if further diagnosis is required. To learn additional keys, turn the ignition OFF; remove the learned key, insert the next new blank key, and repeat the steps from the beginning. "CUSTOMER LEARN" MODE This feature is only available on domestic vehicles or those which have a U.S. country code designator. This procedure requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, Sentry Key programming will require the use of a DRB III scan tool. The steps required to program Sentry Keys with two valid Sentry Keys follows: 1. Obtain the blank Sentry Key(s) that need to be programmed. Cut the keys to match the ignition lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. Alter the ignition switch has been in the ON position for longer than three seconds, but no more than fifteen seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted within 15 seconds of removing the first valid Sentry key. 4. About ten seconds after the completion of Step 3, the indicator light will start to flash and a single audible chime tone will sound to indicate that the system has entered the "Customer Learn" programming mode. 5. Within sixty seconds of entering the "Customer Learn" programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About ten seconds alter the completion of Step 5, a single audible chime tone will sound and the indicator light will stop flashing and stay ON solid for three seconds and then turn OFF to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the "Customer Learn" programming mode and the vehicle may be started using the newly programmed Sentry Key. These steps must be completed in their entirety for each additional Sentry Key to be programmed. If any of the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the "Customer Learn" programming mode and the programming will be unsuccessful. The SKIS will also automatically exit the "Customer Learn" programming mode if: It sees a non-blank Sentry Key when it should see a blank. - If it has already programmed eight (8) valid Sentry Keys. - If the ignition switch is turned to the OFF position for more than about fifty (50) seconds. NOTE: If you attempt to start the vehicle while in "Customer Learn" mode (LED flashing), the vehicle will behave as though an invalid key Is being used (i.e. the engine will stall after two (2) seconds of running). No faults will be logged. - Once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5260 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Relay > Component Information > Description and Operation > Page 5264 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications Fig.1 Remote Keyless Entry Transmitter The transmitter has two 3 volt batteries, which can be removed and replaced without special tools. Insert a dime in the side slot of the transmitter and twist. the halves should separate and the batteries are stacked on top of eachother. The batteries are available at local retail stores. Recommended batteries are Panasonic CR 2016 or equivalent. Battery life is about two years. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5272 Lock Cylinder Switch: Diagrams Decklid Cylinder Lock Switch (VTSS) Driver Cylinder Lock Switch (VTSS) Passenger Cylinder Lock Switch (JR-41) (VTSS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 5273 Lock Cylinder Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Refer to Body, Door - Front, Trim Panel, Removal. Central Locking Switch 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Application and ID Security Lamp/Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Security Alarm ..................................................................................................................................... .......................................................... Red LED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Application and ID > Page 5277 Security Lamp/Indicator: Description and Operation VTSS/SKIS INDICATOR LAMP The Sentry Key Immobilizer System (SKIS) uses an indicator light to convey information on the status of the system to the customer. This light is shared with the Vehicle Theft Security System (VTSS). The light is located in the Instrument Cluster. The indicator light is controlled by the Body Control Module (BCM) based upon messages it receives from the Sentry Key Immobilizer Module (SKIM) on the PCI bus. The BCM performs a four second bulb check, regardless of SKIM messages. After the bulb check, the lamp is controlled according to SKIM messages. Then, the SKIM sends messages to the BCM to operate the light based upon the results of the SKIS self tests. The light may be actuated in two possible ways, flashing or on solid. If the light comes on and stays on solid after a power-up test, this indicates that the SKIM has detected a system malfunction. If the SKIM detects an invalid key when the ignition switch is moved to the ON position, it sends a message on the PCI bus to the BCM, to flash the light. The SKIM can also send a message to flash the light and generate a single audible chime at the same time. These two events occurring simultaneously indicate that the SKIS has been placed into the "Customer Learn" mode. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming for more information on the "Customer Learn" mode. If the light comes ON and stays on after the power-up test, diagnosis of the SKIS should be performed using a DRB III scan tool and the appropriate Body Diagnostic Procedures. The light is not a serviceable component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement Technical Service Bulletin # 899 Date: 001001 Recall - Traveler Module/PCM Replacement October 2000 Dealer Service Instructions for: Customer Satisfaction Notification No. 899 Traveler Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 00-50 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with the Traveler option (Sales Code LET) and NOT equipped with a Smart Key Immobilizer Module (SKIM) (Sales Code - GXX) built through September 25, 2000 (MDH 092512). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The traveler module on about 6,900 of the above vehicles may transmit an erroneous "security system" signal to the Powertrain Control Module (PCM) if the vehicle is facing West when started. This will prevent the engine from starting. Repair: The traveler module must be replaced. If the no-start problem has already occurred, the PCM must also be replaced. Parts Information Due to the small number of involved vehicles expected to require PCM replacement, no parts will be distributed initially. PCM's should be ordered only if a vehicle has experienced a no-start condition. Very few vehicles are expected to require PCM replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement > Page 5286 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD899". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by mail. They are requested a schedule appointments for this service with their dealers. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling cut the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Replace Traveler Module 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the left instrument panel end cover. 3. Using a trim stick, gently pry up on the power mirror switch bezel; then disconnect the switch electrical connector and remove the switch and bezel assembly. 4. Using the trim stick, gently pry up on the instrument panel center trim bezel. 5. Disconnect the HVAC control electrical connectors and set the bezel assembly aside. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement > Page 5287 6. Remove the one screw from the passenger side trim bezel and then remove the passenger side bezel by unsnapping the clips. 7. Remove the one screw from the driver side trim bezel and then remove the driver side bezel by unsnapping the clips. 8. Remove the five (5) screws from the left lower instrument panel, trim/knee blocker. 9. Remove the four (4) cluster bezel screws. 10. Using a trim stick, unsnap the cluster bezel. 11. Disconnect the traveler module electrical connector. 12. Remove the cluster bezel assembly. 13. Remove the two (2) screws that attach the traveler module to the cluster bezel. 14. Remove the traveler module from the cluster bezel. 15. If the bezel on the removed traveler module is not Slate colored, transfer the old traveler bezel to the new traveler module. To remove the bezel, pull up on the two bezel mounting tabs on the bottom of the module. 16. Install the new traveler module into the cluster bezel. Tighten the attaching screws securely. 17. Connect the traveler module electrical connector. 18. Install the cluster bezel. Tighten the four (4) cluster bezel screws securely. 19. Install the left lower instrument trim panel/knee blocker. Tighten the five (5) trim panel screws securely. 20. Install the driver side trim bezel. Tighten the driver side trim bezel screw securely. 21. Install the passenger side trim bezel. Tighten the passenger side trim bezel screw securely. 22. Connect the HVAC control electrical connectors. 23. Install the instrument panel center trim bezel. 24. Connect the power mirror switch electrical connector; then install the switch and bezel assembly. 25. Install the left instrument panel end cover. 26. If the vehicle has experienced a no-start condition due to the erroneous traveler signal, the PCM must be replaced. Continue with Section B - Replace PCM. If the vehicle could be started normally prior to the traveler module replacement, connect the negative battery cable and then return the vehicle to the customer. B. Replace PCM IMPORTANT: Only those vehicles that have experienced a no-start condition require PCM replacement. Very few vehicles are expected to require PCM replacement. 1. Remove the air cleaner box. 2. Disconnect the PCM electrical connectors and move the wiring harness aside. 3. Remove the two (2) bolts and one (1) nut from the PCM bracket. 4. Remove the PCM and Bracket assembly. 5. Remove the PCM from the PCM bracket. 6. Install the new PCM onto the bracket. Tighten the screws to 35 in-lbs (4 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement > Page 5288 7. Install the PCM and bracket assembly. Tighten the two (2) bolts and one (1) nut to 35 in-lbs (4 Nm) 8. Connect the PCM electrical connectors. 9. Install the air cleaner box. 10. Connect the negative battery cable. 11. Using the DRB III scan tool, program the new PCM with the vehicle's Vehicle Identification Number (VIN) and current vehicle mileage. NOTE: Failure to reprogram the new PCM with VIN information and mileage may cause a Diagnostic Trouble Code (DTC) to be set. a. Connect the DRB III to the underdash diagnostic connector. b. Select "DRB III STANDALONE" (1) and then press "Enter". c. Select "1998 - 2001 DIAGNOSTICS" (1) and then press "Enter". d. Select "ENGINE" (1) and press "Enter" three times. e. Select "FUNCTION SCREEN" and scroll to page two (press the right arrow key once) f. Select "MISCELLANEOUS". g. Select "CHECK VIN" (4) and then press "Enter". h. Follow the instructions on the DRB III screen to enter the VIN. CAUTION: Verify that the correct VIN is displayed on the DRB III before pressing the "Enter" key. The VIN cannot be changed once it is entered. If an incorrect VIN is entered, the module must be replaced to correct the VIN error. i. Press the "PAGE BACK" button on the DRB III key pad. j. Select "SRI MEMORY CHECK" (3) and then press "Enter". k. Follow the instructions on the DRB III to enter the current vehicle mileage. 12. After entering the VIN and mileage, check for any additional software updates. Continue with Section C - Check for PCM Software Updates. C. Check for PCM Software Updates: NOTE: The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at the latest release is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON" 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request an MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement > Page 5289 NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button; then continue with Step E. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped) .Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after-all other modules have had their trouble codes erased. 9. Continue with Section D - Install Authorized Software Update Label. D. Install Authorized Software Update Label: Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label, and attach it to the PCM. Cover the label with the clear plastic portion of the label. Continue with Section E - Install the Authorized Modifications Label. E. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label. Then attach the label near the VECI label. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall Traveler Module/PCM Replacement > Page 5290 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement Technical Service Bulletin # 899 Date: 001001 Recall - Traveler Module/PCM Replacement October 2000 Dealer Service Instructions for: Customer Satisfaction Notification No. 899 Traveler Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 00-50 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with the Traveler option (Sales Code LET) and NOT equipped with a Smart Key Immobilizer Module (SKIM) (Sales Code - GXX) built through September 25, 2000 (MDH 092512). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The traveler module on about 6,900 of the above vehicles may transmit an erroneous "security system" signal to the Powertrain Control Module (PCM) if the vehicle is facing West when started. This will prevent the engine from starting. Repair: The traveler module must be replaced. If the no-start problem has already occurred, the PCM must also be replaced. Parts Information Due to the small number of involved vehicles expected to require PCM replacement, no parts will be distributed initially. PCM's should be ordered only if a vehicle has experienced a no-start condition. Very few vehicles are expected to require PCM replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 5296 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD899". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by mail. They are requested a schedule appointments for this service with their dealers. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling cut the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Replace Traveler Module 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the left instrument panel end cover. 3. Using a trim stick, gently pry up on the power mirror switch bezel; then disconnect the switch electrical connector and remove the switch and bezel assembly. 4. Using the trim stick, gently pry up on the instrument panel center trim bezel. 5. Disconnect the HVAC control electrical connectors and set the bezel assembly aside. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 5297 6. Remove the one screw from the passenger side trim bezel and then remove the passenger side bezel by unsnapping the clips. 7. Remove the one screw from the driver side trim bezel and then remove the driver side bezel by unsnapping the clips. 8. Remove the five (5) screws from the left lower instrument panel, trim/knee blocker. 9. Remove the four (4) cluster bezel screws. 10. Using a trim stick, unsnap the cluster bezel. 11. Disconnect the traveler module electrical connector. 12. Remove the cluster bezel assembly. 13. Remove the two (2) screws that attach the traveler module to the cluster bezel. 14. Remove the traveler module from the cluster bezel. 15. If the bezel on the removed traveler module is not Slate colored, transfer the old traveler bezel to the new traveler module. To remove the bezel, pull up on the two bezel mounting tabs on the bottom of the module. 16. Install the new traveler module into the cluster bezel. Tighten the attaching screws securely. 17. Connect the traveler module electrical connector. 18. Install the cluster bezel. Tighten the four (4) cluster bezel screws securely. 19. Install the left lower instrument trim panel/knee blocker. Tighten the five (5) trim panel screws securely. 20. Install the driver side trim bezel. Tighten the driver side trim bezel screw securely. 21. Install the passenger side trim bezel. Tighten the passenger side trim bezel screw securely. 22. Connect the HVAC control electrical connectors. 23. Install the instrument panel center trim bezel. 24. Connect the power mirror switch electrical connector; then install the switch and bezel assembly. 25. Install the left instrument panel end cover. 26. If the vehicle has experienced a no-start condition due to the erroneous traveler signal, the PCM must be replaced. Continue with Section B - Replace PCM. If the vehicle could be started normally prior to the traveler module replacement, connect the negative battery cable and then return the vehicle to the customer. B. Replace PCM IMPORTANT: Only those vehicles that have experienced a no-start condition require PCM replacement. Very few vehicles are expected to require PCM replacement. 1. Remove the air cleaner box. 2. Disconnect the PCM electrical connectors and move the wiring harness aside. 3. Remove the two (2) bolts and one (1) nut from the PCM bracket. 4. Remove the PCM and Bracket assembly. 5. Remove the PCM from the PCM bracket. 6. Install the new PCM onto the bracket. Tighten the screws to 35 in-lbs (4 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 5298 7. Install the PCM and bracket assembly. Tighten the two (2) bolts and one (1) nut to 35 in-lbs (4 Nm) 8. Connect the PCM electrical connectors. 9. Install the air cleaner box. 10. Connect the negative battery cable. 11. Using the DRB III scan tool, program the new PCM with the vehicle's Vehicle Identification Number (VIN) and current vehicle mileage. NOTE: Failure to reprogram the new PCM with VIN information and mileage may cause a Diagnostic Trouble Code (DTC) to be set. a. Connect the DRB III to the underdash diagnostic connector. b. Select "DRB III STANDALONE" (1) and then press "Enter". c. Select "1998 - 2001 DIAGNOSTICS" (1) and then press "Enter". d. Select "ENGINE" (1) and press "Enter" three times. e. Select "FUNCTION SCREEN" and scroll to page two (press the right arrow key once) f. Select "MISCELLANEOUS". g. Select "CHECK VIN" (4) and then press "Enter". h. Follow the instructions on the DRB III screen to enter the VIN. CAUTION: Verify that the correct VIN is displayed on the DRB III before pressing the "Enter" key. The VIN cannot be changed once it is entered. If an incorrect VIN is entered, the module must be replaced to correct the VIN error. i. Press the "PAGE BACK" button on the DRB III key pad. j. Select "SRI MEMORY CHECK" (3) and then press "Enter". k. Follow the instructions on the DRB III to enter the current vehicle mileage. 12. After entering the VIN and mileage, check for any additional software updates. Continue with Section C - Check for PCM Software Updates. C. Check for PCM Software Updates: NOTE: The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at the latest release is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON" 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request an MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 5299 NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button; then continue with Step E. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped) .Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after-all other modules have had their trouble codes erased. 9. Continue with Section D - Install Authorized Software Update Label. D. Install Authorized Software Update Label: Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label, and attach it to the PCM. Cover the label with the clear plastic portion of the label. Continue with Section E - Install the Authorized Modifications Label. E. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label. Then attach the label near the VECI label. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 5300 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Power Amplifier C1 (JR-41) (Premium) Power Amplifier C2 (JR-41) (Premium) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 5305 Amplifier: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the retaining fasteners. Adjust or remove the seat as necessary to gain access. 3. Disconnect the wire harness connector. 4. Remove the amplifier. INSTALLATION 1. Connect wire harness connector to amplifier. 2. Install fasteners Tighten the forward screw to 3 Nm (26.5 in. lbs) and the rear nut to 2 Nm (18 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Locations CD Changer: Locations CD Changer is located in the instrument panel below the radio. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions CD Changer: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 CD Changer: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 CD Changer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 5331 CD Changer: Description and Operation The 4 Disc In-Dash CD Changer (if equipped) is located in the instrument panel below the radio. The remote changer does not use a cartridge or magazine for the CD's. Up to 4 CD's can be directly loaded into this unit, one at a time. Due to its compact design, the CD changer can carry out only one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit provides control over all features of the CD changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD changer. All features you would expect, such as Disc Up/Down, Track Up/Down, Random (same disc only) and Scan are controlled by the radio, which also displays all relevant CD changer information on the radio display. The CD changer will not operate with the ignition in the OFF position. With the ignition OFF, CD's can not be removed from the changer. The CD changer contains a Load/Eject button and an indicator LED for each of the four disc positions as well as an illuminated disc opening. The individual LED indicates whether a CD is currently loaded or ready to load in that particular chamber of the CD changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 5332 CD Changer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove lower center trim bezel. 3. Remove screws from radio. Fig.11 CD Changer 4. Remove screws from CD changer. 5. Remove CD changer from Instrument panel. 6. Disconnect wire connector from CD changer. INSTALLATION 1. Connect wire harness connector to CD changer. 2. Insert CD changer into instrument panel. Make sure that bumper on back of changer is inserted into instrument panel opening. 3. Pull radio from instrument panel far enough to reach behind. Feed CD changer cable through radio opening while inserting changer into instrument panel. 4. Install screws to radio and CD changer. 5. Install lower center trim bezel. 6. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection Remote Switch: Testing and Inspection 1. Remove switch from instrument panel. (Refer to POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). Fig.2 Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 3. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection > Page 5337 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, pry the trim bezel from the instrument panel. 3. Disconnect wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION 1. Install switch to trim bezel. 2. Connect wire harness connector to switch. 3. Install trim bezel to instrument panel. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Left Front Door Speaker Left Rear Speaker Right Front Door Speaker Right Rear Speaker Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Dash Speaker Replacement Speaker: Service and Repair Dash Speaker Replacement REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove A-pillar trim. 3. Remove instrument panel top pad. 4. Remove speaker screws. 5. Disconnect wire harness connector from speaker. Fig.12 Dash Speaker 6. Remove speaker. INSTALLATION 1. Connect wire harness connector to speaker. 2. Install speaker screws. 3. Install instrument panel top cover. 4. Install A-pillar trim. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Dash Speaker Replacement > Page 5343 Speaker: Service and Repair Door Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel. 3. Remove speaker screws. 4. Disconnect wire harness connector from speaker. Fig.13 Door Speaker 5. Remove speaker from door. INSTALLATION 1. Reconnect wire harness to speaker. 2. Align and install speaker to door. 3. Install speaker screws. 4. Install door trim panel. 5. Reconnect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Dash Speaker Replacement > Page 5344 Speaker: Service and Repair Rear Speaker Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Fold down the rear seat backs. 3. Remove C-pillar trim. 4. Remove lower quarter trim behind rear seat backs. 5. Remove fasteners from rear shelf trim. Pull out trim to access speaker. 6. Remove speaker screws. 7. Disconnect wire harness connector. Fig.15 Rear Speaker 8. Remove speaker. INSTALLATION 1. Connect wire harness connector to speaker. 2. Position speaker into opening. 3. Install speaker screws. 4. Install rear shelf trim. 5. Install lower quarter trim panel. 6. Install C-pillar trim. 7. Raise seat backs. 8. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5349 Alarm Module: Diagrams Sentry Key Immobilizer Module Sentry Key Immobilizer Module Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5350 Alarm Module: Service Precautions WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS, WARNINGS, BEFORE ATTEMPTING COMPONENT. DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5351 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it. The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the Body Control Module (BCM), and the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique "Secret Key" code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The "Secret Key" code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the "Secret Key" code can be restored from the PCM by following the SKIM replacement procedure found in the DRB III scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original "Secret Key" code can not be recovered, new ignition keys will be required. The DRB III scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the assembly plant tester. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an "invalid key" message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is "invalid key." Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. The SKIM also sends indicator light status messages to the BCM to operate the light. This is the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5352 Alarm Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative remote cable. 2. Remove knee bolster. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). 5. Remove the two screws securing the SKIM module to the top of the steering column. 6. Rotate the SKIM and its mounting bracket upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKIM from the vehicle. INSTALLATION 1. If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE) Sentry Key Immobilizer Module Initialization. 2. Carefully position the SKIM, the mounting bracket and the antenna ring onto the steering column. 3. Install the two retaining screws. 4. Connect the wire harness connector. 5. Install the steering column upper and lower shrouds. 6. Install the knee bolster. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5356 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Relay > Component Information > Description and Operation > Page 5360 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5365 Lock Cylinder Switch: Diagrams Decklid Cylinder Lock Switch (VTSS) Driver Cylinder Lock Switch (VTSS) Passenger Cylinder Lock Switch (JR-41) (VTSS) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 5366 Lock Cylinder Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Refer to Body, Door - Front, Trim Panel, Removal. Central Locking Switch 3. Disconnect the wiring clip and pigtail wire connector. 4. Remove the Door Cylinder Lock Switch from door lock cylinder. INSTALLATION 1. Install the Door Cylinder Lock Switch onto the door lock cylinder. 2. Connect the wiring clip and pigtail wire connector. 3. Refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection Remote Switch: Testing and Inspection 1. Remove switch from instrument panel. (Refer to POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). Fig.2 Mirror Switch 2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 3. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Testing and Inspection > Page 5370 Remote Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, pry the trim bezel from the instrument panel. 3. Disconnect wire harness connector from switch. 4. Remove switch from bezel. INSTALLATION 1. Install switch to trim bezel. 2. Connect wire harness connector to switch. 3. Install trim bezel to instrument panel. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK REMOVAL 1. Raise vehicle and support on safety stands. Fig. 24 2. Remove bolts (Fig.24). 3. Remove tow hook from vehicle. INSTALLATION 1. Place tow in position. 2. Install bolts (Fig.24). Tighten to 55 to 115 N.m (55 to 85 ft.lbs.) torque. 3. Remove safety stands and lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Trip Computer: Locations The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Trip Computer: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Compass/Mini-Trip Computer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Compass/Mini-Trip Computer (CMTC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5400 Trip Computer: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table CMTC/Traveler .................................................................................................................................... ......................................................... 04798364 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5401 Trip Computer: Description and Operation DESCRIPTION The Compass/Mini-Trip Computer (CMTC) system is located in the center stack between the HVAC outlets. The Compass/Mini-Trip Computer is an electronic control module with a vacuum fluorescent display and two function buttons. The Compass/Mini-Trip Computer communicates on the J1850 Programmable Communication Interface Data Bus Circuit. The functions that are available via activation of the STEP button are as follows: Compass and Temperature - Average Fuel Economy (AVE ECO) - Distance to Empty (DTE) - Instantaneous Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Time (ET) - Tank Screen (OFF) The Compass/Mini-Trip Computer cannot be repaired and, if faulty or damaged it must be replaced. The incandescent lamp for the STEP and US/METRIC button illumination is serviceable. Consult your Mopar (R) Parts Catalog for a specific part number. OPERATION Actuation of the STEP button will cause the Compass/Mini-Trip Computer to change mode of operation and actuation of the US/M button will toggle between English and Metric unit of measurement. A reset of the trip computer information is accomplished by actuating the Step and US/M buttons simultaneously. To reset only the trip condition currently displayed, press and release the STEP and US/M buttons simultaneously for one second until a chime sounds. To reset all trip conditions, hold down the STEP and US/M buttons simultaneously (about 2 seconds) until a second chime sounds and then release the buttons. The Compass/Mini-Trip Computer is active only when the ignition switch is in the ON position. When the ignition switch is turned ON, the Compass Mini- Trip Computer will return to the last function screen that was displayed prior to the ignition being turned OFF. COMPASS/MINI-TRIP COMPUTER MESSAGES The Compass/Mini-Trip Computer will not display information for any of the screens for which it did not receive the proper data over the J1850 PCI bus for that particular screen. Refer to Mini Trip Computer Diagnosis and Testing for more information. The Compass/Mini-Trip Computer receives the following messages from the Body Control Module (BCM): Verification of US/M Status - Display Brightness (Dimming) and Lamp Status Trip Odometer Data - Elapsed Ignition On Time Data - Fuel Efficiency (Average and Instantaneous) - Distance to Empty - Outside Temperature The Compass/Mini-Trip Computer transmits the following messages to the Body Control Module (BCM): Status Request: Beep, Reset, US/M Toggle - Current Display - Compass Heading The Compass/Mini-Trip Computer receives the following message from the Single Board Engine Controller (SBEC): Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5402 Trip Computer: Testing and Inspection DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER The Compass/Mini-Trip Computer is capable of performing a diagnostic self check on many of its internal functions. Compass/Mini-Trip Computer diagnostics may be performed using a DRB III(R) scan tool and the proper Body Diagnostic Procedures or by the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position. The Compass/Mini-Trip Computer will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check, the Compass/Mini-Trip Computer will display one of five messages; - PASS - Passed Self Test - FAIL - Failed Self Test - BUS - Not receiving J1850 messages from Single Board Engine Controller (SBEC) and Body Control Module (BCM) - bus1 - Not receiving J1850 messages from Single Board Engine Controller (SBEC) - bus2 - Not receiving J1850 messages from Body Control Module (BCM) If any segment of the Compass/Mini-Trip Computer fails to light replace the computer. If FAIL is displayed, repeat the test. If it still fails, replace the Compass/Mini-Trip Computer module. If a BUS(X) message is displayed, check the corresponding J1850 PCI Data Bus Circuit for proper operation. Refer to the appropriate diagnostic manual for additional diagnostics. COMPASS CALIBRATION If the "CAL" indicator is lit, the compass should be calibrated. The vehicle will be shipped with the "CAL" light on. If during normal driving, the compass appears to be inaccurate, calibration may be required. To Calibrate the Compass 1. Depress the STEP and US/M buttons simultaneously until CAL appears in the display. Fig.1 Compass Calibration 2. Drive the vehicle in about two circles on a level surface in an area free of large metal objects, such as other vehicles, large buildings, bridges, underground cables, railroad tracks, etc. NOTE: The compass will usually calibrate after the vehicle has been driven in a circle comprising five quadrants or one and a quarter turns. When the "CAL" indicator goes off, the compass is calibrated and should display correct headings (for all conditions). Verify proper calibration by checking North (N), South (S), East (E), and West (W). If the compass does not appear accurate, repeat the calibration procedure in another area. VARIANCE SETTING PROCEDURE Variance is the difference between magnetic North and geographic North. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5403 1. Depress the STEP and US/M buttons simultaneously until VAR appears in the display, then release the buttons. Setting The Variance 2. The CMTC Will display the current variance zone (1-15). If the variance needs to be changed use the STEP button to select the correct zone number from the figure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > CMTC/Traveler Illumination Lamp Replacement Trip Computer: Service and Repair CMTC/Traveler Illumination Lamp Replacement REMOVAL 1. Remove the CMTC/Traveler from the instrument panel. Refer to Body, Instrument Panel, Compass/Mini-Trip Computer, Removal. 2. With the CMTC removed from the cluster bezel, remove the tape from the lamp access opening at the bottom of the CMTC/Traveler. 3. With a screwdriver, twist the bulb assembly 1/4 turn counterclockwise. Remove bulb and replace. INSTALLATION 1. With a screwdriver, twist the bulb 1/4 turn clockwise. 2. Install the tape to the access opening at the bottom of the CMTC/Traveler to prevent any light leaking. 3. Install the CMTC/Traveler. Refer to Body, Instrument Panel, Compass/Mini-Trip Computer, Installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > CMTC/Traveler Illumination Lamp Replacement > Page 5406 Trip Computer: Service and Repair Compass/Mini-Trip Computer Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove the Instrument Cluster Bezel. Refer to Instrument Cluster Bezel for the procedure. 3. With the cluster bezel removed, remove the screw attaching the Compass/Mini-Trip Computer Module to the cluster bezel. 4. Unsnap and remove Compass/Mini-Trip Computer from the cluster bezel. INSTALLATION 1. Snap the Compass/Mini-Trip Computer on the cluster bezel and install the retaining screw. 2. Install the Instrument Cluster Bezel. Refer to Instrument Cluster Bezel for the procedure. 3. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' Body Control Module: Customer Interest A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 24-001-03 > Mar > 03 > A/C - Windows Fog While in 'Floor Mode' > Page 5417 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C Windows Fog While in 'Floor Mode' Body Control Module: All Technical Service Bulletins A/C - Windows Fog While in 'Floor Mode' NUMBER: 24-001-03 GROUP: Heating & A/C DATE: Mar. 28, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE MDS2 MUST BE OPERATING WITH CIS/ISIS CD2130 OR HIGHER AVAILABLE APRIL 14, 2003. SUBJECT: Windows May Begin To Fog When The HVAC Is In Floor Mode OVERVIEW: This bulletin involves flash reprogramming the Body Control Module (BCM) to increase the amount of air coming out of the defroster ducts when operating HVAC in the Floor Mode. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The vehicle operator may experience window fogging in certain climate conditions when operating the HVAC system in the Floor Mode. DIAGNOSIS: If the vehicle operator describes the above Symptom, verify the heater and defroster are functioning properly and that the vehicle operator is using the Fresh Air Mode NOT the Recirculation Mode. Explain to the vehicle operator the condition can be corrected by operating the HVAC system in the Fresh Air Mode with higher blower speed and temperature settings and selecting either the Floor/Defrost Mix Mode or Defrost Mode. Otherwise, the HVAC system can be recalibrated to provide more air flow from the defroster ducts when the Floor Mode is selected. Perform the Repair Procedure if the vehicle operator prefers to have the HVAC recalibrated. EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: WHENEVER A BCM IS REPLACED OR REPROGRAMMED, THE SOFTWARE IN THE CONTROLLER AND DRBIII(R) MUST BE VERIFIED AS HAVING THE LATEST REVISION LEVEL. 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the BCM using the TechCONNECT/MDS2, operating at CD 2130 or higher, and the DRBIII(R) operating at software release level 55.7 or higher. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 24-001-03 > Mar > 03 > A/C Windows Fog While in 'Floor Mode' > Page 5423 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors Body Control Module: Diagrams BCM Connectors Body Control Module C1 Body Control Module C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 5426 Body Control Module C3 Body Control Module C4 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 5427 Body Control Module: Diagrams Junction Block/BCM Connector 8W-12-2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > BCM Connectors > Page 5428 8W-12-5 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 5431 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 Body Control Module: Description and Operation Part 1 of 2 SYSTEM DESCRIPTION The body system on the 2001 JR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled and communicated by the PCI bus, which is described in the Vehicle Communication of this General Information. Always begin by reading the diagnostic trouble codes using the DRB III. Next, look for the symptom in the Diagnostic Information and Procedures of the Table of Contents. This will direct you to the specific tests(s) that must be performed. Important Note: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the Airbag module. In addition, if the vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. Refer to 2001 JR Powertrain Diagnostics for more information. Erase codes in all modules. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5434 Body Control Module: Description and Operation Part 2 of 2 Part 2A AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM The 2001 Airbag System contain the following components: Occupant Restraint Controller (ORC), Airbag Warning Indicator, Clockspring, Driver and Passenger Dual Squib Airbags, Seat belt Tensioners, Left and Right Side Impact Airbag Control Module (SIACM), and Curtain (roof mounted) Airbags. The (ORC) is a new type of Airbag Control Module (ACM) that supports staged airbag deployment. Staged deployment is the ability to trigger airbag system squib inflators all at once or individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, On-board diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel between the front seats inside the vehicle. The ORC cannot be repaired or adjusted and must be replaced. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), Left and Right Side Impact Airbag Control Module (SIACM) and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. The ORC also monitors bus messages from both SIACM. If the ORC detects a monitored system fault or SIACM fault, it sends a message to the instrument cluster via PCI bus to turn on the airbag warning indicator. The ORC can set both active and stored diagnostic trouble codes to aid in the diagnosing system problems. See ORC/SIACM DIAGNOSTIC TROUBLE CODES. The ORC has an internal accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the crash severity to determine the level of driver and front passenger deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag Warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MCI performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. For 2001 driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas. The Occupant Restraint Controller (ORC) uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas it contains directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5435 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III, read Airbag DTC's. If the following active codes are present: If neither of the following codes is an active code: Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or if could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and hybrid inflators are attached and sealed. For 2001 the front passenger airbag with dual stage squib inflators that include a small canister of highly compressed argon gas. The ORC uses vehicle crash severity, to determine the level of airbag deployment. When supplied with the proper electrical signal, the hybrid inflator or inflators discharge the compressed gas if contains directly into the airbag. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTER-CHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5436 CAUTION: DEPLOYED FRONT AIRBAGS MAY OR MAY NOT HAVE LIVE PYROTECHNIC MATERIAL WITHIN THE AIR BAG INFLATOR. DO NOT DISPOSE OF 2001 MODEL YEAR DRIVER AND PASSENGER AIRBAGS UNLESS YOU ARE SURE OF COMPLETE DEPLOYMENT. PLEASE REFER TO THE HAZARDOUS SUBSTANCE CONTROL SYSTEM FOR PROPER DISPOSAL. DISPOSE OF DEPLOYED AIRBAGS IN A MANNER CONSISTENT WITH STATE, PROVINCIAL, LOCAL, AND FEDERAL REGULATIONS. USE THE FOLLOWING TABLE TO IDENTIFY THE STATUS OF THE AIRBAG SQUIB. Airbag Squib Status 1. Using a DRB III read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: Seat Belt Tensioner (SBT) The JR41 4-door driver and front passenger seat belt (retractor) tensioners are mounted to the inboard side of the "B" pillar at the floor. The tensioner is an integral part of the seat belt retractor. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retracts the seat belt. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. The JR27 convertible driver and front passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle is connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits an open or shorted conditions. Side Impact Airbag Control Module (SIACM) Supplemental driver and passenger curtain air-bags provide side impact protection for the occupants. Each side airbag has it's own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just above the seat belt retractor. One, same part number, SIACM is used on both side of the vehicle. However, for proper PCI bus operation each SIACM must have a unique module identification. To provide the unique module identification for both, left and right, the SIACM software looks for a ground on cavity #5 of the SIACM connector. If cavity #5 is grounded the SIACM communicates as a left SIACM otherwise it communicates as a right SIACM. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. If a DTC is active the SIACM will request that the airbag warning lamp be turned on. The results of the system test are transmitted on the PCI Bus to the ORC once each second or on change in lamp state. If the warning lamp status message from the either SIACM contains a lamp on request, the ORC will set an active DTC. At the same time as the DTC is set, the ORC sends a PCI Bus message to the (MIC) requesting the airbag warning indicator be turned on. Observe all ORC warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5437 DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The airbag warning lamp is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is turned to the run or start position, the MIC performs a lamp check by turning the airbag warning indicator on for 6-8 seconds. After the lamp check, if the indicator turns on, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes OFF, there is usually an intermittent problem in the system. Curtain Airbags The Left and Right curtain airbag modules are located in the outboard edge of the roof under the headliner, just above the door opening. The curtain airbag contains a squib and inflator (a small canister of highly compressed argon gas) and a mounting bracket mounted to the C post and tethered to the A post. When supplied with the proper electrical signal the inflator can discharge the compress gas it contains directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 °C (200 °F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. ORC/SIACM Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Always begin diagnostic with the Table of Contents. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the air-bag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. Part 2B Active Codes The code becomes active as soon as the malfunction is detected or key-in, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit or component. It is impossible to erase an active code. Active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. The exception is the Loss of Ignition Run Only code which is an active code only. A stored code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be active. When a trouble code occurs, the airbag warning indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. It no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5438 AUDIO SYSTEM All radio systems available on the 2001 JR communicate on the PCI Bus. They use the bus for three reasons. The first is to communicate trouble codes, second is to receive dimming information, and third is to receive cabin equalization information. The audio system is available in a 4 speaker base system and a 6 speaker system with an external power amplifier. An in-dash CD Changer is also optional. Depending on the manufacturer of the radio, some systems have a front/rear output system and others have a left/right output system. When troubleshooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. The output DTC could refer to a front or rear output or a left or right output. The reason for the difference is the pairing of the output sections of the radio. Some are paired left and right, others are paired front and rear. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. The new in-dash CD-changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD-changer is controlled by your radio, and allows you to individually load up to four discs at one time. However, due to its compact design, the CD-changer can only carry out one operation at a time. For example you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with you system provides control over all features of the CD-changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD-changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD-changer information on the radio display. The CD-changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD-changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Programmable Communication Interface or PCI bus). This network consists of the powertrain control module (PCM), sentry key immobilizer module (SKIM), the Transmission Control Module (TCM), the electro/mechanical instrument cluster (MIC), Compass/mini-trip Computer (CMTC) occupant restraint control (ORC) module, optional Antilock Brakes (ABS), the radio remote CD-player, optional left and right airbag control modules. The (BCM) is operational when battery power is supplied to the module, ignition switch power is needed for ignition switched functions. The body control module provides the following features: A/C switch status/evaporator temperature status BCM diagnostic support Central lock and unlock (VTSS only) Climate Control system support Door ajar switch status Door Lock Inhibit (key in ignition or headlamps/park lamps ON) Electronic Odometer Support Headlamp Time Delay Illuminated Entry with "fade to OFF" Interior lighting with battery save feature Mechanical Instrument Cluster (fuel level, dim data, odometer & warning chime) support Travel information system Power convertible top Power door lock multiplexing control Rear Window Defogger Control Remote Keyless Entry with Panic Mode Remote power deck lid release Rolling door lock control (customer programmable) Sentry key immobilizer support Vehicle Theft Security System Wiper Control (speed sensitive with return to park) The BCM receives information over the PCI Bus from the PCM in order to support certain features. The required information is as follows: Engine RPM - Engine Temperature - Injector on Time and Distance Pulses - Vehicle Speed Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5439 - Charging System Failure, Engine Temperature Limp-In, VTSS Arming Status - Engine Model - "Check Engine" lamp status Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5440 The BCM provides the PCM with information on the A/C switch status and the VTSS status. The JR has several customer programmable features which can be disabled or enabled by the customer. CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5441 Ambient Temperature Sensor The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Powertrain Control Module (PCM), the Programmable Communications Interface (PCI) data bus, and portion of the Compass Mini-Trip Computer (CMTC). If any portion of the ambient temperature sensor circuit fails, the BCM Will self-diagnose the circuit and set a DTC. The CMTC Will lock the display at 54 °C (130 °F) if the sensor is exposed to temperatures above 54 ° (130 °F), or if the sensor is shorted. The CMTC Will lock the display at -40 °C (-40 °F) if the sensor is exposed to temperatures below -40 °C (-40 °F), or if the sensor circuit is open. DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and decklid are in. The DRB III will display the state of the door ajar and the decklid ajar switches in Inputs/Outputs. It's important to note, that when any door, or the decklid is closed, the switch state on the DRB III will show OPEN. When any door, or the decklid is open the switch state on the DRB III will show CLOSED. During diagnosis, if a door or the decklid is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the decklid is open and the DRB III displays the switch state as OPEN, it indicates an open ajar circuit. EXTERIOR LIGHTING SYSTEM Headlamp Delay The headlamp time delay operates when the ignition switch is turned OFF while the headlamps are still ON, and the headlamps are then turned OFF within 45 seconds after the ignition is OFF. This will provide a 90-second time delay before turning OFF the headlamps. Part 2C HEATING AND A/C SYSTEMS A single-zone HVAC system is available on all JR series vehicles. Manual Temperature Control HVAC Control The HVAC system maintains incoming air temperature, airflow, fan speed, and fresh air intake for the entire vehicle from the instrument panel mounted A/C - Heater Control. The full range of temperature that the system can produce in any mode for the entire vehicle is available by positioning the blend Control to the desired range. Air Intake When the fresh-air door is open, outside air is drawn into the HVAC housing through the cowl opening at the base of the windshield. When the fresh-air door is closed, recirculated air is drawn in to the HVAC housing from under the instrument panel. Air Distribution The HVAC unit has four fully adjustable instrument panel outlets. Side-window demister outlets in the instrument panel eliminate the need for door ducts and door-to-instrument panel seals. A single, central mounted outlet delivers air for defrosting the windshield. Two ducts, one on each side of the center console underneath the instrument panel, provide airflow to the driver floor area and the front seat passenger floor area. A/C-heater Control, Switch Operation Blower Switch The rotary Blower Switch has five positions, OFF; Low, M1, M2, and High. Rotating the Blower Switch results in the A/C - Heater Control providing direct blower motor activation, change in blower speed, and blower motor deactivation respectively. The Blower Switch must be in any of the four ON positions to request A/C, and also to have the A/C - Heater Control send a signal to the Body Control Module to signal the door actuators to change door position. Mode Switch The rotary Mode Switch has a total of eight positions. The first three, for A/C request, include Recirc/Bi-level, Panel, and Bi-level. The remaining five positions, for Heat request, include Panel, Bi-level, Floor, Floor/Defrost, and Defrost. The Floor/Defrost position and the Defrost position also provided an A/C request. Mode Switch, A/C Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to any of the three A/C request positions, the Floor/Defrost position, or the Defrost position, will result in the A/C - Heater Control sending a signal to the BCM to send a message to the PCM to provide A/C compressor clutch activation. However, the BCM will only provide this request if EVAP function is found acceptable. Mode Switch, Mode Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch will result in the A/C Heater Control sending a signal to the BCM to signal the actuator to move the mode door. A potentiometer, inside the Mode Door Actuator, and feedback circuits provide the BCM with door position information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5442 Mode Switch, Fresh-air Door Position Change Request Provided that the Blower Switch is in any of the four ON positions, rotating the Mode Switch to the Recirc position will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to close the fresh-air door. While rotating the mode Switch to any other position results in the A/C - Heater Control sending a signal to the BCM to signal the actuator to open the fresh-air door. When the Blower Switch is OFF, the fresh-air door closes to prevent outside air from entering the passenger compartment. Blend Switch The rotary Blend Switch has multiple detents to control the full range of temperature that the system can produce in any mode. Provided that the Blower Switch is an any of the four ON positions, rotating the Blend Switch will result in the A/C - Heater Control sending a signal to the BCM to signal the actuator to move the blend door. A potentiometer, inside the Blend Door Actuator, and feedback circuits provide the BCM with door position information. Rear Window Defogger Switch The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C - Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. Diagnostic Trouble Codes All HVAC Diagnostic Trouble Codes are stored in the Body Control Module. Stored DTCs indicate that a problem has occurred in the HVAC system, and may still be present. To verify a problem is still present in the HVAC system, use the DRB III to erase all stored BCM DTCs. After erasing the DTC(s), use the DRB III to see if the DTC(s) reappear. If necessary, actuate the A/C - Heater Control switches with the ignition ON and with the engine running while monitoring the DRB III to see if the DTC(s) reappear. INTERIOR LIGHTING Courtesy Lamp Control The body controller has direct control over the majority of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door is ajar. 2. The courtesy lamp switch ON the instrument panel is closed. 3. A Remote Keyless entry unlock message is received. If the interior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 15 minutes or until either the dome lamp switch or door ajar switch changes state. Illuminated Entry Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned ON, the illuminated entry also cancels. MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster (MIC) is divided into 4 sections. Primary gauges (Speedometer and Tachometer), secondary gauges (Fuel Level, Engine Coolant Temperature), PCI bus enabled indicator lamps and hardwired enabled indicator lamps. The gauge mechanisms function in the same way. The main differences are in the face and size of the gauge. The Oil Pressure, Brake Warning, Turn Signal and Fog Lamp indicators are directly wired to the circuits that they are indicators for. These indicators are located in, but not controlled by, the MIC and are not part of any MIC self test or diagnostic. All indicators are replaceable bulbs or LEDs. The PCM sends a gauge position message to the BCM through the PCI bus. The MIC receives this message from the BCM, translates it, and positions the gauges. The BCM also sends messages to the MIC to actuate all PCI controlled indicators. These messages are received when the Ignition Switch is in the RUN or START position. When the ignition Switch is turned to the RUN position, a bulb-check is performed. This consists of activating the PCI bus controlled indicators for approximately 2 to 4 seconds. By holding the TRIP/RESET button in while turning the Ignition Switch to the RUN position, you can activate the MIC Self Test. The Following indicators are controlled by PCI bus messages: Malfunction Indicator Lamp - Charging System Warning Indicator - Engine Coolant Temperature Indicator - Cruise Engaged Indicator - Airbag Warning Indicator - Low Fuel Indicator - ABS Warning Indicator - High Beam Indicator Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5443 The following indicators are hardwired and not controlled by PCI bus messages: Seat Belt Indicator - Oil Pressure Indicator - Brake Warning Indicator - VTSS Indicator - Turn Signal Indicators - Fog Lamp Indicators POWER DOOR LOCK SYSTEM The door lock switches provide a variable amount of voltage through the Multiplexed (MUX) circuit to the BCM. Depending upon that input and various conditions that must be met (i.e. door lock inhibit, etc.), the BCM will determine the action to be taken and activate the proper relay for approximately 250 to 350 msec. If the vehicle is equipped with the vehicle theft security system it will have the central locking feature which locks and unlocks all doors from the cylinder lock switches. These switches are on separate multiplexed circuits to the BCM and have trouble codes relating to each of them. RKE Remote Keyless Entry - This feature allows locking and unlocking of the vehicle door(s) by remote control using a hand-held transmitter (sometimes referred to as a fob) to activate a radio receiver (RKE module). This module now plugs into the body control module which is directly connected to the junction block. With this feature RKE can now be added to a non-equipped vehicle by installing a module. If the vehicle is equipped with the vehicle theft security system, RKE will also arm and disarm that system. A 4-button transmitter is used which provides lock, unlock, decklid release and panic features. Decklid release is only operable while the vehicle is in the park position. The module is capable of retaining up to 4 transmitter codes. Rolling code, which increases security, is also included in this system. If the transmitter goes out of synchronization it is easily put back in by pressing the lock button when the transmitter is within range. An external antenna has been added which plugs into the module to provide greater range. RKE will also turn ON the interior lamps when a valid unlock command is received and will extinguish the interior lamps when a lock command is received and all doors are closed. Door Lock Inhibit - When the key is in the ignition and the driver front door is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic (rolling) Door Locks - This feature can be enabled or disabled by using either the DRB III or the customer programmable method. When enabled, all doors will lock when the vehicle reaches a speed of 15 mph (24 km/h) and all doors are closed. If a door is opened and the vehicle slows to below 15 mph (24 km/h), the locks will operate again once all doors are closed and the speed is above 15 mph (24 km/h). Decklid Release - Decklid release is now a function of the body control module. Trouble codes are provided to assist in the diagnosis of this system. Customer programmable features are: Horn chirp, one or two press decklid release, programming a new transmitter (using a previously programmed transmitter), rolling door locks, unlock on exit, and RKE lamp flash. POWER CONVERTIBLE TOP Top Control The body control module now controls all the functions of the convertible top. The body control module supplies a multiplexed voltage of approximately 90% of ignition voltage to the power top switch. Through a series of resistors the power top switch switches the circuit to ground depending on the position of the switch. The BCM then supplies the ground path for the up or down relay as requested. The power top switch has a 4.7-ohm diagnostic resistor that allows the BCM to detect a possible open circuit. Window Drop Relay Assembly The convertible has a new feature that allows the operator to lower all four windows and lower the top at the same time. This is accomplished by pressing the power top switch to the second detent. Through the multiplexed circuit of the power top switch the BCM will supply the ground for the window drop relay assembly. The window drop relay assembly is comprised of four separate relays that are in series with the power window circuits. The relay assembly is located in the driver door. VEHICLE COMMUNICATION The Programmable Communication Interface multiplex system (PCI bus) consists of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its local ground as the bus reference, The wiring is a minimum 20 gage. The bus is designed to handle a maximum number of nodes to meet all of the bus load and timing requirements. The bus resistance and capacitance is designed to provide a maximum level of filtering without distorting the bus symbols. This is why extra capacitance and resistance should not be added to the PCI Data Bus circuitry. In order for an electronic control module to communicate on the PCI data bus, the module must have bus interface electronics consisting of a transmitter/receiver (or transceiver) and Logic control, but termination for loading and filtering the bus, and wiring which interconnects the system. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5444 Because of the unique coding scheme used in the PCI bus, each module is required to have logic control. The data moving on the bus is called symbols. The interface logic performs the following functions: encode and decodes binary data into symbols, synchronizes all bus symbol timing and edges, controls and the sending and receiving of messages, monitors for bus arbitration, monitors for corrupted symbols due to noise and controls the transceiver. The bus logic control also provides the transceiver with the information it needs to transmit symbols on the bus. The transceiver controls the waveshaping of each symbol that it transmits by using internal voltage controlled current drivers. When the bus transceiver is turned ON, the bus driver ramps up the voltage to the set range and maintains this voltage until the driver is turned OFF; at which time the voltage is ramped back down to the low voltage, ground. The transceiver is designed to allow for arbitration between modules. If more than one module is trying to access the PCI bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The PCI bus requires a resistance and capacitance termination load to ground to operate. Because each bus transceiver can only source current to the bus, the resistance load is required to sink this current and pull the bus to ground on the falling edge of the symbols. The bus resistance is minimum of 315 ohms to a maximum of 2 K ohms. The termination capacitance is required for noise filtering and to help in the symbol wave shaping. The bus capacitance shall not be greater than 12,000 pf. Each module on the PCI bus has a small termination load of a parallel resistance and capacitor to make up part of the overall bus termination load. One or two modules on the PCI bus may have a higher load termination to provide stabilizing influence over the variations of the vehicle builds. These modules, called dominant modules, may very for car line to car line. The Powertrain Control Module (PCM) and the body control module (BCM) are the dominant nodes for this vehicle. Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit, and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12 V square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. PCI Bus Communication Failure and individual module no response. Causes of a PCI Bus communication failure include a short to ground or to voltage on any PCI Bus circuit. individual module no response can be caused by an open circuit at the BCM or at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus communications failure would include but are not limited to: All gauges on the MIC stay at zero - All Telltales on MIC illuminated - MIC backlighting at full intensity - No response received from any module on the PCI Bus through the DRB III (Except the PCM) - No start (if equipped with sentry key immobilizer system) Symptoms of individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5445 Diagnosis starts with symptom identification. If a complete PCI Bus failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules (except PCM) are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI Bus circuit or power supply and ground circuits. The DRB III may display "BUS +/- SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI Bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped with that particular module. NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF THE VEHICLES ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB III. PROBLEMS WITH THE OPERATION OF THE BUS OR DRB III MUST BE CORRECTED BEFORE PROCEEDING WITH DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE COMMUNICATIONS CATEGORY. Bus Failure Message Odometer Displays "No Bus" - The Mechanical Instrument Cluster (MIC) cannot communicate over the bus and does not know why. VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The vehicle theft security system (VTSS) is part of the body control module (BCM), which monitors vehicle doors and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5446 headlamps, courtesy lamps, and the VTSS indicator lamp. Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the instrument cluster will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm and the indicator will flash at a slow rate. If the indicator lamp remains steadily lit during the arming process, this can indicate a loss of decklid cylinder lock switch. When something triggers the alarm, the system will signal the headlamps, courtesy lamps, and horn for about 3 minutes, then headlamps for an additional 15 minutes if the offending input is still present. For complaints about the Theft Alarm going OFF on its own use the DRB III and select "Body Computer" then "Input/Output Display" and read the "Last VTSS Cause" status. Tamper Alert - The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch or the RKE. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. System Self-Tests - NOTE: System self tests can be entered only with the DRB III. NOTE: A Powertrain Control Module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes ON after ignition ON and stays ON, the PCI bus communication with the Powertrain Control Module possibly has been lost. WIPER SYSTEM The wiper system provides the driver with the normal wiper (low and high speeds), intermittent wipe, and wipe after wash. The driver selects the wiper function via the resistive multiplexed stalk switch mounted on the steering column. The BCM uses the input signal from the wiper stalk switch, wiper motor park switch, and the washer switch to control the wiper system. The Body Control Module (BCM) then controls the relays and timing functions to provide the driver selected features. Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 mph (6 km/h), the delay time is doubled providing a range of 1 second to 36 seconds. Park after Ignition OFF Because the wiper relays are powered from the battery the BCM can run the wipers to park after the ignition is turned OFF. Wipe after Wash When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. The wiper system utilizes the BCM to control the ON/OFF and hi/low relays fro low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode, and wiper motor park functions. The BCM uses the vehicle speed input to double the usual delay time below 10 mph (17 km/h). WARNINGS VEHICLE DAMAGE WARNINGS Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of 2 > Page 5447 When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second DTC could be set, making diagnosis of the original problem more difficult. ROAD TEST COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition. WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB III SCREEN WHILE IN MOTION. DO NOT HANG THE DRB III FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB III. REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool GLOSSARY OF TERMS ABS Antilock brake system ACM Airbag control module AECM Airbag electronic control module (ACM) ASDM Airbag system diagnostic module (ACM) BCM Body control module CAB Controller antilock brake CMTC Compass/mini-trip computer DAB Driver airbag DLC Data link connector DTC Diagnostic trouble code DR Driver EBL Electric back lite (rear window defogger) HVAC Heater ventilation, air conditioning MIC Mechanical instrument cluster MTC Manual temperature control OBD On board diagnostics ODO Odometer ORC Occupant restraint controller (ACM) PAB Passenger airbag PASS Passenger PCI Programmable Controller Interface (vehicle communication bus) PCM Powertrain control module PDC Power distribution center PWM Pulse width modulated RKE Remote keyless entry SAB Seat airbag SBT Seat belt tensioner SIACM Side impact airbag control module SKIM Sentry key immobilizer module SKIS Sentry key immobilizer system SQUIB Also called initiator (located inside airbag) SRS Supplemental restraint system TCM Transmission control module VFD Vacuum fluorescent display VTSS Vehicle theft security system Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - Use DRB to actuate chime - Body control module chime inoperative Chime Inoperative With Drivers Seat Belt Unfastened Tests 1 - 4 SYMPTOM Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5450 CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED POSSIBLE CAUSES - Seat belt switch status on DRB III - Seat belt switch shorted - Seat belt switch sense short to ground - Instrument cluster - seat belt switch shorted Chime Inoperative With Exterior Lights On and Drivers Door Open Test 1 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LIGHTS ON AND DRIVERS DOOR OPEN POSSIBLE CAUSES - Open headlamp switch output - Body control module Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5451 Tests 1 - 3 Tests 4 - 5 SYMPTOM CHIME INOPERATIVE WITH KEY-IN IGNITION AND DRIVER DOOR OPEN POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - BCM incorrect key-in ignition switch status Chime Sounds With Driver Seat Belt Fastened Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5452 Tests 1 - 4 Test 5 SYMPTOM CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED POSSIBLE CAUSES - Seat belt SW status wrong-open - Seat belt switch open - Ground wire open - Seat belt SW SEN open - Instrument cluster - seat belt sense open Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5453 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVERS DOOR OPEN AND KEY REMOVED FROM IGNITION POSSIBLE CAUSES - Key-in ignition switch status wrong - Key-in ignition switch status wrong - Key-in ignition SW sense short to ground - Body control module - key-in ignition shorted Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5454 Body Control Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5455 Body Control Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5456 Down or Page Up function to display the information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL - JR-41 (Sedan) It is not necessary to remove the headlamp assemblies to remove the front bumper fascia. 1. Release hood latch and open hood. Fig. 1 2. Remove fasteners attaching fascia to front splash shields (Fig.1). 3. Hoist and support vehicle on safety stands. Refer to Vehicle Lifting, for proper hoisting and jacking procedures. 4. Remove inner wheelhouse front wheel house splash shield as necessary to access nut attaching fascia wings to fender. 5. Remove fasteners attaching top of fascia to upper crossmember. 6. Remove fasteners attaching bottom of fascia to radiator closure panel and to brake ducts. 7. Remove screws attaching fascia to front fenders. 8. Slide fascia forward to disengage hooks attaching fascia to bottom of fender. 9. Remove fascia from vehicle. 10. Disengage fog lamp wire connector from body harness, if equipped. INSTALLATION - JR-41 (Sedan) 1. Ensure that energy management foam is properly installed in front fascia. 2. Engage fog lamp wire connector to body wire harness, if equipped. 3. Place fascia on position on vehicle (Fig. 1). 4. Install fasteners attaching fascia to front fenders. 5. Install fasteners attaching bottom of fascia to radiator closure panel and brake ducts. 6. Install fasteners attaching top of fascia to upper crossmember. 7. Install front wheelhouse splash shields. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR FASCIA REMOVAL - JR-41 (Sedan) 1. Release decklid latch and open decklid. 2. Remove left rear tail lamp and disengage license plate wire connector from tail lamp. 3. Peel back trunk carpeting at tail lamps and remove nut and washer from fascia to quarter panel bracket. Discard nut and washer. 4. Remove push-in fasteners attaching decklid slam bumpers to top of fascia. 5. Remove push-in fastener attaching center of fascia to rear closure panel. Fig. 5 6. Remove screws attaching fascia to rear wheelhouse splash shields (Fig.5). 7. Remove screws attaching fascia to quarter panel at the wheelhouse opening. 8. Slide fascia rearward to disengage hooks holding fascia to bottom of quarter panel. 9. Remove fascia from vehicle. INSTALLATION - JR-41 (Sedan) 1. Ensure that the energy management foam is properly installed in rear fascia. 2. Position fascia on vehicle. 3. Slide fascia forward to engage hooks attaching fascia to bottom of quarter panel. 4. Install push-in fastener attaching center of fascia to rear closure panel. 5. Install push-in fasteners attaching decklid slam bumpers to top of fascia. 6. Install new nut and washer to fascia to quarter panel bracket located in the trunk area. 7. Install screws attaching fascia to quarter panel at wheelhouse opening. 8. Install fasteners attaching fascia to rear wheelhouse splash shields. 9. Engage license plate wire connector to left tail lamp. 10. Install tail lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER REINFORCEMENT REMOVAL 1. Remove rear fascia. 2. Support bumper reinforcement on a suitable lifting device. 3. Mark position of nuts on frame rail to aid in installation. Fig. 4 4. Remove nuts attaching rear bumper reinforcement to frame rail (Fig.4). 5. Remove bumper reinforcement from vehicle. INSTALLATION 1. Position rear bumper reinforcement on vehicle. 2. Install nuts attaching bumper reinforcement to frame rail. Use marks made previously to properly position bumper reinforcement. 3. Tighten nuts to 28 N.m (250 in.lbs.) torque. 4. Install rear fascia. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL COVER REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 4 3. Remove screws attaching cowl cover to cowl (Fig. 4). 4. Remove the seal, cowl screen to hood inner panel. 5. Remove clips attaching cowl cover to cowl plenum under hood to cowl bulb seal. 6. Remove cowl cover from vehicle. INSTALLATION 1. Position cowl cover to vehicle. 2. Install clips attaching cowl cover to cowl plenum. 3. Install the seal, cowl screen to hood inner panel. 4. Install screws attaching cowl cover to cowl. 5. Install windshield wiper arms. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel. 2. Raise door glass. 3. Remove water dam as necessary to gain access. 4. Disconnect latch rod at door latch. Fig. 18 5. Remove nuts attaching door handle to outer door panel (Fig. 18). 6. Remove outside door handle from door. INSTALLATION 1. Position outside door handle on door (Fig. 18). 2. Install nuts attaching door handle to outer door panel. 3. Connect latch rod at door latch. 4. Install water dam. 5. Install door trim panel. 6. Verify door handle operation. Adjust door latch as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair HINGE REMOVAL 1. Open and support door on a suitable lifting device. 2. Remove bolts attaching door check strap to lower A-pillar for greater access, if necessary. 3. Mark position of hinges on both the door end frame and lower A-pillar with a grease pencil or other suitable device to ease installation. Fig. 19 4. Remove bolts attaching hinge to door end frame (Fig. 19). 5. Remove bolts attaching hinge to lower A-pillar and remove the hinge. 6. Remove door hinge from vehicle. INSTALLATION 1. If necessary, paint new door hinge prior to installation. 2. Loosely install bolts attaching hinge to lower A-pillar (Fig. 19). 3. Door on a suitable lifting device position door to the hinge on vehicle. 4. Loosely install bolts attaching hinge to door end frame. 5. Align hinges to marks made previously and tighten all bolts. Tighten bolts to 28 N.m (20 ft.lbs.) torque. 6. Install bolts attaching door check strap to lower A-pillar. 7. Verify door fit and operation. Adjust door hinge for proper door alignment, if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments LATCH ADJUSTMENTS Fig. 24 1. Insert a suitable allen wrench through elongated slot in door end frame and loosen bolt 1/2 to one full turn (Fig. 24). 2. Cycle outside door handle twice. 3. Tighten adjusting screw to 3.4 N.m (30 in.lbs.) torque. 4. Verify latch operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5486 Front Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel and watershield. 2. Raise door glass. 3. Remove the bolt and nut for the rear glass run channel and position aside. 4. Disconnect lock rod from lock button bellcrank. Fig. 20 Fig. 21 5. Disengage lock and latch rods from clips on inner door panel (Fig. 20) or (Fig. 21). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5487 Fig. 22 6. Disconnect lock and latch rods from outside door handle and key cylinder at door latch (Fig. 22). 7. Disconnect wire connector from power door lock motor. Fig. 23 8. Remove screws attaching door latch to door end frame (Fig. 23). 9. Remove door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to reopen. 1. Position door latch on vehicle. 2. Install screws attaching door latch to door end frame. 3. Connect wire connector to power door lock motor. 4. Connect lock and latch rods from outside door handle and key cylinder at door latch. 5. Engage lock and latch rods to clips on inner door panel. 6. Connect lock rod from lock button bellcrank. 7. Position the rear glass run channel back and install the bolt and nut. 8. Adjust door latch. 9. Verify operation of door latch. Readjust if necessary. 10. Install door trim panel, and water dam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair CHECK STRAP REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access, Refer to Front Door Panel. 3. Remove bolts attaching check strap to lower A-pillar. Fig. 1 4. Remove bolts attaching check strap to door end frame (Fig. 1). 5. Remove door check strap from vehicle. INSTALLATION 1. Position door check strap on vehicle (Fig. 1). 2. Install bolts attaching check strap to door end frame. 3. Install bolts attaching check strap to lower A-pillar. 4. Install water dam. 5. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top Front Door Panel: Customer Interest Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 5499 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 5500 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top Front Door Panel: All Technical Service Bulletins Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 5506 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 5507 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5508 Front Door Panel: By Symptom Technical Service Bulletin # 23-001-02 Date: 020111 Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5509 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5510 TIME ALLOWANCE: FAILURE CODE: Technical Service Bulletin # 23-001-02 Date: 020111 Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5511 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5512 TIME ALLOWANCE: FAILURE CODE: Technical Service Bulletin # 23-001-02 Date: 020111 Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5513 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 5514 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Water Dam Front Door Panel: Service and Repair Water Dam WATER DAM REMOVAL 1. Remove door trim panel. 2. Remove door speaker, if equipped. CAUTION: Do not use dirty hands or lint type gloves when removing the watershield, adhesive bead will be ruined. Fig. 39 3. Peel watershield and adhesive away from the door inner panel. Start in one corner, carefully working towards the opposite corner. (Fig. 39). 4. Store watershield flat, adhesive side up, covering with wax paper or similar if available to prevent contaminating the adhesive bead. INSTALLATION 1. Insure that the adhesive bead is not broken, so the complete perimeter of the door seal will be maintained. Replace any loose/damaged adhesive with butyl sealer or similar. If repair is not possible, replace with a new watershield. 2. Place the watershield into position using the two depressions that locate into the corresponding holes in the door inner panel. (Fig. 39). 3. Firmly press the adhesive around the perimeter of the door insure complete sealing. Make sure to properly route wiring and linkages. 4. Install door speaker, if equipped. 5. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Water Dam > Page 5517 Front Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Roll door glass down. 2. Disengage two clips attaching speaker grille to door trim panel. They are at the front of the grille, one near the top, and the other one at the bottom. Fig. 29 3. Remove three large washer-headed screws surrounding the speaker (Fig. 29). Fig. 30 4. Remove access cover at front of door trim panel. Remove by prying at its rear edge (Fig. 30). 5. Remove red courtesy reflector from lower tail or door. Disengage by prying at screwdriver notch at bottom of reflector. 6. Remove flag trim panel from door by prying off at two attachment clips points (Fig. 30). 7. Remove seven screws attaching door trim panel to door: (Fig. 29) and (Fig. 30). a. One screw is located at lower rear screw pocket. b. Three screws located along the bottom of door. c. One screw located inside handle opening. d. One screw located at the upper front. e. One screw in the pull cup. 8. Disengage two hidden clips attaching at the rear of the trim panel, by prying off at two attachment clip points. 9. Lift trim panel upward and away from door, disengage trim panel from upper retainer channel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Water Dam > Page 5518 10. Disengage clip attaching latch linkage to back door handle. 11. Disconnect electrical connectors as necessary, including lower foot light, If equipped. 12. Remove door trim panel from door. INSTALLATION 1. Position door trim panel near to door. 2. Connect electrical connectors as necessary, including foot light, if so equipped. 3. Engage clip attaching latch linkage to inside door handle. 4. Lift the door trim slightly to get the lock knob into its bezel opening on the panel. 5. Place front portion of upper trim strip flange into retainer channel, while seating white forward locator pin into mating hole in sheet metal at front of door. 6. Drive screw into forward locator cup. 7. With rear of panel slightly lifted, engage remainder of trim strip flange into retainer channel, working from front to back, pressing down firmly. 8. Engage two hidden clips attaching rear of door trim to their mating (green) grommet holes in the door. Press the rear of the panel firmly in toward the door, listening for engagement clicking sounds at BOTH of the clips. 9. Install seven screws attaching door trim panel to door: (Fig. 29) and (Fig. 30). a. One screw in the pull cup. b. One screw located inside handle opening. c. One screw located at the upper front. d. One screw is located at lower rear screw pocket. e. Three screws located along the bottom of door. 10. Snap screw covers closed. 11. Install three large washer headed screws surrounding the speaker (Fig. 29). 12. Install speaker grille by first engaging rear edge hinge flaps to mating slots, then pressing grille on to seat the two clips at front. 13. Install red courtesy reflector by first engaging rear edge hinge flaps to mating slots, then snap front in to position. 14. Install access cover at front of door trim panel. First engage slots at front, then snap in at rear edge (Fig. 30). 15. Place flag trim panel into position and engage clips (Fig. 30). 16. Close door window. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments DOOR PIN ASSEMBLY ADJUSTMENTS 1. Open the door and mark the position of the door pin receiver using a grease pencil or equivalent. 2. Put clay or other suitable substance, into the hole of the door pin receiver. Fig. 38 3. Lightly close the door to indent the clay with the door pin. (Fig. 38). NOTE: The alignment of the pin indentation to the receiver cup should be centered. 4. If the door pin receiver needs to go for/aft in the car, remove the door pin receiver and add/remove the pin receiver shims if necessary. NOTE: 3 mm total of shims are standard, but this can vary depending on the fit of the door. Door pin shims are available in 1 and 0.5 mm sizes. 5. For up/down movement, loosen the receiver bolts and move the door pin up or down if necessary. 6. Check alignment and readjust if required and tighten the bolts to 12 N.m (9 ft.lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Latch Striker Front Door Striker: Service and Repair Latch Striker LATCH STRIKER REMOVAL 1. Mark outline of door latch striker on B-pillar to aid in installation. Fig. 25 2. Remove screws attaching door latch striker to B-pillar (Fig. 25). 3. Remove latch striker from vehicle. NOTE: Be sure to check for any shims between door latch striker and B-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation. INSTALLATION 1. Position door latch striker and any shims on vehicle. 2. Loosely install screws attaching latch striker to B-pillar. 3. Align latch striker to marks on B-pillar made previously. 4. Tighten all fasteners. 5. Verify door fit and operation. Adjust door latch striker as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Latch Striker > Page 5524 Front Door Striker: Service and Repair Door Pin Assembly DOOR PIN ASSEMBLY REMOVAL Fig. 36 1. Open the door, remove the door pin bolts and remove the door pin. (Fig. 36). Fig. 37 2. Remove the receiver bolts and remove the receiver and shims if equipped. (Fig. 37). INSTALLATION 1. Install the door pin assembly and install the bolts. 2. Tighten the bolts to 12 N.m (9 ft.lbs.). 3. Install the receiver and the shims if equipped. 4. Install the receiver bolts and tighten to 12 N.m (9 ft.lbs.). 5. Adjust the door pin assembly and receiver. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal Front Door Weatherstrip: Service and Repair A - Pillar Seal A - PILLAR SEAL REMOVAL 1. Open front door. 2. Using a fork-type tool (C-4829), disengage push-in fasteners attaching A-pillar seal to A-pillar. 3. Remove A-pillar seal from vehicle. INSTALLATION 1. Place A-pillar seal into position. 2. Install push-in fasteners attaching A-pillar seal to A-pillar. 3. Close front door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5529 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. Fig. 5 2. Remove two screws (Fig. 5). 3. Position splash shield out of way. 4. Starting at the bottom of the A-pillar, pull the drip rail weatherstrip from the windshield side molding. 5. Pull the drip rail weatherstrip from the roof rail pinch flange above door openings. Fig. 6 6. Remove drip rail weatherstrip from vehicle (Fig. 6). INSTALLATION 1. Place drip rail weatherstrip into position. 2. Push drip rail weatherstrip on to the roof rail pinch flange above door openings. 3. Starting at the bottom of the A-pillar, push the drip rail weatherstrip on to the windshield side molding. 4. Position splash shield. 5. Install two screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5530 6. Close front and rear doors. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5531 Front Door Weatherstrip: Service and Repair A - Pillar Weatherstrip Retainer and Molding A - PILLAR WEATHERSTRIP RETAINER AND MOLDING REMOVAL 1. Partially raise convertible top. 2. Remove header and A-pillar weatherstrip as necessary to gain access. Fig. 1 3. Remove screws holding A-pillar weatherstrip retainer to A-pillar (Fig. 1). 4. Remove retainer from vehicle. 5. Remove screws attaching A-pillar molding to A-pillar. 6. Remove A-pillar molding from vehicle. INSTALLATION 1. Clean A-pillar of any seal material residue. 2. Position A-pillar molding to vehicle. 3. Install screws attaching A-pillar molding to A-pillar. 4. Position A-pillar weatherstrip retainer on A-pillar. 5. Install screws attaching retainer to A-pillar. Install middle screw first and then work outward. 6. Install header and A-pillar weatherstrip. 7. Lower and secure convertible top. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5532 Front Door Weatherstrip: Service and Repair Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5533 Front Door Weatherstrip: Service and Repair A - Pillar Seal A - PILLAR SEAL REMOVAL 1. Open front door. 2. Using a fork-type tool (C-4829), disengage push-in fasteners attaching A-pillar seal to A-pillar. 3. Remove A-pillar seal from vehicle. INSTALLATION 1. Place A-pillar seal into position. 2. Install push-in fasteners attaching A-pillar seal to A-pillar. 3. Close front door. Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. Fig. 5 2. Remove two screws (Fig. 5). 3. Position splash shield out of way. 4. Starting at the bottom of the A-pillar, pull the drip rail weatherstrip from the windshield side molding. 5. Pull the drip rail weatherstrip from the roof rail pinch flange above door openings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5534 Fig. 6 6. Remove drip rail weatherstrip from vehicle (Fig. 6). INSTALLATION 1. Place drip rail weatherstrip into position. 2. Push drip rail weatherstrip on to the roof rail pinch flange above door openings. 3. Starting at the bottom of the A-pillar, push the drip rail weatherstrip on to the windshield side molding. 4. Position splash shield. 5. Install two screws. 6. Close front and rear doors. A - Pillar Weatherstrip Retainer and Molding A - PILLAR WEATHERSTRIP RETAINER AND MOLDING REMOVAL 1. Partially raise convertible top. 2. Remove header and A-pillar weatherstrip as necessary to gain access. Fig. 1 3. Remove screws holding A-pillar weatherstrip retainer to A-pillar (Fig. 1). 4. Remove retainer from vehicle. 5. Remove screws attaching A-pillar molding to A-pillar. 6. Remove A-pillar molding from vehicle. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5535 1. Clean A-pillar of any seal material residue. 2. Position A-pillar molding to vehicle. 3. Install screws attaching A-pillar molding to A-pillar. 4. Position A-pillar weatherstrip retainer on A-pillar. 5. Install screws attaching retainer to A-pillar. Install middle screw first and then work outward. 6. Install header and A-pillar weatherstrip. 7. Lower and secure convertible top. Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Quarter Panel Weatherstrip QUARTER PANEL WEATHERSTRIP REMOVAL 1. Remove door sill trim panel. 2. Remove push in fasteners holding weatherstrip to B-pillar. 3. Remove weatherstrip from door opening flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5536 Fig. 17 4. Remove quarter panel weatherstrip from vehicle (Fig. 17). INSTALLATION 1. Position panel weatherstrip onto vehicle. 2. Install weatherstrip to door opening flange. 3. Install push in fasteners attaching weatherstrip to B-pillar. 4. Install door sill trim panel. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL 1. Open door. 2. Using fork tool C-4829, disengage push in fasteners attaching secondary sill weatherstrip to bottom of door. Fig. 23 3. Remove secondary sill weatherstrip from vehicle (Fig. 23). INSTALLATION 1. Place secondary sill weatherstrip into position. 2. Install push in fasteners attaching secondary sill weatherstrip to bottom of door. 3. Close door. Side View Mirror Flag / Door Glass Channel Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5537 SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 5538 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5544 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5545 Front Door Window Glass Weatherstrip: Service and Repair Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5546 Front Door Window Glass Weatherstrip: Service and Repair Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5547 INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5548 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5549 Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5550 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5551 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5552 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL Fig. 10 1. Remove screw attaching rearward end of molding to front door (Fig. 10). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5553 Fig. 11 2. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 11). 3. Lift up on the rear of the belt molding and pull rearward to remove. INSTALLATION 1. Place belt molding in position. 2. Using your hand press downward at each clip attaching belt molding to door till in position. 3. Install screw attaching rearward end of molding to front door. Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. 2. Remove bolt attaching bottom of front lower run channel to inner door panel. 3. Pull glass run weatherstrip from door glass opening frame. Fig. 8 4. Remove lower run channel through opening at top of door (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5554 INSTALLATION 1. Install lower run channel through opening at top of door. 2. Push glass run weatherstrip to door glass opening frame. 3. Install bolt attaching bottom of front lower run channel to inner door panel. 4. Install door glass. Door Glass Inner Belt Stabilizer DOOR GLASS INNER BELT STABILIZER REMOVAL 1. Remove door trim panel. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Remove nut attaching inner belt stabilizer to door panel. Fig. 17 4. Remove inner belt stabilizer from door (Fig. 17). INSTALLATION 1. Place inner belt stabilizer into position. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Install nut attaching inner belt stabilizer to door panel. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. 4. Install door trim panel. Door Inner Belt Weatherstrip DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5555 Fig. 3 2. Pull upward on rear edge of inner belt weatherstrip (Fig. 3). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Start leading edge of weatherstrip on vehicle. 2. Press the leading edge of the weatherstrip forward until edge is tight to the mirror flag. 3. Press weatherstrip into position on door panel. 4. Install door trim panel. Header / A - Pillar Weatherstrip HEADER / A - PILLAR WEATHERSTRIP REMOVAL 1. Partially raise convertible top. 2. Remove inside rear view mirror. 3. Remove sun visors. 4. Remove header trim panel. 5. Remove both door sill trim panels. Fig. 12 6. Remove nuts holding header and A-pillar weatherstrip at upper corners of windshield (Fig. 12). 7. Remove push in fasteners at lower corners of windshield holding weatherstrip to A-pillar. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5556 8. Remove header and A-pillar weatherstrip from vehicle. 9. Clean any residual seal material from header panel. INSTALLATION Fig. 13 CAUTION: Ensure that the butyl patch and butyl rope at each corner of the windshield is present and in good condition (Fig. 13). The butyl is critical for the water management system. Replace as necessary. 1. Install new L foam starting at upper screw on A-pillar retainer. Fig. 14 2. Install new L foam starting at upper screw on A-pillar retainer (Fig. 14). 3. Position header and A-pillar weatherstrip on vehicle. 4. Secure weatherstrip into retainers at header and A-pillar. 5. Install nuts at upper corners of windshield. 6. Install push in fasteners at lower corners of windshield. 7. Install door sill trim panels. 8. Install header trim panel. 9. Install sun visors. 10. Install inside rear view mirror. 11. Lower and secure convertible top. Outer Door Belt Weatherstrip Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 5557 OUTER DOOR BELT WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 16 2. Remove screws attaching outer belt weatherstrip to outer door panel (Fig. 16). 3. Remove outer belt weatherstrip from the vehicle. INSTALLATION 1. Position outer belt weatherstrip on vehicle. 2. Install screws to hold outer weatherstrip to outer door panel. 3. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove door trim panel. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector. 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. Front Door Regulator 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator in door through access hole in door panel. 2. Position regulator on door panel. 3. Tighten bolts attaching regulator to door panel. 4. Position screw and bolt heads in keyhole slots in door panel. 5. Tighten screw attaching regulator scissor channel to door panel. 6. Connect power window motor wire electrical connector. 7. Position glass in regulator roller channel. 8. Tighten fasteners attaching door glass to roller channel. 9. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 5562 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector. 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. Fig. 33 7. Remove regulator from door panel (Fig. 33). 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. REMOVAL - JR-27 (Convertible) ONLY 1. Remove door trim panel and water shield. 2. Disconnect wire connector to power window motor. 3. Remove nuts attaching regulator lift channel to door glass. 4. Secure door glass in upward position. 5. Mark position of rear bolt of roller channel to inner door panel to aid in installation. 6. Remove bolt attaching rear of roller channel to door panel. 7. Loosen bolt attaching front of roller channel to door panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 5563 Fig. 34 8. Remove roller channel from door panel (Fig. 34). 9. Loosen bolts attaching window regulator to inner door panel reinforcement. 10. Remove bolt heads from key hole slots in inner door panel. 11. Remove window regulator through large hole in inner door panel (Fig. 34). 12. Remove power window motor from regulator. INSTALLATION 1. Position regulator in door through access hole in door panel. 2. Position regulator on door panel. 3. Tighten bolts attaching regulator to door panel. 4. Position screw and bolt heads in keyhole slots in door panel. 5. Tighten screw attaching regulator scissor channel to door panel. 6. Connect power window motor wire electrical connector. 7. Position glass in regulator roller channel. 8. Tighten fasteners attaching door glass to roller channel. 9. Install door trim panel. INSTALLATION - JR-27 (Convertible) ONLY 1. Install power window motor on regulator. 2. Move window regulator into position in door and engage bolt heads into key hole slots in inner door panel reinforcement and tighten bolts. 3. Install roller channel to door panel. 4. Install bolt at rear of roller channel. Make sure that bolt is aligned to mark on inner door panel made previously. 5. Tighten front and rear bolts of roller channel. 6. Install nuts attaching regulator lift channel to door glass. 7. Verify glass fit and operation. Adjust door glass, if necessary. 8. Connect wire connector to power window motor. 9. Install door water dam and trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove rear door trim panel. 2. Close door glass. 3. Disengage clip holding linkage to outside handle. Fig. 7 4. Remove linkage from outside handle (Fig. 7). 5. Remove nuts holding outside handle to outer door panel. 6. Remove outside door handle from vehicle. INSTALLATION 1. Position outside door handle from vehicle. 2. Install nuts attaching outside handle to outer door panel. 3. Connect linkage to outside handle (Fig. 7). 4. Connect clip holding linkage to outside handle. 5. Replace the clips attaching trim panel to perimeter of door. 6. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair HINGE REMOVAL 1. Remove the door. 2. Mark hinge attachment locations with a grease pencil or other suitable device to aid installation. Fig. 8 3. Remove the bolts and nuts and remove the hinges (Fig. 8). INSTALLATION 1. If necessary, paint new door hinge prior to installation. 2. Loosely install bolts attaching hinge to lower B-pillar. 3. Door on a suitable lifting device position door to the hinge on vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 5572 Fig. 9 4. Loosely install nuts attaching hinge to door end frame (Fig. 9). 5. Align hinge to marks made previously and tighten bolts and nuts to 28 N.m (20 ft.lbs.) torque. 6. Install bolts attaching door check strap to lower A-pillar. 7. Verify door fit and operation. Adjust door hinge for proper door alignment, as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair LATCH REMOVAL 1. Remove rear door trim panel. 2. Close door glass. 3. Remove lower rear run channel. 4. Disengage clips attaching linkage rods to door latch. Fig. 10 5. Remove linkage rods from latch (Fig. 10). 6. Remove screws attaching latch to door end frame. 7. Remove latch from door. INSTALLATION CAUTION: Do not close door before adjusting the door latch, door may fail to open. 1. Place rear door latch into position. 2. Install screws attaching latch to door end frame. 3. Install linkage rods from latch. 4. Engage clips attaching linkage rods to door latch. 5. Install lower rear run channel. 6. Open door glass. 7. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair REAR CHECK STRAP REMOVAL 1. Remove rear door trim panel. 2. Remove the watershield as necessary to gain access to the latch. Refer to Rear Door Panel. 3. Remove bolt attaching check strap to hinge pillar. Fig. 2 4. Remove bolt attaching check strap to inner door panel (Fig. 2). 5. Remove bolts attaching check strap to door end frame. 6. Remove check strap from vehicle. INSTALLATION 1. Place check strap into position. 2. Install bolts attaching check strap to door end frame. 3. Install bolt attaching check strap to inner door panel. 4. Install bolt attaching check strap to hinge pillar. 5. Position the watershield back. 6. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Watershield Rear Door Panel: Service and Repair Watershield WATERSHIELD REMOVAL 1. Remove door trim panel. 2. Remove door speaker, if equipped. CAUTION: Do not use dirty hands or lint type gloves when removing the watershield, adhesive bead will be ruined. 3. Peel watershield and adhesive away from the door inner panel. Start in one corner, carefully working towards the opposite corner. 4. Store watershield flat, adhesive side up, covering with wax paper or similar if available to prevent contaminating the adhesive bead. INSTALLATION 1. Insure that the adhesive bead is not broken, so the complete perimeter of the door seal will be maintained. Replace any loose/damaged adhesive with butyl sealer or similar. If sealing repair is not possible, replace with a new watershield. Fig. 39 2. Place the watershield into position using the two depressions that locate into the corresponding holes in the door inner panel. (Fig. 39) 3. Firmly press the adhesive around the perimeter of the door insure complete sealing. Make sure to properly route wiring and linkages. 4. Install door speaker, if equipped. 5. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Watershield > Page 5583 Rear Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Open rear door. 2. Lower window. Fig. 12 3. Open the screw cap from bottom of arm rest pull cup and remove the screw (Fig. 12). 4. Open the screw cap from behind door latch handle and remove the screw. 5. Remove the screws along the bottom of the trim panel. 6. Using a trim stick C-4755 or equivalent, disengage clips holding perimeter of trim panel to rear door. 7. Remove trim panel from inner belt weatherstrip at top of door. 8. Disconnect wiring harness at door opening. 9. Remove top of trim panel from door. Fig. 13 10. Disengage clip holding linkage to latch handle (Fig. 13). 11. Remove linkage from latch handle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Watershield > Page 5584 12. Lift trim up and off lock button. 13. Remove rear door trim panel from vehicle. INSTALLATION 1. Position rear door trim panel on vehicle. 2. Connect linkage to latch handle. 3. Engage clip holding linkage to latch handle. 4. Connect wiring harness at door opening. 5. Position the lock knob through the trim panel and engage trim panel from inner belt weatherstrip at top of door. 6. Align the clips attaching perimeter of trim panel to rear door with the grommets and engage. 7. Install screws attaching door trim panel to door. (Fig. 12) 8. Install screw holding door latch handle to door and close the screw cap. 9. Install screw from bottom of arm rest pull cup and close the screw cap. 10. Connect battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Mark outline of door latch striker on C-pillar to aid installation. Fig. 11 2. Remove screws attaching door latch striker to C-pillar (Fig. 11). 3. Remove door latch striker from vehicle. NOTE: Be sure to check for any shims between door latch striker and C-pillar. If any shims are found, they must be reinstalled with the new door latch striker to maintain proper door operation. INSTALLATION 1. Position door latch striker and any shims on vehicle. 2. Loosely install screws attaching latch striker to C-pillar. 3. Align latch striker to marks on C-pillar made previously. 4. Tighten all fasteners. 5. Verify door fit and operation. Adjust door latch striker as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Front And Rear Door Opening Weatherstrip Rear Door Weatherstrip: Service and Repair Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Front And Rear Door Opening Weatherstrip > Page 5592 Rear Door Weatherstrip: Service and Repair Rear Door B - Pillar Door Seal REAR DOOR B - PILLAR DOOR SEAL REMOVAL 1. Using a suitable heat gun, warm seal to approximately 100 degrees F to ease adhesive separation. Fig. 18 2. Peel B-pillar seal from upper door frame, top to bottom (Fig. 18). 3. Clean adhesive residue from door frame. INSTALLATION 1. If original seal is reused, clean adhesive residue from back of seal. 2. Apply body side molding tape to back of seal. 3. Peel protective paper from back of tape. 4. Place cutout in seal around screw head at bottom of seal location. 5. Align seal to edge of door frame. 6. Press adhesive onto door frame. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove rear door trim panel. 2. Pull upward at front end of inner belt weatherstrip. Fig. 20 3. Remove inner belt weatherstrip from vehicle (Fig. 20). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Push downward on the inner belt weatherstrip. 3. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 5598 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL Fig. 21 1. Remove screw attaching forward end of molding to rear door (Fig. 21). 2. Disengage clips attaching rearward end of belt molding to rear door. Fig. 22 3. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 22). 4. Remove belt molding from door. INSTALLATION 1. Place belt molding into position. 2. Push or tap downward at each clip attaching belt molding to door. 3. Engage clips attaching rearward end of belt molding to rear door. 4. Install screw attaching forward end of molding to rear door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 5599 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 19 2. Pull glass run weatherstrip from door glass opening frame (Fig. 19). INSTALLATION 1. Install glass run weatherstrip to door glass opening frame. 2. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove door waterdam. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector, if equipped. Rear Door Regulator 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator on door panel through access hole in door panel. 2. Tighten bolts attaching regulator to door panel. 3. Install screw and bolt heads on scissor channel to keyhole slots in door panel. 4. Tighten screw attaching regulator scissor channel to door panel. 5. Connect power window motor wire connector, if equipped. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door waterdam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 5604 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door waterdam. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector, if equipped. Fig. 14 4. Loosen screw attaching regulator scissor channel to door panel (Fig. 14). 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator on door panel through access hole in door panel. 2. Tighten bolts attaching regulator to door panel. 3. Install screw and bolt heads on scissor channel to keyhole slots in door panel. 4. Tighten screw attaching regulator scissor channel to door panel. 5. Connect power window motor wire connector, if equipped. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door waterdam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open fuel filler door. Fig. 7 2. Remove the two torx screws (Fig. 7). 3. Remove fuel filler door from vehicle. INSTALLATION 1. Place fuel filler door into position. 2. Install the two torx screws. 3. Ensure that door operates properly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE REMOVAL 1. Support hood on the side that requires hinge replacement. 2. Mark hinge attachment locations with a grease pencil or other suitable device to aid installation. 3. Remove cowl cover. 4. Remove bolts attaching hood to hinge. 5. Remove bolts attaching hood hinge to load beam inner and remove hinge from vehicle. INSTALLATION 1. If necessary, paint new hinge before installation. 2. Place hinge in position on vehicle. 3. Install bolts to attach hood hinge to load beam inner. 4. Install bolts to attach hood to hinge. 5. Align all marks and secure bolts. 6. Tighten bolts to 28 N.m (20 ft.lbs.) torque. 7. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. 8. Install cowl cover. 9. Verify hood latch operation. Adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair LATCH REMOVAL 1. Release hood latch and open hood. 2. Support hood on prop rod. 3. Mark outline of hood latch on radiator support crossmember with a grease pencil or other suitable device to aid installation. Fig. 3 4. Remove nuts attaching hood latch to upper radiator support crossmember (Fig. 3). 5. Remove hood latch from vehicle. Fig. 4 6. Disengage remote release cable from hood latch (Fig. 4). INSTALLATION 1. Engage remote release cable into hood latch (Fig. 4). 2. Position hood latch on vehicle. 3. Install nuts attaching hood latch onto upper radiator support crossmember. 4. Tighten nut to 28 N.m (20 ft.lbs.) torque. 5. Verify operation. Adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE REMOVAL 1. Remove hood latch. 2. Remove left front cowl trim panel. Fig. 5 3. Remove screws attaching hood release handle to inner cowl panel (Fig. 5). Fig. 6 4. Release clips attaching hood release cable to left inner frame rail (Fig. 6). 5. Disengage rubber grommet at lower dash panel. 6. Disengage push-in fastener attaching hood release cable to dash panel. 7. Remove hood release cable from vehicle. INSTALLATION 1. Route hood release cable through hole in lower dash panel and along inner frame rail. 2. Engage rubber grommet to lower dash panel. 3. Engage push-in fastener attaching hood release cable to lower dash panel. 4. Install screws attaching hood release cable handle to inner cowl panel. 5. Tighten screws to 1.8 N.m (16 in.lbs.) torque. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 5618 6. Install left front cowl trim panel. 7. Engage hood release cable into clips along inner frame rail (Fig. 6). 8. Install hood latch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair PROP ROD REMOVAL 1. Release hood latch and open hood. CAUTION: Do not place prop-rod or substitute against outer hood panel, damage to exterior finish will result. 2. Prop hood open using a length of wooden dowel rod, ex (Broomstick). Fig. 7 3. Disengage prop-rod from retainer attaching prop-rod to radiator closure panel (Fig. 7). 4. Remove prop-rod from vehicle. INSTALLATION CAUTION: Do not place prop-rod or substitute against outer hood panel, damage to exterior finish will result. 1. Place prop-rod into position. 2. Engage prop-rod from retainer attaching prop-rod to radiator closure panel. 3. Remove temporary hood prop rod. 4. Close hood. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair ADJUSTER BUMPER REMOVAL 1. Release hood latch and open hood. 2. Rotate hood adjuster bumper counterclockwise. Fig. 1 3. Remove hood adjuster bumper from headlamp reinforcement (Fig. 1). INSTALLATION Fig. 2 1. Ensure that hood overslam bumpers proper position (Fig. 2). 2. Start hood adjuster bumper into headlamp reinforcement (Fig. 1). 3. Rotate hood adjuster bumper clockwise. Adjust hood adjuster bumper to achieve a hood height that is flush across the top surfaces along fenders. 4. Close hood. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair HINGE REMOVAL 1. Open decklid. 2. Mark outline of hinge on quarter panel trough and inside of decklid to aid installation. 3. Place a padded block between the deck panel and the decklid. Fig. 2 4. Remove the gas prop-rod lock caps (Fig. 2). 5. Remove prop-rod from mounting studs. 6. Remove bolts attaching hinge to decklid. 7. Place decklid against padded block and hold it steady. 8. Remove bolts attaching hinge to quarter panel trough. 9. Remove hinge from vehicle. INSTALLATION 1. Place hinge in the mark outline of hinge on quarter panel trough and inside of decklid to aid in positioning hinge. 2. Install hinge to vehicle. 3. Install bolts attaching hinge to quarter panel trough. 4. Tighten bolts to 22.5 N.m (200 in.lbs.) torque. 5. Place decklid against padded block and hold it steady. 6. Install bolts attaching hinge to decklid. 7. Tighten bolts to 22.5 N.m (200 in.lbs.) torque. 8. Install prop-rod to mounting studs. 9. Install the gas prop-rod lock caps. 10. Remove the padded block between the deck panel and the decklid. 11. Close decklid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair DECKLID LATCH REMOVAL 1. Release decklid latch and open decklid. 2. Mark outline of decklid latch on decklid to aid in installation. Fig. 3 3. Disconnect wire connectors to remote release solenoid, if so equipped (Fig. 3). 4. Remove bolts attaching decklid latch to decklid. 5. Remove decklid latch from vehicle. INSTALLATION 1. Position decklid latch on vehicle. 2. Loosely install bolts attaching decklid latch to decklid. 3. Tighten bolts to 12 N.m (106 in.lbs.) torque. 4. Align decklid latch to marks made previously on decklid and tighten bolts. 5. Connect wire connectors to remote release solenoid, if so equipped. 6. Verify fit of decklid to deck panel and decklid latch operation. Adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Service and Repair Trunk / Liftgate Latch Release Cable: Service and Repair EMERGENCY RELEASE CABLE REMOVAL Fig. 6 1. Remove the decklid latch cover (Fig. 6). Fig. 7 2. Unclip cable and handle assembly (Fig. 7). INSTALLATION 1. Clip emergency release cable onto the latch. 2. Install the decklid latch cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair DECKLID LOCK CYLINDER REMOVAL 1. Release decklid latch and open decklid. 2. Remove decklid latch. Fig. 5 3. Remove clip attaching decklid lock cylinder to security alarm switch, if so equipped (Fig. 5). 4. Remove security alarm switch, if so equipped. 5. Remove clip attaching decklid lock cylinder to decklid. 6. Remove decklid lock cylinder from vehicle. INSTALLATION 1. Position decklid lock cylinder on vehicle. 2. Install clip holding decklid lock cylinder to decklid. 3. Install security alarm switch, if so equipped. 4. Install clip attaching decklid lock cylinder to security alarm switch, if so equipped. 5. Install decklid latch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair GAS PROP REMOVAL 1. Open decklid. Fig. 2 2. Remove the gas prop-rod lock caps (Fig. 2). 3. Remove prop-rod from mounting studs. INSTALLATION 1. Install prop-rod to mounting studs. 2. Install the gas prop-rod lock caps. 3. Close decklid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5644 Decklid Release Solenoid/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5645 Trunk / Liftgate Solenoid: Testing and Inspection 1. Confirm motor lead wire is connected and 10 volts or more are available at solenoid. 2. Provide proper ground through latch mounting screws. 3. Remove latch and examine plunger. Plunger should spring back when pressed. 4. Insure that solenoid plunger travel is adequate approximately 16 mm (5/8 inch). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 5646 Trunk / Liftgate Solenoid: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable remote terminal from the remote battery post. 2. Raise deck lid to the full up position. 3. Remove latch cover push pins then remove cover. 4. Remove two retaining nuts to latch and motor, then remove latch and motor assembly. INSTALLATION 1. Install the latch and motor assembly. Install the two retaining nuts. 2. Install latch cover and push pins. 3. Close the deck lid. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair DECKLID LATCH STRIKER REMOVAL 1. Release decklid latch and open decklid. 2. Mark outline of decklid latch striker on rear closure panel to aid in installation. Fig. 4 3. Remove bolts attaching decklid latch striker to rear closure panel (Fig. 4). 4. Remove striker from vehicle. INSTALLATION 1. Position striker in vehicle. 2. Loosely install bolts attaching decklid latch striker to rear closure panel. 3. Align decklid latch striker to marks made previously on rear closure panel. 4. Tighten bolts to 12 N.m (106 in.lbs.) torque. 5. Verify fit of decklid to deck panel and operation of decklid latch. Adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Decklid Release Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 5653 Trunk / Liftgate Switch: Service and Repair REMOVAL 1. Open hood and disconnect the negative battery cable remote terminal from the remote battery post. 2. Remove left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Removal. 3. Disconnect the wire connector. 4. Pinch four tabs around side of decklid release switch on the rear side of the left lower instrument panel trim, and push switch through opening. INSTALLATION 1. Position the decklid release switch over opening of the left lower instrument panel trim, and push switch through opening. 2. Connect the wire connector. 3. Install the left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair DECKLID OPENING WEATHERSTRIP REMOVAL 1. Release decklid latch and open decklid. 2. Disconnect and isolate the battery negative cable. 3. Remove four push pins and remove the latch cover. 4. Disconnect the three harness electrical connectors and remove the ground strap screw. 5. Tape the wires together and tape in one chase wire. 6. Route the wires through the decklid. Fig. 2 7. Pull decklid opening weatherstrip from decklid opening flange (Fig. 2). 8. Remove decklid opening weatherstrip from vehicle. INSTALLATION 1. Position decklid opening weatherstrip on vehicle (Fig. 2). 2. Starting at center weatherstrip over decklid latch striker and press weatherstrip firmly onto decklid opening flange. Ensure that the weatherstrip seats properly along the entire length. 3. Route the wire harness through the decklid and remove the tape and chase wire. 4. Connect the three harness connectors and install the ground strap screw. 5. Install the latch cover and install the four push pins. 6. Connect the battery negative cable. 7. Verify decklid operation and sealing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES REMOVAL - FOAM TAPE 1. Mark reference points before removing. 2. Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. 3. Using a trim stick C 4755 or equivalent, gently pry up at corners and remove. 4. Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover. INSTALLATION - FOAM TAPE 1. Clean panel surface with isopropyl alcohol. 2. Align badging to reference points. 3. Install and press securely to full adhesive contact. 4. Clean away any reference points. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL COVER REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 4 3. Remove screws attaching cowl cover to cowl (Fig. 4). 4. Remove the seal, cowl screen to hood inner panel. 5. Remove clips attaching cowl cover to cowl plenum under hood to cowl bulb seal. 6. Remove cowl cover from vehicle. INSTALLATION 1. Position cowl cover to vehicle. 2. Install clips attaching cowl cover to cowl plenum. 3. Install the seal, cowl screen to hood inner panel. 4. Install screws attaching cowl cover to cowl. 5. Install windshield wiper arms. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS REMOVAL 1. Warm the affected body side molding and body metal to approximately 38 degrees C (100 degrees F) using a suitable heat lamp or heat gun. Fig. 3 2. Pull body side molding from vehicle (Fig. 3). 3. Remove adhesive tape residue from surface of vehicle. INSTALLATION 1. If molding is to be reused, remove tape residue from molding. Clean back of molding with Mopar(R) Super Kleen solvent or equivalent. Wipe molding dry with lint free cloth. Apply new body side molding (two sided adhesive) tape to back of molding. 2. Clean body surface with Mopar(R) Super Kleen solvent or equivalent. Wipe surface dry with a lint free cloth. 3. Apply a length of masking tape on the body parallel to the top edge of the molding to use as a guide, if necessary. 4. Remove protective cover from tape on back of molding. Apply molding to body below the masking tape guide. 5. Remove masking tape guide. Heat body metal and body side molding to approximately 38 degrees C (100 degrees F) using a suitable heat lamp or heat gun. 6. Firmly press body side molding to body surface to insure adhesion. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Left Front Wheelhouse Splash Shield Front Fender Liner: Service and Repair Left Front Wheelhouse Splash Shield LEFT FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Remove left front wheel. Fig. 11 2. Remove the seven push pin fasteners, the three screws, and remove the transmission splash shield (Fig. 11). Fig. 10 3. Remove the fender trim (Fig. 10). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Left Front Wheelhouse Splash Shield > Page 5673 Fig. 12 4. Remove the four push pin fasteners and remove the wheelhouse splash shield (Fig. 12). INSTALLATION 1. Install the wheelhouse splash shield and install the 4 push pin fasteners. 2. Install the transmission splash shield, the seven push pin fasteners, and the three screws. 3. Install the fender trim and the trim screws. 4. Install the wheel assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Left Front Wheelhouse Splash Shield > Page 5674 Front Fender Liner: Service and Repair Right Front Wheelhouse Splash Shield RIGHT FRONT WHEELHOUSE SPLASH SHIELD REMOVAL Fig. 10 1. Remove the screws and remove the fender trim (Fig. 10). 2. Remove right front wheel. Fig. 14 3. Remove the eight push pin fasteners, two screws and remove the splash shield. (Fig. 14). INSTALLATION 1. Install the wheelhouse splash shield and install the eight push pin fasteners and two screws. 2. Install the wheel assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Remove the wheel. Fig. 13 2. Remove the six push pin fasteners, two screws and remove the wheelhouse splash shield (Fig. 13). INSTALLATION 1. Position the splash shield and install the six push pin fasteners and two screws. 2. Install the wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair FRONT SUSPENSION CROSS-MEMBER REMOVAL 1. Hoist and support vehicle on safety stands. Refer to Vehicle Lifting. 2. Place a suitable lifting device under front suspension crossmember. 3. Remove bolts attaching suspension strut to the lower control arm. 4. Disengage lower ball joints from lower control arms. Fig. 13 5. Remove 3 bolts attaching rear engine mount to crossmember (Fig.13). If equipped, manual transmission bracket will come down when these bolts are removed. It may be necessary to loosen damper mounting bolt at engine structural collar to allow bracket and damper to swing down sufficiently (Fig.13). 6. Remove bolts attaching front of suspension crossmember to frame rails under upper control arms. 7. Loosen bolts attaching rear of suspension cross-member to frame rail torque boxes. 8. Allow the front of the suspension crossmember to swing away from the frame rails. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5684 Fig. 14 9. Remove bolts attaching steering gear to top of suspension crossmember (Fig. 14). CAUTION: Do not allow steering gear to hang by the pressure or return hoses, damage to hoses can result. 10. Using mechanics wire, tie steering gear to structure above. 11. Raise crossmember back into position. 12. Remove bolts attaching rear of crossmember to frame rail torque boxes. 13. Lower front suspension crossmember away from bottom of vehicle. INSTALLATION 1. Raise front suspension crossmember into position on vehicle. 2. Loosely install bolts attaching rear of cross-member to frame rail torque boxes. 3. Lower crossmember and install bolts attaching steering gear to top of suspension crossmember. 4. Raise crossmember into position. 5. Tighten bolts holding rear of suspension cross-member to frame rail torque boxes. 6. Install bolts attaching front of suspension crossmember to frame rails under upper control arm. 7. Engage lower ball joint to lower control arms. 8. Install 3 bolts attaching rear engine mount to crossmember (Fig. 13). If equipped, make sure manual transmission bracket is positioned in place before installing bolts (Fig. 13). Tighten bolts to 65 N.m (48 ft.lbs.) torque. 9. Install bolts attaching suspension strut to lower control arm. 10. Lower vehicle. 11. After assembly is complete, check front end alignment and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation Rear Cross-Member: Description and Operation REAR SUSPENSION CROSS-MEMBER DESCRIPTION This vehicle is equipped with a bolt in type rear suspension crossmember. The crossmember on this vehicle is the same for all of the optional suspensions that are available on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 5688 Rear Cross-Member: Service and Repair REAR SUSPENSION CROSS-MEMBER REMOVAL 1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Vehicle Lifting. 2. Remove both rear wheel and tire assemblies from the vehicle. Fig. 15 3. Remove the shock absorber clevis bracket to rear knuckle attaching bolt and nut on both sides of the vehicle (Fig.15). Fig. 16 4. Remove muffler support bracket from rear frame rail (Fig.16). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 5689 Fig. 17 5. Remove the rear exhaust pipe hanger from the rear suspension crossmember (Fig.17). Let exhaust system drop down as far as possible. Fig. 18 6. Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal (Fig.18). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 5690 Fig. 19 7. If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on upper control arm (Fig.19). 8. Remove the nuts and bolts on each side of vehicle attaching the 4 lateral links to the knuckles. Fig. 20 9. Disconnect the clips attaching line bundle to crossmember (Fig.20). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 5691 Fig. 21 10. Remove the 4 bolts attaching the rear suspension crossmember to rear frame rails (Fig. 21). Fig. 22 11. Lower the rear suspension crossmember enough to access the upper control arm pivot bar to crossmember attaching bolts (Fig.22). Remove the 4 bolts attaching the upper control arms to the suspension crossmember. Remove the control arms from the crossmember. 12. Lower the rear suspension crossmember, lateral arms and stabilizer bar as far as possible using the transmission jack. Then with the aid of a helper remove rear suspension crossmember from the vehicle. NOTE: When installing the lateral links on the crossmember, the lateral link attaching bolts must be installed as listed below. Install the forward lateral link to crossmember bolts so that the head of the bolt will be toward the front of the vehicle when the crossmember is installed. Install the rear lateral link to crossmember bolts so that the threaded end of the bolt will be facing toward the front of the vehicle when the crossmember is installed. 13. Transfer the lateral links, stabilizer bar mounting brackets and the stabilizer bar and bushings to the replacement crossmember before installing the replacement crossmember in the vehicle. Tighten the stabilizer bar mounting bracket to rear crossmember mounting bolts to 27 N.m (20 ft.lbs.) torque. Tighten the 4 lateral link to crossmember attaching bolts to 95 N.m (80 ft.lbs.) torque. INSTALLATION 1. Install the rear suspension crossmember, lateral arms and rear stabilizer bar back into the vehicle as an assembly. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Description and Operation > Page 5692 2. With the aid of a helper position rear suspension crossmember back in vehicle and support it using the transmission jack. 3. Align the upper control arm pivot bars with the mounting holes in the rear suspension crossmember. Install and tighten the 4 pivot bar to crossmember attaching bolts (Fig.22) to 107 N.m (80 ft.lbs.) torque. CAUTION: While raising crossmember use care not to pinch any lines. 4. Using transmission jack, raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts. 5. Connect line bundle clips to crossmember (Fig.20). Fig. 23 6. Position a drift of the appropriate size into the positioning hole in each side of rear suspension cross-member and locating holes in the frame rail of the body. (Fig. 23). This is required to properly position rear suspension crossmember side-to-side and front-to-rear in the body of the vehicle. Then tighten the 4 crossmember to frame rail attaching bolts to 95 N.m (70 ft.lbs.) torque. Remove drifts from rear suspension crossmember. 7. Align lateral links with knuckles and install the lateral arm to knuckle attaching bolts. Tighten the 4 lateral arm to spindle attaching bolts to 95 N.m (70 ft.lbs.) torque. 8. Remove transmission jack supporting rear suspension crossmember. 9. Install muffler support bracket on rear frame rail (Fig.16). Install rear exhaust pipe hanger on rear suspension crossmember (Fig.17). 10. If vehicle is equipped with antilock brakes, install the wheel speed sensor cable routing clip on upper control arm mounting bracket (Fig.19). Install and securely tighten attaching bolt. 11. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified 129 N.m (95 ft.lbs.) torque. 12. Lower vehicle to the ground. 13. Check and reset if required, rear wheel alignment to meet the preferred specifications. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair GRILLE REMOVAL - JR-41 (Sedan) 1. Remove front bumper fascia from the vehicle, Refer to Front Bumpers. Fig. 8 2. Unsnap upper and lower grille surround(s). Using a trim stick if necessary (Fig. 8). 3. Remove screws attaching grille. 4. Remove grille from fascia. REMOVAL - JR-27 (Convertible) 1. Remove front bumper fascia, Refer to Front Bumpers. 2. Remove fascia from the vehicle. 3. Remove foam impact bar from fascia. Fig. 9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 5696 4. Remove clips attaching grille (Fig. 9). 5. Remove grille from fascia. 6. Transfer medallion. 7. Remove grille from fascia. INSTALLATION 1. Position grille on fascia. 2. Install screw(s) attaching grille to fascia (Fig. 8). 3. Press into position the upper and lower grille surround(s). 4. Place fascia into position. 5. Install front bumper fascia. INSTALLATION - JR-27 (Convertible) 1. Position grille on fascia. 2. Install screws attaching grille to fascia (Fig. 9). 3. Install foam impact bar to fascia. 4. Place fascia into position. 5. Install front bumper fascia. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair CARPETS AND FLOOR MATS REMOVAL 1. Remove door sill scuff plates. 2. Remove rear seat cushion. 3. Remove front seats. 4. Remove amplifier on passenger side of floor pan, if equipped. 5. Remove bolts attaching front seat belts to floor. 6. Remove lower B-pillar trim panels as necessary to clear carpet. 7. Remove cowl trim panels. 8. Remove floor console. 9. Remove forward instrument panel console. Fig. 3 10. Remove push pin fasteners (Fig. 3). 11. Pull carpet from behind brake pedal, accelerator pedal, and HVAC. 12. Fold carpet to center of vehicle. 13. Remove carpet from vehicle through passenger door opening. REMOVAL - JR-27 (Convertible) ONLY 1. Lower convertible top to full down position. 2. Remove front seats. 3. Remove rear seat cushion. 4. Remove floor console and center instrument panel console. 5. Remove door sill trim panels. 6. Remove cowl trim panels. 7. Remove quarter trim panels. 8. Remove amplifier on passenger side of floor pan, if so equipped. 9. Remove wiring troughs holding carpet at outboard ends of rear seat crossmember. 10. Remove accelerator pedal. 11. Remove instrument panel hush panels. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 5701 Fig. 4 12. Remove push-in fasteners from rear of carpet attaching carpet to rear seat crossmember (Fig. 4). 13. Remove plastic sill retainers from metal clips along door sill panel. 14. Remove carpet from vehicle. INSTALLATION 1. Install carpet into vehicle through passenger door opening. 2. Unfold carpet into position. 3. Install carpet behind brake pedal, accelerator pedal, and HVAC. 4. Install the tunnel push pin fastener. 5. Install the front seat and crossmember push pin fasteners. 6. Install the two push pin fasteners into the floor pan. 7. Install forward instrument panel console. 8. Install floor console. 9. Install cowl trim panels. 10. Install lower B-pillar trim panels as necessary. 11. Install bolts attaching front seat belts to floor. 12. Install amplifier on passenger side of floor pan, if equipped. 13. Install front seats. 14. Install rear seat cushion. 15. Install the eight push pin fasteners into the door opening sills. 16. Install door opening sill plates. INSTALLATION - JR-27 (Convertible) ONLY 1. Position carpet in vehicle (Fig. 4). 2. Install push in fasteners from rear of carpet attaching carpet to rear seat crossmember. 3. Install front seat push pin fasteners. 4. Feed wiring connectors for the seats and amplifier, if equipped, through slits in carpet. 5. Install plastic sill retainers in metal clips along door sill panel. 6. Install wiring troughs attaching carpet at outboard ends of rear seat crossmember. 7. Install amplifier on passenger side of floor pan, if so equipped. 8. Install quarter trim panels. 9. Install cowl trim panels. 10. Install door sill trim panels. 11. Install instrument panel hush panel. 12. Install accelerator pedal. 13. Install floor console and center instrument panel console. 14. Install rear seat cushion. 15. Install front seats. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 5702 16. Raise and secure convertible top. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Forward Instrument Panel Console Console: Service and Repair Forward Instrument Panel Console FORWARD INSTRUMENT PANEL CONSOLE REMOVAL 1. Remove floor console. 2. Remove instrument panel cluster hood. 3. Remove instrument panel center bezel. 4. Remove left knee bolster. 5. Release glove box door catches and allow to hang downward. Fig. 15 6. Remove screws holding storage bin to forward instrument panel console (Fig. 15). 7. Remove storage bin from forward instrument panel console. 8. Remove screws holding forward instrument console to shifter mounting bracket. 9. Remove screws attaching forward instrument panel console to instrument panel at sides of storage bin area. 10. Remove screws attaching forward instrument panel console to instrument panel support braces. 11. Remove forward instrument panel console from vehicle. INSTALLATION 1. Position forward instrument panel console to vehicle. 2. Install screws attaching forward instrument panel console to instrument panel support braces. 3. Install screws attaching forward instrument panel console to instrument panel at sides of storage bin area. 4. Install screws attaching forward instrument panel console to shifter mounting bracket. 5. Install storage bin from forward instrument panel console. 6. Install screws attaching storage bin to forward instrument panel console. 7. Release glove box door catches and allow to hang downward. 8. Install left knee bolster. 9. Install instrument panel center bezel. 10. Install instrument panel cluster hood. 11. Install floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Forward Instrument Panel Console > Page 5707 Console: Service and Repair Floor Console FLOOR CONSOLE REMOVAL 1. Raise parking brake lever as high as possible. 2. Move transmission shifter to neutral position. 3. Loosen set screw on front of shifter knob and remove shift lever knob. NOTE: Do not use a trim stick or tool to remove transmission range indicator. Fig. 11 4. Remove transmission range indicator bezel by squeezing the sides slightly and lifting up until the locking tabs are free of the floor console. Refer to (Fig. 11) for pressure points. 5. Disconnect transmission range indicator bezel wire connector on the underside of bezel. Fig. 12 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Forward Instrument Panel Console > Page 5708 6. Remove screws, next to floor shifter and in console storage compartment, attaching floor console to brackets on floor pan (Fig. 12). 7. Disconnect wire connector for floor console accessories at floor pan. 8. Remove console from vehicle. NOTE: The grip portion of the parking brake lever will only fit through the wider lower portion of the slot in the floor console. INSTALLATION NOTE: The grip portion of the parking brake lever will only fit through the wider lower portion of the slot in the floor console. 1. Place floor console in position. Fig. 13 2. Connect wire connector for floor console accessories at floor pan (Fig. 13). 3. Verify that the rear locator pin on the bottom of the storage bin is engaged to the slot in the body bracket and the front pin is engaged to the shift mechanism. 4. Install screws, next to floor shifter and in console storage compartment, holding floor console to brackets on floor pan. Fig. 14 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Forward Instrument Panel Console > Page 5709 5. Connect transmission range indicator bezel wire connector on the underside of bezel (Fig. 14). 6. Install transmission range indicator bezel by align alignment pins with holes in console. Apply a downward pressure until the locking tabs snap into position. 7. Install shift lever knob and tighten set screw on front of shifter knob. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5714 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Application and ID Drink Holders: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table CUP Holder ......................................................................................................................................... ................................................................. PC37 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Application and ID > Page 5718 Drink Holders: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a flat bladed tool, pry lamp bezel from instrument panel. 3. Disconnect wire harness connector. 4. Remove cover from lamp and remove bulb. INSTALLATION 1. Install bulb and cover to lamp. 2. Connect wire harness connector. 3. Press lamp into position in instrument panel. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box GLOVE BOX REMOVAL 1. Open glove box. 2. Push in on sides of glove box bin and lower door. 3. Pivot glove box downward and disengage hinge hooks from instrument panel. 4. Remove glove box. INSTALLATION 1. Place glove box in position. 2. Engage hinge hooks into instrument panel and pivot glove box upward. 3. Push in sides of glove box bin and snap glove box assembly into instrument panel. 4. Close glove box door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 5723 Glove Compartment: Service and Repair Glove Box Latch Replacement GLOVE BOX LATCH REMOVAL 1. Open glove box. 2. Push in on sides of glove box bin and lower door. 3. Pivot glove box downward and disengage hinge hooks from instrument panel. 4. Remove glove box. 5. Remove the assembly screws. 6. Disassemble the glove box. 7. Separate the latch from the glove box assembly. INSTALLATION 1. Install the latch onto the glove box assembly. 2. Assemble the glove box. 3. Install the assembly screws. 4. Engage hinge hooks into instrument panel and pivot glove box upward. 5. Push in sides of glove box bin and snap glove box assembly into instrument panel. 6. Close glove box door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER REMOVAL CAUTION: Special Tool 6967 is needed to remove the rear locating clip attached to the headlining just forward of the rear window. 1. Remove the door opening weatherstrips. 2. Remove instrument panel end cap/fuse cover. 3. Remove the sun visors. 4. Remove sun visor supports. 5. Remove left A-pillar trim. 6. Remove front/rear assist handles and/or coat hooks. 7. Remove right and left upper B-pillar trim. 8. Remove upper quarter trim, as necessary. Refer to Trim Panel. 9. Disconnect headliner electrical connector along instrument panel bracket. Fig. 16 10. Disconnect headliner electrical connector from fuse panel (Fig. 16). 11. Pull down on the rear of the map lamp and sun roof switch to disengage clips from roof panel, if equipped. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 5727 Fig. 17 12. Using Special Tool 6967, disengage headline rear locating clip holding headlining to roof above rear window (Fig. 17). 13. Pull down on headliner around sun roof to disengage hook and loop fastener, if equipped. 14. Disconnect the sunroof module electrical connector, if equipped. 15. Recline front seats. 16. Tilt steering wheel fully up. 17. Move shifter fully rearward. 18. Lower headliner. 19. Remove headliner through passenger front door opening. INSTALLATION NOTE: Do not remove the cardboard light blocker from the reading lamp. 1. Transfer front map lamp and bracket. 2. Transfer sunroof switch. 3. Transfer rear dome lamp. 4. Fully recline both front seats. 5. Tilt steering wheel fully up. 6. Move shifter fully rearward. 7. Move headliner into vehicle through front passenger door. 8. Lay headlining wiring harness out along A-pillar to prevent capturing between headlining and roof. 9. Install left inboard sun visor support. 10. Align rear locator with mating hole in roof bow and press upward on headlining until rear locator engages. 11. Install coat hooks. 12. Install assist handles. 13. Install sun visors. 14. Connect electrical connector to sunroof switch, if equipped. 15. Push upward on sunroof switch to engage into switch retainer, if equipped. 16. Push upward on headlining around sunroof opening to engage hook and loop fasteners, if equipped. 17. Connect map lamp electrical connector, if equipped. 18. Confirm the headliner is not hung up on the side air bag deployment ramp. 19. Push upward on map lamp to engage lamp to headlining, if equipped. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 5728 20. Connect dome lamp wire connector to dome lamp. 21. Install sunroof opening. 22. Install headlining wiring harness to A-pillar and fuse panel. 23. Install upper quarter trim as necessary. 24. Install right and left B-pillar trim. NOTE: It is not possible to reinstall the push in fasteners holding the wiring harness to the instrument panel bracket and to the fuse panel area. Wrap these two fasteners with foam tape to prevent buzz, squeak, and rattle complaints (Fig. 16). 25. Install the A-pillar trim. 26. Install the weatherstrip on to door opening. 27. Verify that the door opening weatherstrip lip overlaps the edge of the headlining and trim panels. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair Rear Shelf: Service and Repair REAR SHELF TRIM PANEL REMOVAL 1. Remove upper quarter trim panels as necessary. Refer to Trim Panel. 2. Fold seat backs down. Fig. 21 3. Remove the center plug (Fig. 21). 4. Remove close out panel trim. Fig. 22 5. Remove push-in fasteners attaching rear shelf trim to shelf panel (Fig. 22). 6. Disconnect the center shoulder belt at the base. 7. Pull trim forward to disengage clip attaching trim to shelf panel. 8. Feed seat belt through the seat belt opening in the shelf panel. CAUTION: Do not pull on child tether covers or use as a handle for removal of panel. 9. Remove shelf trim from vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Page 5732 INSTALLATION 1. Feed center shoulder belt through opening in shelf panel. 2. Place rear shelf trim into position. 3. Push trim rearward to engage clip attaching rear shelf trim to shelf panel. 4. Install push-in fasteners attaching rear shelf trim to shelf panel. CAUTION: Do not pull on child tether covers or use as a handle for installation of panel. 5. Install close out trim panel. 6. Install center plug. 7. Install upper quarter trim panels. 8. Connect the center shoulder seat belt. 9. Fold seat backs up. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor SUN VISOR REMOVAL Fig. 29 1. Disengage sun visor from center support (Fig. 29). 2. Remove screws attaching sun visor to roof header. 3. Remove sun visor from header. 4. If equipped, disconnect wire connector from body harness. 5. Remove sun visor from vehicle. INSTALLATION 1. Place sun visor into position. 2. If equipped, connect wire connector to body harness. 3. Install screw attaching sun visor to header. 4. Install screws attaching sun visor to roof header. 5. Connect sun visor to center support. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 5737 Sun Visor: Service and Repair Sun Visor Support SUN VISOR SUPPORT REMOVAL 1. Disengage sun visor from center support. 2. Remove screw attaching support to roof header, 3. Remove support from vehicle. INSTALLATION 1. Place support into position. 2. Install screw attaching support to roof header, 3. Engage sun visor to center support. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures Heat Staking STANDARD PROCEDURE - HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Plastic Body Panel Repair PLASTIC BODY PANEL REPAIR There are many different types of plastics used in today's automotive environment. We group plastics in three different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion promoter for repair. These types of plastic are used extensively on DaimlerChrysler Motors vehicles. Always follow repair material manufacturer's plastic identification and repair procedures. Rigid Plastics: Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and Polycarbonates. Semi-Rigid Plastics: Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels. Flexible Plastics: Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers. Repair Procedure: The repair procedure for all three categories of plastics is basically the same. The one difference is the material used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic repair. Adhesion Promoter / Surface Modifier: Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics that require the use of adhesion promoter/ surface modifiers. Always follow repair material manufacturer's plastic identification and repair procedures. PANEL SECTIONING Fig. 1 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5742 If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel (Fig.1). To bond two plastic panels together, a reinforcement must overlap both panels. The panels must be "V'd" at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag. When bonding plastic panels, Follow repair material manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured. The assembly can be held together with clamps, rivets, etc. A faster cure can be obtained by heating with a heat lamp or heat gun. After the parts have been bonded and have had time to cure, rough sand the seam and apply the final adhesive filler to the area being repaired. Smooth the filler with a spreader, wooden tongue depressor, or squeegee. For fine texturing, a small amount of water can be applied to the filler surface while smoothing. The cured filler can be sanded as necessary and, as a final step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair. PANEL REINFORCEMENT Fig. 2 Fig. 3 Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing. Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semi-rigid or flexible repair materials should be used for semi-rigid or flexible backing reinforcement (Fig.2) and (Fig.3). Open meshed fiberglass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall tape used, the stronger the repair. Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar plastic and bond with structural adhesive. The reinforcement should cover the entire break and should have a generous amount of overlap on either side of the cracked or broken area. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5743 Fig. 4 When repairing plastic, the damaged area is first "V'd" out, or beveled. Large bonding areas are desirable when repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a 20 degree angle will increase the bonding surface for a repair (Fig.4). It is recommended that sharp edges be avoided because the joint may show through after the panel is refinished. Fig. 5 - Panel repair for both flexible and rigid panels are basically the same. The primary difference between flexible panel repair and rigid panel repair is in the adhesive materials used (Fig. 5). - The technician should first decide what needs to be done when working on any type of body panel. One should determine if it is possible to return the damage part to its original strength and appearance without exceeding the value of the replacement part. - When plastic repairs are required, it is recommended that the part be left on the vehicle when ever possible. That will save time, and the panel will remain stationary during the repair. Misalignment can cause stress in the repair areas and can result in future failure. VISUAL INSPECTION Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors, and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may require partial removal of interior trim or inner panels. Fig. 6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5744 Fig. 7 Identify the type of repair: Puncture or Crack -Damage that has penetrated completely through the panel. Damage is confined to one general area; a panel section is not required. However, a backer panel, open fiberglass tape, or matted material must be bonded from behind (Fig. 7) (Fig. 6). PANEL SURFACE PREPARATION If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area should be stripped of paint and freed from wax and oil. Scuff surfaces around repair area with 360 grit wet/dry sandpaper, or equivalent, to assure adhesion of repair materials. PATCHING PANELS An panel that has extensive puncture type damage can be repaired by cutting out the damaged material (Fig. 7). Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20 degrees to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas. PANEL PATCH FABRICATIONS A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following operation if required: Fig. 8 1. Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required (Fig. 8). 2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area. 3. Apply a liberal coat of adhesive over the reinforcement mesh (Fig. 8). If necessary apply a second or third coat of adhesive and mesh after first Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5745 coat has cured. The thickness of the patch should be the same as the repair area. 4. After patch has cured, peel waxed paper or plastic from the back of the patch. 5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength. PANEL PATCH INSTALLATION 1. Make a paper or cardboard pattern the size and shape of the cutout hole in the panel. 2. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces. 3. Using the pattern as a guide, cut the patch to size. 4. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout. 5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole (Fig. 7). 6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout. 7. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side. 8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper. 9. Mix enough adhesive to cover one side of all support squares. 10. Apply adhesive to cover one side of all support squares. Fig. 9 11. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares (Fig. 9). Fig. 10 12. Position patch in cutout against support squares and adjust patch until the gap is equal along all sides (Fig. 10). 13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5746 Fig. 11 14. Apply a coat of adhesive to the exposed ends of the support squares (Fig. 11). Fig. 12 15. Install screws to hold the patch to support squares (Fig. 12). Tighten screws until patch surface is flush with panel surface. 16. Allow adhesive to cure, and remove all screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5747 Fig. 13 17. Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch (Fig. 13). With compressed air, blow dust from around patch. Fig. 14 18. Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch (Fig. 14). 19. Mix enough adhesive to cover the entire patch area. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5748 Fig. 15 20. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair (Fig. 15). PATCHED PANEL SURFACING After patch panel is installed, the patch area can be finished using the same methods as finishing other types of body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5749 Trim Panel: Removal and Replacement Center Header Trim Panel CENTER HEADER TRIM PANEL REMOVAL 1. Remove both sun visor support centers. Fig. 5 2. Pull trim rearward to disengage clips attaching header trim panel to header panel (Fig. 5). 3. Remove header trim panel from vehicle. INSTALLATION 1. Position header trim panel on vehicle. 2. Align the two locating pins on back of header trim panel to holes in header panel. 3. Engage the two clips on header trim panel to slots in header panel. 4. Attach the two sun visor support centers. Cowl Trim COWL TRIM PANEL REMOVAL 1. Remove door sill trim panel. 2. Remove screws attaching cowl trim panel to inner cowl panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5750 Fig. 6 3. Remove cowl trim panel from vehicle (Fig. 6). INSTALLATION 1. Position cowl trim panel to vehicle. 2. Install screws attaching cowl trim panel to inner cowl panel. 3. Install door sill trim panel. Door Sill Trim Panel DOOR SILL TRIM PANEL REMOVAL Fig. 7 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5751 Fig. 8 1. Using a fork type prying tool, disengage clips holding door sill trim panel to door sill (Fig. 7) and (Fig. 8). 2. Starting at forward end of sill trim panel, pull upward on sill trim panel in order to disengage clips attaching sill trim panel to door opening flange. 3. Remove door sill trim panel from vehicle. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5752 Fig. 10 1. JR-27 (Convertible), place the attaching sill clips in position as show in (Fig. 10). Fig. 9 2. Place door sill trim panel into position (Fig. 9). 3. Align locator tab to the locator slot in door sill. NOTE: Check that header/A-pillar and quarter panel weatherstrips are properly positioned. Incorrect positioning will interfere with clip engagement to door opening flange and damage door sill trim panel. 4. Pushing downward on sill trim panel to engage tabs and attaching clips to the door sill. Front Door Trim Panel TRIM PANEL REMOVAL (1) Roll door glass down. (2) Disengage two clips attaching speaker grille to door trim panel. They are at the front of the grille, one near the top, and the other one at the bottom. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5753 (3) Remove three large washer-headed screws rounding the speaker (Fig. 28). (4) Remove access cover at front of door trim panel. Remove by prying at its rear edge (Fig. 29). (5) Remove red courtesy reflector from lower tail or door. Disengage by prying at screwdriver notch at bottom of reflector. (6) Remove flag trim panel from door by prying off at two attachment clips points (Fig. 29). (7) Remove seven screws attaching door trim panel to door: (Fig. 28) and (Fig. 29). (a) One screw is located at lower rear screw pocket. (b) Three screws located along the bottom of door. (c) One screw located inside handle opening. (d) One screw located at the upper front. (e) One screw in the pull cup. (8) Disengage two hidden clips attaching at the rear of the trim panel, by prying off at two attachment clip points. (9) Lift trim panel upward and away from door, disengage trim panel from upper retainer channel. (10) Disengage clip attaching latch linkage to back door handle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5754 (11) Disconnect electrical connectors as necessary, including lower foot light, If equipped. (12) Remove door trim panel from door. INSTALLATION (1) Position door trim panel near to door. (2) Connect electrical connectors as necessary, including foot light, if so equipped. (3) Engage clip attaching latch linkage to inside door handle. (4) Lift the door trim slightly to get the lock knob into its bezel opening on the panel. (5) Place front portion of upper trim strip flange into retainer channel, while seating white forward locator pin into mating bole in sheetmetal at front of door. (6) Drive screw into forward locator cup. (7) With rear of panel slightly lifted, engage remainder of trim strip flange into retainer channel, working from front to back, pressing down firmly. (8) Engage two hidden clips attaching rear of door trim to their mating (green) grommet holes in the door. Press the rear of the panel firmly in toward the door, listening for engagement clicking sounds at BOTH of the clips. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5755 (9) Install seven screws attaching door trim panel to door: (Fig. 28) and (Fig. 29). (a) One screw in the pull cup. (b) One screw located inside handle opening. (c) One screw located at the upper front. (d) One screw is located at lower rear screw pocket. (e) Three screws located along the bottom of door. (10) Snap screw covers closed. (11) Install three large washer headed screws rounding the speaker (Fig. 28). (12) Install speaker grille by first engaging rear edge hinge flaps to mating slots, then pressing grille on to seat the two clips at front. (13) Install red courtesy reflector by first engaging rear edge hinge flaps to mating slots, then snap front in to position. (14) Install access cover at front of door trim panel. First engage slots at front, then snap in at rear edge (Fig. 29). (15) Place flag trim panel into position and engage clips (Fig. 29). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5756 (16) Close door window. Header Trim Panel - Right or Left HEADER TRIM PANEL - RIGHT OR LEFT REMOVAL - JR-27 (Convertible) ONLY 1. Remove sun visor(s). 2. Remove center header trim panel Trim Panel. 3. Disengage clip attaching header trim panel to header panel. Fig. 18 4. Remove header trim panel from vehicle (Fig. 18). INSTALLATION - JR-27 (Convertible) ONLY 1. Position header trim panel on vehicle. 2. Align locating pins on back side of trim panel to holes in header panel. 3. Engage clip on trim panel to slots in header panel. 4. Install center header trim panel. 5. Install sun visor. Lower Quarter Trim Panel LOWER QUARTER TRIM REMOVAL 1. Remove upper quarter trim panels. Refer to Trim Panel. 2. Remove the punch pins from the lower quarter trim flange. 3. Disengage the clips attaching the lower quarter trim to the body. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5757 Fig. 1 4. Remove lower quarter trim from vehicle (Fig. 1). INSTALLATION 1. Place lower quarter trim into position. 2. Engage the clips attaching the lower quarter trim to the body. 3. Install the push pins into the lower quarter trim flange. 4. Install the upper quarter trim panel. A-Pillar Trim A - PILLAR TRIM REMOVAL 1. Remove the front door opening weatherstrip along the A-pillar. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5758 Fig. 1 2. Disengage clips attaching A-pillar trim to A-pillar (Fig. 1). 3. Remove A-pillar trim from vehicle. REMOVAL - JR-27 (Convertible) ONLY 1. Remove header molding panel, Refer to Trim Panels. 2. Disengage clips attaching A-pillar trim panel to A-pillar. Fig. 2 3. Remove trim panel from vehicle (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5759 INSTALLATION 1. Place A-pillar trim into position. 2. Engage clips attaching A-pillar trim to A-pillar. 3. Install the door opening weatherstrip to the A-pillar. INSTALLATION - JR-27 (Convertible) ONLY 1. Position trim panel near A-pillar. 2. Align locating pins on back side of trim panel to holes in A-pillar. 3. Press clips on A-pillar trim panel into slots in A-pillar. 4. Install header molding panel. B-Pillar Lower Trim B - PILLAR LOWER TRIM REMOVAL 1. Remove upper B-pillar trim. Refer to Trim Panel. Fig. 1 2. Disengage clips attaching seat belt access panel to lower B-pillar trim (Fig. 1). 3. Remove scuff plates. Refer to Trim Panel. 4. Remove the screws attaching the trim to the door sills. 5. Disengage clips attaching lower B-pillar trim to B-pillar. 6. Route seat belt webbing through access hole in lower B-pillar trim. 7. Remove lower B-pillar trim from vehicle. INSTALLATION 1. Place lower B-pillar trim into position. 2. Route seat belt webbing through access hole in lower B-pillar trim. 3. Engage clips attaching lower B-pillar trim to B-pillar. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5760 4. Install the screws attaching the trim to the door sills. 5. Install scuff plates. 6. Engage clips attaching seat belt access panel to lower B-pillar trim. 7. Install upper B-pillar trim. B-Pillar Upper Trim UPPER B - PILLAR TRIM REMOVAL 1. Remove the door opening weatherstrips. 2. Pry shoulder belt knob straight off height adjuster using a trim stick (C-4755). 3. Remove seat belt turning loop cover. 4. Remove bolt attaching turning loop to height adjuster. 5. Remove bolt attaching seat belt lower anchor to floor. 6. Disengage clips attaching upper B-pillar trim to B-pillar. Fig. 1 7. Remove upper B-pillar trim from vehicle (Fig. 1). INSTALLATION 1. Place upper B-pillar trim into position. 2. Engage clips attaching upper B-pillar trim to B-pillar. 3. Install bolt attaching seat belt lower anchor to floor. 4. Install bolt attaching turning loop to height adjuster. 5. Install seat belt turning loop cover. 6. Push shoulder belt knob straight on height adjuster. 7. Install the door opening weatherstrips. Quarter Panel Trim QUARTER TRIM PANEL REMOVAL Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5761 1. Lower convertible top. 2. Remove rear seat cushion and rear seat back. 3. Remove door sill trim panel. Fig. 19 4. Remove speaker grille (Fig. 19). Fig. 20 5. Remove vertical screws and inboard screw attaching quarter trim panel to inner quarter panel (Fig. 20). 6. Remove screws attaching quarter trim panel to inner quarter panel through the speaker opening. 7. Lift metal retainer blade at the front out of clip. 8. Pull trim panel from inner quarter panel and disconnect speaker wiring connector. 9. Remove quarter trim panel from vehicle. INSTALLATION 1. Replace push in fasteners. 2. Position quarter trim panel on vehicle. 3. Connect speaker wiring connector. 4. Install screws attaching quarter trim panel to inner quarter panel through the speaker opening. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5762 5. Install vertical screws and inboard screw attaching quarter trim panel to inner quarter panel. 6. Place toe blade into slotted sill clip. 7. Install door sill trim panel. 8. Install speaker grille. 9. Install rear seat cushion and rear seat back. Upper Quarter Trim UPPER QUARTER TRIM REMOVAL 1. Remove the door opening weatherstrips as necessary. 2. Remove rear seat cushion. 3. Remove bolt attaching rear seat belt anchor to floor. Fig. 30 4. On vehicles equipped with a side curtain air bag, open the screw cap covers and remove the screws (Fig. 30). 5. Fold the seat back down. Fig. 31 6. Disengage clips attaching upper quarter trim to inner quarter panel (Fig. 30) and (Fig. 31). 7. Route seat belt webbing through access hole in upper quarter trim. 8. Remove upper quarter trim panel from vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5763 INSTALLATION 1. Place upper quarter trim panel into position. 2. Route seat belt webbing through access hole in upper quarter trim. 3. Engage clips attaching upper quarter trim to inner quarter panel. 4. On vehicles equipped with side curtain air bag, install the screws and close the screw cap covers. 5. Install bolt attaching rear seat belt anchor to floor. 6. Install rear seat cushion. 7. Install the door opening weatherstrips as necessary. Rear Door Trim Panel REMOVAL 1. Open rear door. 2. Lower window. Fig.7 Rear Door Trim Panel 3. Open the screw cap from bottom of arm rest pull cup and remove the screw. 4. Open the screw cap from behind door latch handle and remove the screw. 5. Remove the screws along the bottom of the trim panel. 6. Using a trim stick C-4755 or equivalent, disengage clips holding perimeter of trim panel to rear door. 7. Remove trim panel from inner belt weatherstrip at top of door. 8. Disconnect wiring harness at door opening. 9. Remove top of trim panel from door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5764 Fig.11 Linkage Clip 10. Disengage clip holding linkage to latch handle. 11. Remove linkage from latch handle. 12. Lift trim up and off lock button. 13. Remove rear door trim panel from vehicle. INSTALLATION 1. Position rear door trim panel on vehicle. 2. Connect linkage to latch handle. 3. Engage clip holding linkage to latch handle. 4. Connect wiring harness at door opening. 5. Position the lock knob through the trim panel and engage trim panel from inner belt weatherstrip at top of door. 6. Align the clips attaching perimeter of trim panel to rear door with the grommets and engage. 7. Install screws attaching door trim panel to door. 8. Install screw holding door latch handle to door and close the screw cap. 9. Install screw from bottom of arm rest pull cup and close the screw cap. 10. Connect battery. Rear Shelf Trim Panel REAR SHELF TRIM PANEL REMOVAL 1. Remove upper quarter trim panels as necessary. Refer to Trim Panel. 2. Fold seat backs down. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5765 Fig. 21 3. Remove the center plug (Fig. 21). 4. Remove close out panel trim. Fig. 22 5. Remove push-in fasteners attaching rear shelf trim to shelf panel (Fig. 22). 6. Disconnect the center shoulder belt at the base. 7. Pull trim forward to disengage clip attaching trim to shelf panel. 8. Feed seat belt through the seat belt opening in the shelf panel. CAUTION: Do not pull on child tether covers or use as a handle for removal of panel. 9. Remove shelf trim from vehicle. INSTALLATION 1. Feed center shoulder belt through opening in shelf panel. 2. Place rear shelf trim into position. 3. Push trim rearward to engage clip attaching rear shelf trim to shelf panel. 4. Install push-in fasteners attaching rear shelf trim to shelf panel. CAUTION: Do not pull on child tether covers or use as a handle for installation of panel. 5. Install close out trim panel. 6. Install center plug. 7. Install upper quarter trim panels. 8. Connect the center shoulder seat belt. 9. Fold seat backs up. Upper Deck Molding UPPER DECK MOLDING REMOVAL 1. Lower convertible top to midway position. 2. Remove screws attaching upper deck molding to rear deck panel above convertible top rear attachment. 3. Open decklid. 4. Remove screws attaching upper deck molding to rear deck panel inside decklid water trough. 5. Disconnect wire connector for CHMSL. 6. Remove upper deck molding from vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 5766 INSTALLATION 1. Position upper deck molding on vehicle. 2. Connect wire connector for CHMSL. 3. Install screws attaching upper deck molding to rear deck panel inside decklid water trough. 4. Install screws attaching upper deck molding to rear deck panel above convertible top rear attachment. 5. Raise and secure convertible top. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove outside door handle. Fig. 27 2. Remove clip attaching lock cylinder to outside door panel (Fig. 27). 3. Disengage clip attaching link to key cylinder. 4. Remove lock cylinder from outer door panel. INSTALLATION 1. Position lock cylinder and gasket in door outer panel. 2. Install clip attaching lock cylinder to outside door panel. 3. Engage link to key cylinder. 4. Install outside door handle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Service and Repair Door Lock Knob: Service and Repair LOCK BUTTON BELL CRANK REMOVAL 1. Remove door trim panel. 2. Disengage clip holding lock linkage to bell crank. 3. Rotate bell crank until retaining ears align with slots in door panel. Fig. 26 4. Remove bell crank from door (Fig. 26). INSTALLATION 1. Place bell crank into position. 2. Rotate bell crank until retaining ears align with slots in door panel. 3. Engage clip attaching lock linkage to bell crank. 4. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5779 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Relay > Component Information > Description and Operation > Page 5783 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications Fig.1 Remote Keyless Entry Transmitter The transmitter has two 3 volt batteries, which can be removed and replaced without special tools. Insert a dime in the side slot of the transmitter and twist. the halves should separate and the batteries are stacked on top of eachother. The batteries are available at local retail stores. Recommended batteries are Panasonic CR 2016 or equivalent. Battery life is about two years. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 5792 Power Door Lock Actuator: Testing and Inspection Make certain battery is in normal condition before circuits are tested. To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem maybe caused by a shorted motor, a bad switch, or a bad relay. Disconnecting a defective motor will allow the others to work. Fig.3 Door Lock Motor - Typical To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. The door lock motor is integral to the door latch. If found defective, the entire door latch must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 5796 Power Door Lock Switch: Testing and Inspection VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check fuse 13 in the Junction Block for a blown fuse. Refer to Wiring Diagrams for circuit information. Door Lock Switch Continuity DOOR LOCK SWITCH Remove the switch from its mounting location. Using an ohmmeter, refer to the table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 5797 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove door trim panel, refer to Body, Door - Front, Trim Panel, Removal. 3. Disconnect switch wire connector. 4. Remove switch using a trim stick (special tool #C-4755) or equivalent. INSTALLATION 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the door trim panel, refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair DECKLID LOCK CYLINDER REMOVAL 1. Release decklid latch and open decklid. 2. Remove decklid latch. Fig. 5 3. Remove clip attaching decklid lock cylinder to security alarm switch, if so equipped (Fig. 5). 4. Remove security alarm switch, if so equipped. 5. Remove clip attaching decklid lock cylinder to decklid. 6. Remove decklid lock cylinder from vehicle. INSTALLATION 1. Position decklid lock cylinder on vehicle. 2. Install clip holding decklid lock cylinder to decklid. 3. Install security alarm switch, if so equipped. 4. Install clip attaching decklid lock cylinder to security alarm switch, if so equipped. 5. Install decklid latch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Outside Rearview Mirror - Glass Replacement Mirrors: Technical Service Bulletins Outside Rearview Mirror - Glass Replacement NUMBER: 23-015-02 GROUP: Body DATE: Apr. 1, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-027-01, DATED SEPT. 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND SALES CODES. SUBJECT: Outside Rearview Mirror Glass Replacement MODELS DISCUSSION: It is unnecessary to replace the entire outside rearview mirror assembly when the mirror glass is damaged or broken. Replacement mirror glasses are available from MOPAR. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Outside Rearview Mirror - Glass Replacement > Page 5805 PARTS REQUIRED: Because of the extremely long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). REPAIR PROCEDURE: WARNING: ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING THE MIRROR ASSEMBLY FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BROKEN GLASS. NOTE: SOME REPLACEMENT MIRROR GLASS/HOLDER ASSEMBLIES ARE PACKAGED WITH REMOVAL/INSTALLATION INSTRUCTIONS WHICH SHOULD BE FOLLOWED, BUT IF NO INSTRUCTIONS ARE PACKAGED WITH THE REPLACEMENT GLASS/HOLDER ONE OF THE FOLLOWING PROCEDURES SHOULD BE USED. PROCEDURE FOR KJ, NS, RS, WG, WJ, XJ, and ZJ 1. Adjust the mirror glass to the full down and centered side to side position. 2. Position a wide leverage device (trim stick) between the bottom edge of the glass/holder assembly and the inside of the mirror housing/shell. 3. Firmly apply upward pressure to the leverage device/mirror glass until the glass assembly disengages from the adapter plate in the mirror housing/shell. 4. Disconnect all wire terminals from the glass/holder if equipped. 5. Connect all wire terminals to the replacement glass/holder if equipped. 6. Locate the four snap tab cavities on the back side of the glass/holder and align them with the four snap tabs found on the front of the adapter plate. 7. Loosely position the tabs to align and position the wide leverage device between the top edge of the glass/holder assembly and the inside of the mirror housing/shell. 8. Firmly apply downward pressure to the leverage device/mirror glass until the glass assembly ergages from the adapter plate in the mirror housing/shell. Correct assembly will result with a firm click. The glass should exhibit even gaps to the housing/shell when complete. 9. Pull lightly on the corners of the glass/holder to ensure all four tabs are engaged and that there is no free play. PROCEDURE FOR AB, AN, BR/BE, DN, JA, JR, LH, PR, PT AND R1 1. Carefully pull/pry the broken mirror glass holder from the mirror assembly. NOTE: REPLACE THE MIRROR ASSEMBLY IF ANY DAMAGE IS IDENTIFIED ON THE MIRROR MOTOR HOUSING. 2. If equipped, disconnect the heated mirror wires from the terminals on the mirror glass/holder. CAUTION: IT IS IMPORTANT TO MAKE SURE THE MOTOR IS SQUARE TO THE GLASS HOLDER PRIOR TO GLASS/HOLDER ATTACHMENT, OTHERWISE THE GLASS/HOLDER COULD BE INSTALLED INCORRECTLY CAUSING POOR RETENTION. 3. Connect the heated mirror wires to the terminals on the back of the mirror glass, if equipped. Then, position the new mirror glass/holder to the mirror housing assembly. NOTE: POSITION THE MIRROR GLASS/HOLDER SO THAT THE MOISTURE DRAIN HOLE ON THE MIRROR GLASS/HOLDER ASSEMBLY, IF SO EQUIPPED, IS FACING DOWNWARD. 4. Align the mirror glass/holder to the mirror motor housing. NOTE: ENSURE THAT THE PROTECTIVE RUBBER COVER OF THE MIRROR MOTOR HOUSING, IF SO EQUIPPED, IS POSITIONED CORRECTLY AROUND THE BOTTOM OF THE FINGERS AREA. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Outside Rearview Mirror - Glass Replacement > Page 5806 5. Using one hand, firmly press the mirror glass/holder assembly into place while at the same time supporting the housing assembly from the backside with the other hand. NOTE: PRESSURE MUST BE APPLIED EQUALLY OVER THE CENTER PORTION OF THE MIRROR TO ENGAGE THE MIRROR GLASS/HOLDER TO THE HOUSING ASSEMBLY. ONE OR MORE CLICKS MAY BE HEARD WHEN ENGAGEMENT TAKES PLACE. IT IS IMPORTANT TO MAKE SURE THAT THE GLASS/HOLDER IS FULLY ENGAGED. PERFORM A FINAL RETENTION CHECK BY PUSHING ON THE MIRROR WITH YOUR HAND ONE ADDITIONAL TIME PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. 6. Verify proper mirror adjustment functions and retention of the mirror glass/holder assembly by gently pulling outward on the mirror glass/holder. 7. Repeat Steps 4 through 6 if the mirror glass/holder detaches from the mirror motor housing. PROCEDURE FOR DR 1. Installation instructions are packaged with the replacement glass. PROCEDURE FOR PL 1. Push the glass holder fully inboard. Then place fingers under the outboard portion of the glass/holder and pull outboard and rearward until this portion of the glass/holder is disengaged, then push inboard until fully disengaged. Remove the glass/holder from the mirror assembly. NOTE: REPLACE THE MIRROR ASSEMBLY IF ANY DAMAGE IS IDENTIFIED ON THE MIRROR MOTOR HOUSING. 2. If equipped, disconnect the heated mirror wires from the terminals on the mirror glass/holder. CAUTION: IT IS IMPORTANT TO MAKE SURE THE MOTOR IS SQUARE TO THE GLASS HOLDER PRIOR TO GLASS/HOLDER ATTACHMENT, OTHERWISE THE GLASS/HOLDER COULD BE INSTALLED INCORRECTLY CAUSING POOR RETENTION. 3. Connect the heated mirror wires to the terminals on the back of the mirror glass, if equipped. Then, position the new mirror glass/holder to the mirror housing assembly. NOTE: POSITION THE MIRROR GLASS/HOLDER SO THAT THE MOISTURE DRAIN HOLE ON THE MIRROR GLASS/HOLDER ASSEMBLY, IF SO EQUIPPED, IS FACING DOWNWARD. 4. Align the mirror glass/holder to the mirror motor housing. NOTE: ENSURE THAT THE PROTECTIVE RUBBER COVER OF THE MIRROR MOTOR HOUSING, IF SO EQUIPPED, IS POSITIONED CORRECTLY AROUND THE BOTTOM OF THE FINGERS AREA. 5. Install the replacement glass/holder in the reverse order followed in step 1. NOTE: PRESSURE MUST BE APPLIED EQUALLY OVER THE CENTER PORTION OF THE MIRROR TO ENGAGE THE MIRROR GLASS/HOLDER TO THE HOUSING ASSEMBLY. ONE OR MORE CLICKS MAY BE HEARD WHEN ENGAGEMENT TAKES PLACE. IT IS IMPORTANT TO MAKE SURE THAT THE GLASS/HOLDER IS FULLY ENGAGED. PERFORM A FINAL RETENTION CHECK BY PUSHING ON THE MIRROR WITH YOUR HAND ONE ADDITIONAL TIME PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. 6. Verify proper mirror adjustment functions and retention of the mirror glass/holder assembly by gently pulling outward on the mirror glass/holder. 7. Repeat Steps 4 through 6 if the mirror glass/holder detaches from the mirror motor housing. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Outside Rearview Mirror - Glass Replacement > Page 5807 TIME ALLOWANCE FAILURE CODE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Page 5808 Mirrors: Locations Power mirrors are controlled by a single switch located on the instrument panel to the left of the steering column. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions Mirrors: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Mirrors: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 C311 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Page 5830 Mirrors: Description and Operation POWER MIRRORS Power mirrors are controlled by a single switch located on the instrument panel to the left of the steering column. The power mirrors are connected to battery feed at all times. Each mirror head contains two electric motors and two drive mechanisms. One motor and drive controls mirror up-and-down movement, and the other controls right-and-left movement. The vehicle is equipped with an Ignition OFF Draw Fuse which is used when it is originally shipped from the factory This fuse is located in the Junction Block and helps prevent battery discharge during storage when disconnected. This fuse is included in the power mirror circuitry and should be checked if the mirrors are inoperative. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Page 5831 Mirrors: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power mirror switch. (Refer to POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). 3. Disconnect wire connector from the switch. Mirror Motor Test Fig. 1 Mirror Switch Harness Connector 4. Using two jumper wires, one connected to a 12 volt battery source, and the other connected to a good body ground. Refer to the Mirror Motor Test table for appropriate mirror response, using the mirror switch wiring harness connector. 5. If test results are not obtained as shown in the Mirror Motor Test table, check for open or shorted circuit, or replace mirror assembly as necessary. If mirror motor tests OK, go to Mirror Switch Test. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Side View Mirror Mirrors: Service and Repair Side View Mirror SIDE VIEW MIRROR REMOVAL Fig. 15 1. Remove side view mirror cover (Fig. 15). 2. Remove the door trim panel. 3. Disconnect power window mirror motor wire connector, if so equipped. 4. Disengage wire harness grommet from mirror flag, if so equipped. 5. Disconnect manual mirror adjuster from side mirror cover, if so equipped. Fig. 16 6. Remove nuts attaching side view mirror to mirror flag (Fig. 16). 7. Remove side view mirror from vehicle. INSTALLATION 1. Feed power mirror wire harness through hole in mirror flag and seat grommet. Do not pull on wire harness to seat grommet, if so equipped. 2. Route adjuster cables through hole in mirror flag, grommet. Do not pull on cables to seat grommet. 3. Position side view mirror to vehicle. 4. Install nuts attaching side view mirror to mirror flag. 5. Engage push in fastener attaching power mirror wire connector to inner door panel, if so equipped. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Side View Mirror > Page 5834 6. Engage power mirror motor wire connector. 7. Install door trim panel. 8. Connect cables to adjuster on side view mirror cover. 9. Install side view mirror cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Side View Mirror > Page 5835 Mirrors: Service and Repair Side View Mirror Glass SIDE VIEW MIRROR GLASS REMOVAL WARNING: ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING THE MIRROR ASSEMBLY. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BROKEN GLASS. 1. Carefully pull/pry the broken glass holder from the mirror assembly. 2. Disconnect the heated mirror electrical connectors from the terminals on the mirror glass holder, if equipped. INSTALLATION CAUTION: It is important to make sure the motor is square to the glass holder (attaching fingers) prior to glass holder attachment, otherwise the glass holder could be installed incorrectly causing poor retention and possible repeat failure. 1. Position the new mirror glass holder to the mirror assembly. NOTE: Position the mirror glass holder so that the moisture drain hole on the mirror glass holder assembly is facing downward. 2. Align the mirror glass holder's attaching fingers to the mirror motor housing. NOTE: Ensure that the protective rubber cover of the mirror motor housing is positioned correctly around the bottom of the fingers area. 3. Using one hand, firmly press the mirror glass holder assembly into place while at the same time supporting the housing assembly from the backside with the other hand. NOTE: Pressure must be applied equally over the center portion of the mirror to engage the mirror glass holder's attaching fingers to the corresponding fingers on the housing assembly. One or more clicks may be heard when finger engagement takes place. 4. Verify retention of the mirror glass holder assembly by gently pulling outward on the mirror glass holder. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Side View Mirror > Page 5836 Mirrors: Service and Repair Rear View Mirror REAR VIEW MIRROR REMOVAL 1. Remove screws attaching inside rear view mirror to header panel. 2. Disconnect wire connector to rear view mirror, if so equipped. Fig. 23 3. Remove rear view mirror from vehicle (Fig. 23) REMOVAL - JR-27 (Convertible) ONLY All vehicles with driver and passenger side airbags must have a colored coded five Bullet point airbag warning label applied to the sun visor, verify label availability and ensure the label is installed. 1. Disengage sun visor from sun visor support. 2. Remove screws attaching sun visor to header panel. 3. Disconnect lighted vanity mirror wiring. Fig. 24 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Side View Mirror > Page 5837 4. Remove sun visor from vehicle (Fig. 24). INSTALLATION 1. Position inside rear view mirror to vehicle. 2. Connect wire connector to rear view mirror, if so equipped. 3. Install screws attaching rear view mirror to header panel. INSTALLATION - JR-27 (Convertible) ONLY All vehicles with driver and passenger side airbags must have a colored coded five Bullet point airbag warning label applied to the sun visor, verify label availability and ensure the label is installed. 1. Position sun visor to vehicle. 2. Connect lighted vanity mirror wire connector. 3. Install screws attaching sun visor to header panel. 4. Engage sun visor to sun visor support. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID Exterior Colors Interior Colors Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 5842 Paint: Description and Operation BASECOAT / CLEARCOAT FINISH DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: - Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. - Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINTED SURFACE TOUCH-UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. Refer to Information Labels or Paint. WARNING: USE AN OSHA APPROVED RESPIRATOR AND SAFETY GLASSES WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL - BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 5845 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING / BUFFING AND POLISHING DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair RADIATOR SUPPORT CROSS-MEMBER REMOVAL 1. Release hood latch and open hood. 2. Remove push-in fasteners attaching fascia/ grille to radiator support crossmember. 3. Remove bolts attaching support braces to bottom of radiator support crossmember. 4. Remove bolts attaching crossmember to radiator closure panel. 5. Remove nuts attaching hood latch to radiator support crossmember. 6. Remove radiator support crossmember from vehicle. INSTALLATION 1. Install radiator support crossmember to vehicle. 2. Install nuts attaching hood latch to radiator support crossmember. 3. Install bolts attaching crossmember to radiator closure panel. 4. Install bolts attaching support braces to bottom of radiator support crossmember. 5. Install push-in fasteners attaching fascia/grille to radiator support crossmember. 6. Close hood. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 5853 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the remote battery negative cable from the terminal on the shock tower. The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. 2. Open the front driver's door and remove end cap. 3. Remove power mirror switch bezel. 4. Remove the left lower instrument panel trim. 5. Remove silencer. 6. Remove wire harness connectors from Junction Block. 7. Remove Junction Block three mounting screws. 8. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 9. Disconnect BCM wire connectors and remove the assembly. 10. Remove Junction Block/BCM from vehicle. 11. With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 12. Disconnect BCM from the Junction Block. 13. Unsnap the remote keyless entry module from the BCM. NOTE: The Remote Keyless Entry (RKE) module is attached to the BCM. This must be transferred (if equipped) to the new BCM If being replaced. - If BCM is replaced, the VTSS must be enabled in the new BCM via the DRB III in order to start the vehicle. INSTALLATION 1. Snap the remote keyless entry module onto the BCM. 2. Connect BCM to the Junction Block. 3. Connect the BCM and junction block together. 4. Install the Junction Block/BCM into vehicle. 5. Connect BCM wire connectors and install the assembly onto instrument panel. 6. Install the Junction Block/BCM by pushing straight up. 7. Install the Junction Block three mounting screws. 8. Install the wire harness connectors to the Junction Block, 9. Install the silencer. 10. Install the left lower instrument panel trim. 11. Install the power mirror switch bezel. 12. Install the left end cover. 13. Connect the remote battery negative cable to the remote terminal on the shock tower. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Relay > Component Information > Description and Operation Keyless Entry Relay: Description and Operation ILLUMINATED ENTRY RELAY The Illuminated Entry System is available on vehicles equipped with the Remote Keyless Entry system. The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is activated. The Remote Keyless Entry Module and the Body Controller are used to control the system. Courtesy lamps will turn ON for 30 seconds (±1 second) and fade to OFF over a five second period. The Illuminated Entry System also turns ON the courtesy lamps (and ignition switch lamp) when door is opened. The courtesy lamps will remain ON while the door is open, then fade to OFF 30 seconds (±1 second) after the last door is closed. The courtesy and ignition switch lamps will fade to OFF immediately when the ignition is switched to ON. The Illuminated Entry System cannot be activated during the 30 second (± second) period after the ignition switch is turned OFF. After a door is opened and closed during this 30 second period, the system will function as previously described. When the battery voltage has been interrupted to the Illuminated Entry System, the system will not function until the remote keyless entry UNLOCK is actuated. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Relay > Component Information > Description and Operation > Page 5857 Keyless Entry Relay: Testing and Inspection When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that remote keyless entry system is operating properly before testing illuminated entry circuits. The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module Sunroof / Moonroof Module: Service and Repair Express Module REMOVAL - EXPRESS MODULE 1. Remove A-pillar trim, sun visors, and map lamps/mini console. 2. Remove sunroof opening trim lace. 3. Pull headliner down as necessary to gain access to sunroof express module. Fig.7 Sunroof Express Module & Drive Motor 4. Disconnect the express module wire harness connectors. 5. Remove express module from the keyway by sliding module towards the center of the vehicle. INSTALLATION - EXPRESS MODULE 1. Place express module in the keyway located in sunroof module and slide module outward to lock it into position. 2. Set headliner into position. 3. Connect drive motor, express module, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Install A-pillar trim, sun visors, and map lamps/mini console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module > Page 5862 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL - MODULE ASSEMBLY 1. Move glass panel to the fully closed position. 2. Disconnect battery negative cable. 3. Recline both front seats. 4. Remove sunroof opening trim lace. 5. Remove control switch. 6. Disconnect wire harness. 7. Remove headliner 8. Disconnect the drain tubes from sunroof housing. Fig.6 Sunroof Module Assembly 9. Loosen fasteners attaching sunroof module assembly. 10. With the aid of a helper, remove fasteners attaching sunroof module assembly to roof panel. INSTALLATION - MODULE ASSEMBLY NOTE: There are locating pins on the roof panel near the front corners of the sunroof opening that will help position the sunroof module correctly. 1. With the Glass panel in the fully closed position. 2. Raise rear end of sunroof module assembly and guide into position and start fasteners. 3. Tighten the fasteners holding the sunroof module to roof panel. Tighten the fasteners to 11 N.m (97 in. lbs.) torque. 4. Connect the drain tubes to the sunroof housing. 5. Connect wire harness. 6. Set headliner into position. 7. Connect express module, drive motor, and control switch wire connectors. 8. Test sunroof operation, adjust as necessary. 9. Finish installing the headliner. 10. Install sunroof opening trim lace. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair REMOVAL 1. Place the sunroof glass panel in the vent position 2. Move the sunshade to the closed position Fig.8 Sunroof Opening Trim Lace 3. From the outside of the vehicle, using a flat blade tool, disengage the rear sunshade guides. Pushing the guide toward the center of the vehicle. Raise up on sunshade and slide it rearward out through the opening. Release the front two guides and remove sunshade from the vehicle. CAUTION: Use care not to crease the sunshade when removing or installing. 4. Remove the sunshade handle from sunshade by compressing the back side of the handle together and pull the handle out. INSTALLATION 1. Install sunshade handle into the sunshade, by pressing the handle into place until the tabs lock behind the sunshade. 2. Install the sunshade into the vehicle between the roof and the glass panel in the vent position. 3. Move the sunshade to the closed position. Through the opening using a flat tool, engage the rear guides into the guide rails. 4. Slide sunshade rearward to access the front two guides. Engage the front guides into the guide rails. 5. Ensure the sunshade operation and operate the sunroof. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection Sunroof / Moonroof Motor: Testing and Inspection ADJUSTMENTS DRIVE MOTOR NOTE: The timing of both the drive motor and the sunroof module play a critical roles in the proper function of the sunroof. The sunroof assembly come in the proper position. As long as the motor is not has not been removed. If the drive motor is removed and cycled the motor will have to be Timed. If the sunroof glass panel has been moved from the park position with the drive motor removed. 1. With drive motor removed from the sunroof assembly check the time of the drive motor. 2. Plug the wire connectors to the drive motor. Do not attach motor to sunroof assembly. Fig. 2 3. Turn ignition switch to the accessory position, tap the drive motor open position switch until the motor timing mark align up straight across (Fig. 2). 4. Install drive motor. SUNROOF MODULE NOTE: If the drive motor is removed and the sunroof glass or cables are moved the sunroof module will have to be timed. 1. With the drive motor removed. 2. Remove sunroof glass panel. 3. Now place both right and left arms in the closed position. Using a screwdriver, push the plastic cable all the way forward in the track until the glass mounting arm drops into the closed position. 4. Repeat this on the other side. 5. To verify correct timing, there is an 1/8 inch hole in the cable ramp that must be aligned with the front glass mounting screw hole. 6. Using an awl, verify alignment of both right and left timing holes. The tracks will now be timed to the fully closed position. 7. With the drive motor in the fully closed position. Install drive motor. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation Sunroof / Moonroof Motor: Service and Repair Removal and Installation DRIVE MOTOR REMOVAL NOTE: The sunroof system is timed from the factory so that the motor shuts off automatically when the sunroof window reaches a certain position. Extreme care must be taken when removing the motor from the sunroof module assembly or this timing may be thrown off causing damage to the sunroof system. Anytime the motor needs to be removed from the module assembly the sunroof window must be in the FULLY CLOSED POSITION. 1. If glass panel is not in the fully closed position and the motor inoperative, remove motor and move by hand into position. 2. Remove A-pillar trim, sun visors, and map lamps/mini console. 3. Disconnect the control switch wire connector. 4. Remove sunroof opening trim lace. 5. Remove headliner as necessary to gain access to sunroof drive motor. 6. Disconnect the drive motor wire harness connectors. 7. Remove drive motor attaching screws and remove motor from the sunroof housing. INSTALLATION 1. Before installing a new motor or the original motor ensure that the motor and module are timed to the closed position. 2. Ensure that sunroof is in the FULLY closed position before mounting the motor. If necessary, move the sunroof glass to the fully closed position by hand with the motor disconnected from the sunroof housing. Fig.2 Sunroof Drive Motor Timing 3. To time the drive motor connect all wire connectors to the express module. Run motor in the close position till the hole in the gear aligns with the Timing Marks shown in. 4. Place drive motor into position on the sunroof housing and install attaching screws. 5. Set headliner into position. 6. Connect express module, drive motor, and control switch wire connectors. 7. Test sunroof operation, adjust as necessary. 8. Finish installing the headliner. 9. Install sunroof opening trim lace. 10. Connect the control switch wire connector. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation > Page 5873 Sunroof / Moonroof Motor: Service and Repair Sunroof Drive Motor SUNROOF DRIVE MOTOR REMOVAL NOTE: The sunroof system is timed from the factory so that the motor shuts off automatically when the sunroof window reaches a certain position. Extreme care must be taken when removing the motor from the sunroof module assembly or this timing may be thrown off causing damage to the sunroof system. Anytime the motor needs to be removed from the module assembly the sunroof window must be in the FULLY CLOSED POSITION if possible. If glass panel is not in the fully closed position and the motor is removed or inoperative. 1. Remove A-pillar trim. Refer to Trim Panel. 2. Remove sun visors. 3. Remove map lamps/mini console. 4. Disconnect the control switch wire connector. 5. Remove sunroof opening trim lace. 6. Remove headliner as necessary to gain access to sunroof drive motor. 7. Disconnect the drive motor wire harness connectors. 8. Remove drive motor attaching screws. 9. Remove motor from the sunroof housing. INSTALLATION NOTE: Before installing a new motor or the original motor ensure that the sunroof glass panel is in the FULLY CLOSED POSITION. If sunroof glass panel is not in the FULLY CLOSED POSITION. If the original drive motor or new drive motor is not in the CLOSED POSITION. A new drive motor comes in the PARK POSITION, but if the drive motor not in the fully closed position. 1. Ensure that sunroof module is in the FULLY closed position before mounting the motor. If not in the fully closed position. 2. To time the drive motor. 3. Place drive motor into position on the sunroof housing and install attaching screws. 4. Connect drive motor, and control switch wire connectors. 5. Test sunroof drive motor operation, adjust as necessary. 6. Install sunroof glass panel. 7. Verify sunroof operation and alignment, and adjust as necessary. 8. Installing the headliner. 9. Install sunroof opening trim lace. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Removal and Installation > Page 5874 Sunroof / Moonroof Motor: Service and Repair Sunroof Module Assembly SUNROOF MODULE ASSEMBLY REMOVAL 1. Move glass panel to the fully closed position. 2. Disconnect battery negative cable. 3. Recline both front seats. 4. Remove sunroof opening trim lace. 5. Remove control switch. 6. Disconnect wire harness. 7. Remove headliner. 8. Disconnect the drain tubes from sunroof housing. Fig. 6 9. Loosen fasteners attaching sunroof module assembly (Fig. 6). 10. With the aid of a helper, remove fasteners attaching sunroof module assembly to roof panel. INSTALLATION NOTE: There are locating pins on the roof panel near the front corners of the sunroof opening that will help position the sunroof module correctly. 1. With the glass panel in the fully closed position. 2. Raise rear end of sunroof module assembly and guide into position and start fasteners. 3. Tighten the fasteners holding the sunroof module to roof panel. Tighten the fasteners to 11 N.m (97 in.lbs.) torque. 4. Connect the drain tubes to the sunroof housing. 5. Connect wire harness. 6. Set headliner into position. 7. Connect battery negative cable. 8. Connect express module, drive motor, and control switch wire connectors. 9. Test sunroof operation, adjust as necessary. 10. Finish installing the headliner. 11. Install sunroof opening trim lace. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures CONTROL SWITCH REMOVAL Fig.1 Sunroof Control Switch 1. Using a flat blade tool, release switch from the headliner. 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 5879 Sunroof / Moonroof Switch: Removal and Replacement SUNROOF CONTROL SWITCH REMOVAL Fig. 1 1. Using a flat blade tool, release switch from the headliner (Fig. 1). 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures Sunroof / Moonroof Windguard: Procedures WIND DEFLECTOR REMOVAL 1. Open sunroof glass panel. Fig.10 Wind Deflector Hinge Pin 2. Remove hinge pins by pushing them outboard to release the wind deflector from sunroof housing. Fig.11 Wind Deflector 3. Remove wind deflector. INSTALLATION 1. Place wind deflector on wind deflector brackets. 2. Install wind deflector hinge pins. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Procedures > Page 5884 Sunroof / Moonroof Windguard: Removal and Replacement WIND DEFLECTOR REMOVAL 1. Open sunroof glass panel. Fig. 11 2. Remove hinge pins by pushing them outboard to release the wind deflector from sunroof housing (Fig. 11). Fig. 12 3. Remove wind deflector (Fig. 12). INSTALLATION 1. Place wind deflector on wind deflector brackets. 2. Install wind deflector hinge pins. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Front Hose FRONT HOSES REMOVAL 1. Move glass panel to the fully closed position. 2. Remove sunroof opening trim lace 3. Disconnect the control switch and wire connector. 4. Remove headliner. Fig.4 Sunroof Housing Drain Hoses 5. Disconnect the drain hose from the sunroof housing. 6. Drain any liquid from hose connection, if necessary. 7. Attach new drain hose to old hose with tape that is to be replaced. 8. Work the old hose back and forth to loosen the sealer. 9. Pull the old hose out through the bottom and the new hose through. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 5889 Fig.4 Sunroof Housing Drain Hoses 1. Connect the drain hose to the sunroof housing and test drainage. 2. Set headliner into position. 3. Connect express module, drive motor, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Connect the control switch wire connector. Install control switch. Rear Hose REAR HOUSING HOSE REMOVAL 1. Move glass panel to the fully closed position. 2. Remove sunroof opening trim lace. 3. Disconnect the control switch and wire connector. 4. Remove headliner. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 5890 Fig.4 Sunroof Housing Drain Hoses 5. Disconnect the drain hose from the sunroof housing. 6. Drain any liquid from hose connection, if necessary. 7. Attach new drain hose to old hose with tape that is to be replaced. 8. Work the old hose back and forth to loosen the sealer. 9. Pull the old hose out through the bottom and the new hose through. INSTALLATION 1. Connect the drain hose to the sunroof housing and test drainage. 2. Set headliner into position. 3. Connect express module, drive motor, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Connect the control switch wire connector. Install control switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 5891 Sunroof / Moonroof Drain: Removal and Replacement SUNROOF HOUSING DRAIN HOSE REMOVAL FRONT HOSES 1. Move glass panel to the fully closed position. 2. Remove sunroof opening trim lace. 3. Disconnect the control switch and wire connector. 4. Remove headliner. Fig. 4 5. Disconnect the drain hose from the sunroof housing (Fig. 4). 6. Drain any liquid from hose connection, if necessary. 7. Attach new drain hose to old hose with tape that is to be replaced. 8. Work the old hose back and forth to loosen the sealer. 9. Pull the old hose out through the bottom and the new hose through. REAR HOUSING HOSE 1. Move glass panel to the fully closed position. 2. Remove sunroof opening trim lace. 3. Disconnect the control switch and wire connector. 4. Remove headliner. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 5892 Fig. 5 5. Disconnect the drain hose from the sunroof housing (Fig. 5). 6. Drain any liquid from hose connection, if necessary. 7. Attach new drain hose to old hose with tape that is to be replaced. 8. Work the old hose back and forth to loosen the sealer. 9. Pull the old hose out through the bottom and the new hose through. INSTALLATION FRONT HOSES 1. Connect the drain hose to the sunroof housing and test drainage (Fig. 4). 2. Set headliner into position. 3. Connect express module, drive motor, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Connect the control switch wire connector. Install control switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 5893 REAR HOUSING HOSE 1. Connect the drain hose to the sunroof housing and test drainage (Fig. 5). 2. Set headliner into position. 3. Connect express module, drive motor, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Connect the control switch wire connector. Install control switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Opening Trim Lace Sunroof / Moonroof Interior Trim Panel: Service and Repair Opening Trim Lace OPENING TRIM LACE REMOVAL Fig. 7 Remove lace by starting at the joint and pull one end of the lace away from the headliner until the entire lace is removed (Fig. 7). INSTALLATION Install lace by starting at the spot of the previous joint, fully seat the lace in place around the sunroof opening. Cut to fit if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Opening Trim Lace > Page 5898 Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunshade SUNSHADE REMOVAL 1. Place the sunroof glass panel in the vent position. 2. Move the sunshade to the closed position. Fig. 8 Fig. 9 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Opening Trim Lace > Page 5899 Fig. 10 3. From the outside of the vehicle, using a flat blade tool, disengage the rear sunshade guides. Pushing the guide toward the center of the vehicle (Fig. 8). Raise up on sunshade and slide it rearward out through the opening (Fig. 9). Release the front two guides and remove sunshade from the vehicle (Fig. 10). CAUTION: Use care not to crease the sunshade when removing or installing. 4. Remove the sunshade handle from sunshade by compressing the back side of the handle together and pull the handle out. INSTALLATION 1. Install sunshade handle into the sunshade, by pressing the handle into place until the tabs lock behind the sunshade. 2. Install the sunshade into the vehicle between the roof and the glass panel in the vent position (Fig. 9). 3. Move the sunshade to the closed position. Through the opening using a flat tool, engage the rear guides into the guide rails (Fig. 8). 4. Slide sunshade rearward to access the front two guides. Engage the front guides into the guide rails (Fig. 10). 5. Ensure the sunshade operation and operate the sunroof. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module Sunroof / Moonroof Module: Service and Repair Express Module REMOVAL - EXPRESS MODULE 1. Remove A-pillar trim, sun visors, and map lamps/mini console. 2. Remove sunroof opening trim lace. 3. Pull headliner down as necessary to gain access to sunroof express module. Fig.7 Sunroof Express Module & Drive Motor 4. Disconnect the express module wire harness connectors. 5. Remove express module from the keyway by sliding module towards the center of the vehicle. INSTALLATION - EXPRESS MODULE 1. Place express module in the keyway located in sunroof module and slide module outward to lock it into position. 2. Set headliner into position. 3. Connect drive motor, express module, and control switch wire connectors. 4. Test sunroof operation, adjust as necessary. 5. Finish installing headliner. 6. Install sunroof opening trim lace. 7. Install A-pillar trim, sun visors, and map lamps/mini console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair > Express Module > Page 5904 Sunroof / Moonroof Module: Service and Repair Sunroof Module Assembly REMOVAL - MODULE ASSEMBLY 1. Move glass panel to the fully closed position. 2. Disconnect battery negative cable. 3. Recline both front seats. 4. Remove sunroof opening trim lace. 5. Remove control switch. 6. Disconnect wire harness. 7. Remove headliner 8. Disconnect the drain tubes from sunroof housing. Fig.6 Sunroof Module Assembly 9. Loosen fasteners attaching sunroof module assembly. 10. With the aid of a helper, remove fasteners attaching sunroof module assembly to roof panel. INSTALLATION - MODULE ASSEMBLY NOTE: There are locating pins on the roof panel near the front corners of the sunroof opening that will help position the sunroof module correctly. 1. With the Glass panel in the fully closed position. 2. Raise rear end of sunroof module assembly and guide into position and start fasteners. 3. Tighten the fasteners holding the sunroof module to roof panel. Tighten the fasteners to 11 N.m (97 in. lbs.) torque. 4. Connect the drain tubes to the sunroof housing. 5. Connect wire harness. 6. Set headliner into position. 7. Connect express module, drive motor, and control switch wire connectors. 8. Test sunroof operation, adjust as necessary. 9. Finish installing the headliner. 10. Install sunroof opening trim lace. 11. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments SUNROOF GLASS PANEL ADJUSTMENTS 1. Move the sunshade rearward to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Loosen the forward and center screws on each side enough to make the front adjustment. 4. Adjust the front of the sunroof glass panel 1 mm (1/32 inch) below the top surface of the roof panel. 5. Tighten the front two screws. 6. Loosen the rear screws on each side enough to make the rear adjustment. 7. Adjust the rear of the sunroof glass panel 1 mm (1/32 inch) above the top surface of the roof panel. 8. Tighten the rear two screws. 9. Check for proper fit. If not OK, repeat glass panel adjustment. If OK, tighten the center two screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures Sunroof / Moonroof Panel: Procedures Sunroof Glass Panel GLASS PANEL REMOVAL 1. Slide sunshade rearward to the open position. 2. Move the glass panel to the vent position. Fig.3 Sunroof Glass Panel Screws 3. Remove the glass panel screws on each side. 4. Lift off glass panel and remove from vehicle. INSTALLATION 1. Position glass panel on to mechanism. 2. Start the six attaching screws. 3. Close glass. 4. Center glass in opening by running a business card around the glass. 5. Adjust front height of glass, just below roof panel. 6. Tighten front two screws. 7. Adjust rear height of glass, just above roof panel. 8. Tighten remaining screws. 9. Verify sunroof operation and alignment. Check fit and adjust as necessary. Sunroof Glass Panel Seal REMOVAL 1. Remove sunroof glass panel. 2. Grasp the seal and pull seal away from the glass panel. The seal is a one piece seal. INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Install seal on glass. Using care working the seal around the glass, being careful not to over stretch the seal while installing. 2. Install sunroof glass panel. 3. Test sunroof operation, adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Procedures > Page 5910 Sunroof / Moonroof Panel: Removal and Replacement SUNROOF GLASS PANEL REMOVAL 1. Slide sunshade rearward to the open position. 2. Move the glass panel to the vent position. Fig. 3 3. Remove the glass panel screws on each side (Fig. 3). 4. Lift off glass panel and remove from vehicle. INSTALLATION 1. Position glass panel on to mechanism. 2. Start the six attaching screws. 3. Close glass. 4. Center glass in opening by running a business card around the glass. 5. Adjust front height of glass, just below roof panel. 6. Tighten front two screws. 7. Adjust rear height of glass, just above roof panel. 8. Tighten remaining screws. 9. Verify sunroof operation and alignment. Check fit and adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures Sunroof / Moonroof Weatherstrip: Procedures OPENING TRIM LACE REMOVAL Fig.8 Sunroof Opening Trim Lace Remove lace by starting at the joint and pull one end of the lace away from the headliner until the entire lace is removed. INSTALLATION Install lace by starting at the spot of the previous joint, fully seat the lace in place around the sunroof opening, cut to fit if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 5915 Sunroof / Moonroof Weatherstrip: Removal and Replacement SUNROOF GLASS PANEL SEAL REMOVAL 1. Remove sunroof glass panel. 2. Grasp the seal and pull seal away from the glass panel. The seal is a one piece seal. INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Install seal on glass. Using care working the seal around the glass, being careful not to over stretch the seal while installing. 2. Install sunroof glass panel. 3. Test sunroof operation, adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair Head Rest: Service and Repair HEADREST REMOVAL 1. Raise head restraint slightly. Fig. 1 2. Insert a stiff wire into the hole on the right hand side head restraint sleeve/guide and push to release latch (Fig. 1). 3. At the same time, press the button on the head restraint sleeve/guide left hand side and pull upward to release the head restraint. 4. Remove head restraint from seat back. INSTALLATION 1. Place head restraint in position. 2. Push head restraint down into the lock position. 3. Raise head restraint to ensure it locks at the last stop. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation Power Seat Motor: Description and Operation RECLINER MOTOR The eight-way power seat option includes an electrically operated seat back recliner mechanism. The only visible evidence of this option is the separate power seat recliner switch control knob that is located on the outboard seat cushion side shield, just behind the other power seat switch control knob. Power Seat Recliner And Track The power seat recliner unit is mounted in the place of a seat hinge on the outboard side of the seat. The upper hinge plate of the power seat recliner mechanism is secured with screws to the seat back frame and is concealed beneath the seat back trim cover and padding. The lower hinge plate and the motor and drive unit of the power seat recliner mechanism is secured with screws to the seat cushion frame, and is concealed by the outboard seat cushion side shield. The power seat recliner cannot be repaired. If the unit is faulty or damaged, it must be replaced. Refer to Bucket Seat Recliner in the Body for the service procedure. The power seat recliner includes a reversible electric motor that is secured to the lower hinge plate of the recliner unit. The motor is connected to a gearbox that moves the upper hinge plate of the power seat recliner through a screw-type drive unit. The driver side power seat recliner motor also has a position potentiometer integral to the motor assembly, which electronically monitors the motor position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 5926 Power Seat Switch: Service Precautions WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 5927 Power Seat Switch: Description and Operation Vehicles equipped with power seats utilize a eight-way power seat switch. This eight-way power seat switch features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the eight-way power seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. The power seat tracks can be adjusted in eight different ways using the power seat switches. See the owners manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 5928 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from its mounting position. Refer to the procedure. Switch Continuity Test Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table and the seat switch connector. If there is no continuity in any of the switch positions, replace switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 5929 Power Seat Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Power Seat Switch 2. Remove the seat cushion side shield from the front seat. Refer to the Body for the procedure. 3. Remove the knobs from the seat switch by gently prying straight off. 4. Remove the switch attaching screws. 5. Remove switch from cushion side shield INSTALLATION 1. Position the switch and install the four switch attaching screws. 2. Install the knobs on the switch. 3. Connect wiring electrical connector on switch. 4. Install the seat cushion side shield. Refer to Body for the procedure. 5. Connect the negative battery cable remote terminal on the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-032-04 > Sep > 04 > Interior - Power Seat Will Not Adjust Seat Track: Customer Interest Interior - Power Seat Will Not Adjust NUMBER: 23-032-04 GROUP: Body DATE: September 2, 2004 SUBJECT: Power Seat Will Not Adjust OVERVIEW: This bulletin involves cleaning and lubricating the power seat adjuster linkage. MODELS: 2001 - 2005 (JR) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The power seat adjuster binds and will not move due to a lack of lubrication and slight accumulation of oxidation on the surface of some of the seat adjuster linkages. DIAGNOSIS: With the binding seat in the vehicle, illuminate the underside of the seat and observe the bottom of the seat from the rear passenger foot well using a mirror. If slight surface oxidation is readily visible on the either of the two long horizontal, fore/aft adjuster screws, perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Unbolt the seat from the vehicle floor and tip it backward to expose the adjuster mechanism. 2. Clean the oxidized parts with a wire brush and cycle the seat adjuster switch back and forth several times. 3. If the seat power adjuster remains seized and is not functional, seat adjuster replacement is required. Refer to the service information on TechCONNECT for replacement procedures and Quick LOP for the Time Allowance. 4. If the seat adjuster operation is restored, apply a liberal coat of grease, p/n 05017414AA, to the entire length of both adjuster screw mechanisms and function the seat through its full range of motion to evenly distribute the grease. 5. Attach the seat to the vehicle, torque the fasteners to 61 Nm (45 ft. lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-032-04 > Sep > 04 > Interior - Power Seat Will Not Adjust > Page 5938 Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement Seat Track: Customer Interest Power Seat Adjuster - Fore/Aft Movement NUMBER: 23-028-01 REV. A GROUP: Body DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-01, DATED SEPT. 28, 2001 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, PARTS USAGE CLARIFICATION AND A CAUTION STATEMENT. SUBJECT: Power Seat Adjuster Loose Fore/Aft OVERVIEW: This bulletin involves installing a revised power seat adjuster drive block screw to the inboard side of the power seat track(s). MODELS: **2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan** 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: Power seat has slight fore/aft movement most noticeable during acceleration or braking. DIAGNOSIS: If this condition can be duplicated or the vehicle operator describes the Symptom/Condition on either the driver's, passenger's, or both power seats, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: **REPAIR PROCEDURE RS/RG**: 1. Place the vehicle on an appropriate hoist. 2. Open the hood and disconnect/isolate the negative battery cable. 3. Raise the vehicle and remove the four nuts attaching the power seat (either driver's, passenger's or both) risers to the floor. 4. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement > Page 5943 5. Lift the power seat up off its mounting and lie the seat with the seat back on the floor of the vehicle providing access to the seat track. NOTE: DO NOT DISCONNECT ANY WIRING CONNECTORS TO THE SEAT OR A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 6. If equipped, remove the two screws attaching the memory seat/mirror control module (driver's side only) from the seat track and place module aside. Do not disconnect any wires from the module. 7. Remove the drive block screw from the lower track assembly inboard side (seat belt buckle side) with a T-50 Torx bit and discard the screw (Fig. 1). The outboard side screw is NOT to be replaced on either the driver's or passenger's seat. CAUTION: **REPLACING THE OUTBOARD BOLT WILL DAMAGE THE SEAT TRACK BEYOND REPAIR.** 8. Install revised drive block screw, p/n 05080982AA, into the inboard drive block and finger tighten. 9. Torque the drive block screw to 28 Nm (250 in. lbs.). 10. If removed, install the memory seat/mirror control module to the seat track (drivers side only). 11. Place seat and riser into the floor. 12. If required, perform steps 5 through 11 on the other power seat. 13. Lift the vehicle and install nuts attaching front seat(s) risers to the floor. Tighten nuts to 60 Nm (44 ft. lbs.). 14. Lower vehicle. 15. Connect the negative battery cable and set clock to correct time. **REPAIR PROCEDURE JR41: 1. Remove the 4 bolts attaching the seat to the floor and lay the seat on its back. NOTE: DO NOT DISCONNECT ANY WIRING CONNECTORS TO THE SEAT OR A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 2. Remove the drive block screw from the lower track assembly inboard side (seat belt buckle side) with a T-50 Torx bit and discard the screw (Fig. 1). The outboard side screw is NOT to be replaced. CAUTION: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement > Page 5944 REPLACING THE OUTBOARD BOLT WILL DAMAGE THE SEAT TRACK BEYOND REPAIR. 3. Install revised drive block screw, p/n 05080982AA, into the inboard drive block and finger tighten. 4. Torque the drive block screw to 28 Nm (250 in. lbs.). 5. Place seat attachment points on the floor and align the mounting holes. 6. Tighten the seat to floor attaching bolts to 60 Nm (44 ft. lbs.).** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-032-04 > Sep > 04 > Interior - Power Seat Will Not Adjust Seat Track: All Technical Service Bulletins Interior - Power Seat Will Not Adjust NUMBER: 23-032-04 GROUP: Body DATE: September 2, 2004 SUBJECT: Power Seat Will Not Adjust OVERVIEW: This bulletin involves cleaning and lubricating the power seat adjuster linkage. MODELS: 2001 - 2005 (JR) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: The power seat adjuster binds and will not move due to a lack of lubrication and slight accumulation of oxidation on the surface of some of the seat adjuster linkages. DIAGNOSIS: With the binding seat in the vehicle, illuminate the underside of the seat and observe the bottom of the seat from the rear passenger foot well using a mirror. If slight surface oxidation is readily visible on the either of the two long horizontal, fore/aft adjuster screws, perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Unbolt the seat from the vehicle floor and tip it backward to expose the adjuster mechanism. 2. Clean the oxidized parts with a wire brush and cycle the seat adjuster switch back and forth several times. 3. If the seat power adjuster remains seized and is not functional, seat adjuster replacement is required. Refer to the service information on TechCONNECT for replacement procedures and Quick LOP for the Time Allowance. 4. If the seat adjuster operation is restored, apply a liberal coat of grease, p/n 05017414AA, to the entire length of both adjuster screw mechanisms and function the seat through its full range of motion to evenly distribute the grease. 5. Attach the seat to the vehicle, torque the fasteners to 61 Nm (45 ft. lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-032-04 > Sep > 04 > Interior - Power Seat Will Not Adjust > Page 5950 Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement Seat Track: All Technical Service Bulletins Power Seat Adjuster - Fore/Aft Movement NUMBER: 23-028-01 REV. A GROUP: Body DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-01, DATED SEPT. 28, 2001 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, PARTS USAGE CLARIFICATION AND A CAUTION STATEMENT. SUBJECT: Power Seat Adjuster Loose Fore/Aft OVERVIEW: This bulletin involves installing a revised power seat adjuster drive block screw to the inboard side of the power seat track(s). MODELS: **2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan** 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: Power seat has slight fore/aft movement most noticeable during acceleration or braking. DIAGNOSIS: If this condition can be duplicated or the vehicle operator describes the Symptom/Condition on either the driver's, passenger's, or both power seats, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: **REPAIR PROCEDURE RS/RG**: 1. Place the vehicle on an appropriate hoist. 2. Open the hood and disconnect/isolate the negative battery cable. 3. Raise the vehicle and remove the four nuts attaching the power seat (either driver's, passenger's or both) risers to the floor. 4. Lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement > Page 5955 5. Lift the power seat up off its mounting and lie the seat with the seat back on the floor of the vehicle providing access to the seat track. NOTE: DO NOT DISCONNECT ANY WIRING CONNECTORS TO THE SEAT OR A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 6. If equipped, remove the two screws attaching the memory seat/mirror control module (driver's side only) from the seat track and place module aside. Do not disconnect any wires from the module. 7. Remove the drive block screw from the lower track assembly inboard side (seat belt buckle side) with a T-50 Torx bit and discard the screw (Fig. 1). The outboard side screw is NOT to be replaced on either the driver's or passenger's seat. CAUTION: **REPLACING THE OUTBOARD BOLT WILL DAMAGE THE SEAT TRACK BEYOND REPAIR.** 8. Install revised drive block screw, p/n 05080982AA, into the inboard drive block and finger tighten. 9. Torque the drive block screw to 28 Nm (250 in. lbs.). 10. If removed, install the memory seat/mirror control module to the seat track (drivers side only). 11. Place seat and riser into the floor. 12. If required, perform steps 5 through 11 on the other power seat. 13. Lift the vehicle and install nuts attaching front seat(s) risers to the floor. Tighten nuts to 60 Nm (44 ft. lbs.). 14. Lower vehicle. 15. Connect the negative battery cable and set clock to correct time. **REPAIR PROCEDURE JR41: 1. Remove the 4 bolts attaching the seat to the floor and lay the seat on its back. NOTE: DO NOT DISCONNECT ANY WIRING CONNECTORS TO THE SEAT OR A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 2. Remove the drive block screw from the lower track assembly inboard side (seat belt buckle side) with a T-50 Torx bit and discard the screw (Fig. 1). The outboard side screw is NOT to be replaced. CAUTION: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-028-01A > Nov > 01 > Power Seat Adjuster - Fore/Aft Movement > Page 5956 REPLACING THE OUTBOARD BOLT WILL DAMAGE THE SEAT TRACK BEYOND REPAIR. 3. Install revised drive block screw, p/n 05080982AA, into the inboard drive block and finger tighten. 4. Torque the drive block screw to 28 Nm (250 in. lbs.). 5. Place seat attachment points on the floor and align the mounting holes. 6. Tighten the seat to floor attaching bolts to 60 Nm (44 ft. lbs.).** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Page 5957 Seat Track: Locations The power seat track unit located under the drivers seat. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Page 5958 Seat Track: Description and Operation The eight-way power seat options include a single electrically operated power seat track unit located under the drivers seat. The power seat track unit replaces the standard equipment manual seat track. The lower half of the power seat track is secured at the front with two bolts to the floor panel seat cross member, and at the rear with two bolts to the floor panel. Four fasteners secure the bottom of the seat cushion frame to four studs on the upper half of the power seat track unit. The power seat track unit cannot be repaired, and is serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat track unit must be replaced. Refer to Bucket Seat Track Adjuster in the Body for the procedure. The power seat track unit includes three reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. The third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Page 5959 Seat Track: Testing and Inspection 1. Remove power seat switch from seat. 2. Disconnect wire harness connector. 3. Check Pin 1 for battery voltage and Pin 5 for ground. Switch Harness Connector Circuit Test Fig.4 Switch Harness Connector 4. To test the seat motors, refer to the, and verify proper seat responses. Using two jumper wires, connect one to a battery supply and the second to a ground. Connect the other ends to the seat wire harness connector as described in the Switch Harness Connector Circuit Test table. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Page 5960 Seat Track: Service and Repair REMOVAL Before the seat track can be removed, the front seat assembly must be removed from the vehicle. Refer to the Body for the Front Seat Removal and Installation procedure. 1. Disconnect and isolate the battery negative remote cable. 2. Remove the appropriate front seat from the vehicle. Once the front seat is removed, lay it on a clean surface upside down to expose the underside of the seat assembly. 3. Remove the seat cushion side shields from the seat assembly. Refer to the Body for the Seat Cushion Side Shield Removal and Installation procedure. 4. Disconnect the necessary power seat electrical connectors. 5. Remove the bolts retaining the power seat track to the seat assembly and remove. INSTALLATION 1. Position the seat track and install the retaining bolts. Torque the bolts to 12 Nm (108 in. lbs.). 2. Connect the necessary power seat electrical connectors. 3. Install the seat cushion side shields on the seat assembly. Refer to the Body for the Seat Cushion Side Shield Installation procedure. 4. Install the appropriate front seat in the vehicle. Refer to the Body for the Seat Installation procedure. 5. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 5965 Power Door Lock Switch: Testing and Inspection VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal: - Touch other test light lead to battery feed B+ terminal. - If test light comes on, the wiring circuit between the battery and switch is functional. - If test light does not come on, check fuse 13 in the Junction Block for a blown fuse. Refer to Wiring Diagrams for circuit information. Door Lock Switch Continuity DOOR LOCK SWITCH Remove the switch from its mounting location. Using an ohmmeter, refer to the table to determine if the continuity is correct in the LOCK and UNLOCK switch positions. If these results are not obtained, replace the switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 5966 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove door trim panel, refer to Body, Door - Front, Trim Panel, Removal. 3. Disconnect switch wire connector. 4. Remove switch using a trim stick (special tool #C-4755) or equivalent. INSTALLATION 1. Install the switch by snapping into place. 2. Connect switch wire connector. 3. Install the door trim panel, refer to Body, Door - Front, Trim Panel, Installation. 4. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 5970 Power Seat Switch: Service Precautions WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 5971 Power Seat Switch: Description and Operation Vehicles equipped with power seats utilize a eight-way power seat switch. This eight-way power seat switch features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the eight-way power seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. The power seat tracks can be adjusted in eight different ways using the power seat switches. See the owners manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 5972 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from its mounting position. Refer to the procedure. Switch Continuity Test Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table and the seat switch connector. If there is no continuity in any of the switch positions, replace switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 5973 Power Seat Switch: Service and Repair REMOVAL 1. Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. WARNING: SOME VEHICLES ARE EQUIPPED WITH SIDE AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Power Seat Switch 2. Remove the seat cushion side shield from the front seat. Refer to the Body for the procedure. 3. Remove the knobs from the seat switch by gently prying straight off. 4. Remove the switch attaching screws. 5. Remove switch from cushion side shield INSTALLATION 1. Position the switch and install the four switch attaching screws. 2. Install the knobs on the switch. 3. Connect wiring electrical connector on switch. 4. Install the seat cushion side shield. Refer to Body for the procedure. 5. Connect the negative battery cable remote terminal on the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures CONTROL SWITCH REMOVAL Fig.1 Sunroof Control Switch 1. Using a flat blade tool, release switch from the headliner. 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 5978 Sunroof / Moonroof Switch: Removal and Replacement SUNROOF CONTROL SWITCH REMOVAL Fig. 1 1. Using a flat blade tool, release switch from the headliner (Fig. 1). 2. Disconnect the wire connector from the switch. INSTALLATION 1. Connect the wire connector to the control switch. 2. Install control switch into headliner. 3. Test sunroof operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Decklid Release Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 5982 Trunk / Liftgate Switch: Service and Repair REMOVAL 1. Open hood and disconnect the negative battery cable remote terminal from the remote battery post. 2. Remove left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Removal. 3. Disconnect the wire connector. 4. Pinch four tabs around side of decklid release switch on the rear side of the left lower instrument panel trim, and push switch through opening. INSTALLATION 1. Position the decklid release switch over opening of the left lower instrument panel trim, and push switch through opening. 2. Connect the wire connector. 3. Install the left lower instrument panel cover. Refer to Body, Instrument Panel, Left Lower Instrument Panel Trim, Installation. 4. Connect the negative battery cable remote terminal to the remote battery post. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Battery Splash Shield Splash Guard: Service and Repair Battery Splash Shield BATTERY SPLASH SHIELD REMOVAL Fig. 2 1. Remove the three push-pin fasteners and remove the splash shield (Fig. 2). INSTALLATION 1. Install the splash shield and install the 3 pushpin fasteners. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Battery Splash Shield > Page 5987 Splash Guard: Service and Repair Accessory Drive Belt Splash Shield ACCESSORY DRIVE BELT SPLASH SHIELD REMOVAL 1. Remove the right front wheelhouse splash shield. Fig. 1 2. Remove the six push-in fasteners attaching accessory drive belt splash shield to frame rail (Fig. 1). 3. Remove accessory drive belt splash shield from vehicle. INSTALLATION 1. Install splash shield and install the six push-in fasteners attaching accessory drive belt splash shield to frame rail. 2. Install the right front wheelhouse splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair SPOILER REMOVAL - JR-41 (Sedan) 1. Remove the decklid cover if necessary. Refer to Trim Panel. Fig. 17 2. Remove the four nuts and remove the spoiler (Fig. 17). REMOVAL - JR-27 (Convertible) 1. Remove the decklid cover if necessary. Refer to Trim Panel. Fig. 18 2. Remove the three nuts (Fig. 18). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Page 5992 Fig. 19 3. Using a trim stick or a suitable tool release the double sided tape attaching spoiler to the decklid (Fig. 19). 4. Raising the rear edge of spoiler so the studs clear the decklid and remove the spoiler. 5. Clean area by remove all of the double sided tape and thoroughly clean the area with MOPAR(R) Super Kleen, or equivalent. INSTALLATION - JR-41 (Sedan) 1. Install the spoiler and nuts (Fig. 17). 2. Tighten nuts to 3 N.m (30 in.lbs.) torque. 3. Install the decklid cover. INSTALLATION - JR-27 (Convertible) 1. Clean the area of the decklid and spoiler that is to be bonded, with an alcohol based cleaner. 2. Install double sided tape to the spoiler if necessary. 3. Peel the backing from tape on the bottom side of spoiler (Fig. 19). 4. Position spoiler on the decklid aligning studs to holes and spoiler into position. 5. Press firmly on the leading edge of spoiler to assure adhesion. 6. Raise decklid and install nuts attaching spoiler to the decklid. Tighten nuts to 5 N.m (45 in.lbs.) torque (Fig. 18). 7. Close decklid. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front Strut / Shock Tower: Customer Interest Body/Suspension - Clunk/Pop Sound From Vehicle Front NUMBER: 23-039-04 GROUP: Body DATE: September 24, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-03, DATED May 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR. SUBJECT: Pop/Clunk Sound From Front Of Vehicle OVERVIEW: This bulletin involves installing two rivets in each front shock tower/wheel well area. MODELS: 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Vehicle produces an intermittent front end popping or clunk type sound while driving over road inputs that cause the body to come under a twisting load. This sound may also be produced when in park & idle by turning the steering wheel quickly, 90 degrees, to the left and back to the right. DIAGNOSIS: If the vehicle operator describes the above Symptom, turn the steering wheel quickly, 90 degrees, to the left and back to the right while the transmission is in park and the engine is at idle. If a popping or clunk type sound is heard, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove both front tire/wheel assemblies. 3. Remove wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6001 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6002 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front Strut / Shock Tower: All Technical Service Bulletins Body/Suspension - Clunk/Pop Sound From Vehicle Front NUMBER: 23-039-04 GROUP: Body DATE: September 24, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-03, DATED May 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR. SUBJECT: Pop/Clunk Sound From Front Of Vehicle OVERVIEW: This bulletin involves installing two rivets in each front shock tower/wheel well area. MODELS: 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Vehicle produces an intermittent front end popping or clunk type sound while driving over road inputs that cause the body to come under a twisting load. This sound may also be produced when in park & idle by turning the steering wheel quickly, 90 degrees, to the left and back to the right. DIAGNOSIS: If the vehicle operator describes the above Symptom, turn the steering wheel quickly, 90 degrees, to the left and back to the right while the transmission is in park and the engine is at idle. If a popping or clunk type sound is heard, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove both front tire/wheel assemblies. 3. Remove wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6008 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6009 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK REMOVAL 1. Raise vehicle and support on safety stands. Fig. 24 2. Remove bolts (Fig.24). 3. Remove tow hook from vehicle. INSTALLATION 1. Place tow in position. 2. Install bolts (Fig.24). Tighten to 55 to 115 N.m (55 to 85 ft.lbs.) torque. 3. Remove safety stands and lower vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL COVER REMOVAL 1. Release hood latch and open hood. 2. Remove windshield wiper arms. Fig. 4 3. Remove screws attaching cowl cover to cowl (Fig. 4). 4. Remove the seal, cowl screen to hood inner panel. 5. Remove clips attaching cowl cover to cowl plenum under hood to cowl bulb seal. 6. Remove cowl cover from vehicle. INSTALLATION 1. Position cowl cover to vehicle. 2. Install clips attaching cowl cover to cowl plenum. 3. Install the seal, cowl screen to hood inner panel. 4. Install screws attaching cowl cover to cowl. 5. Install windshield wiper arms. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal Front Door Weatherstrip: Service and Repair A - Pillar Seal A - PILLAR SEAL REMOVAL 1. Open front door. 2. Using a fork-type tool (C-4829), disengage push-in fasteners attaching A-pillar seal to A-pillar. 3. Remove A-pillar seal from vehicle. INSTALLATION 1. Place A-pillar seal into position. 2. Install push-in fasteners attaching A-pillar seal to A-pillar. 3. Close front door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6023 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. Fig. 5 2. Remove two screws (Fig. 5). 3. Position splash shield out of way. 4. Starting at the bottom of the A-pillar, pull the drip rail weatherstrip from the windshield side molding. 5. Pull the drip rail weatherstrip from the roof rail pinch flange above door openings. Fig. 6 6. Remove drip rail weatherstrip from vehicle (Fig. 6). INSTALLATION 1. Place drip rail weatherstrip into position. 2. Push drip rail weatherstrip on to the roof rail pinch flange above door openings. 3. Starting at the bottom of the A-pillar, push the drip rail weatherstrip on to the windshield side molding. 4. Position splash shield. 5. Install two screws. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6024 6. Close front and rear doors. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6025 Front Door Weatherstrip: Service and Repair A - Pillar Weatherstrip Retainer and Molding A - PILLAR WEATHERSTRIP RETAINER AND MOLDING REMOVAL 1. Partially raise convertible top. 2. Remove header and A-pillar weatherstrip as necessary to gain access. Fig. 1 3. Remove screws holding A-pillar weatherstrip retainer to A-pillar (Fig. 1). 4. Remove retainer from vehicle. 5. Remove screws attaching A-pillar molding to A-pillar. 6. Remove A-pillar molding from vehicle. INSTALLATION 1. Clean A-pillar of any seal material residue. 2. Position A-pillar molding to vehicle. 3. Install screws attaching A-pillar molding to A-pillar. 4. Position A-pillar weatherstrip retainer on A-pillar. 5. Install screws attaching retainer to A-pillar. Install middle screw first and then work outward. 6. Install header and A-pillar weatherstrip. 7. Lower and secure convertible top. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6026 Front Door Weatherstrip: Service and Repair Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6027 Front Door Weatherstrip: Service and Repair A - Pillar Seal A - PILLAR SEAL REMOVAL 1. Open front door. 2. Using a fork-type tool (C-4829), disengage push-in fasteners attaching A-pillar seal to A-pillar. 3. Remove A-pillar seal from vehicle. INSTALLATION 1. Place A-pillar seal into position. 2. Install push-in fasteners attaching A-pillar seal to A-pillar. 3. Close front door. Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open front and rear doors. Fig. 5 2. Remove two screws (Fig. 5). 3. Position splash shield out of way. 4. Starting at the bottom of the A-pillar, pull the drip rail weatherstrip from the windshield side molding. 5. Pull the drip rail weatherstrip from the roof rail pinch flange above door openings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6028 Fig. 6 6. Remove drip rail weatherstrip from vehicle (Fig. 6). INSTALLATION 1. Place drip rail weatherstrip into position. 2. Push drip rail weatherstrip on to the roof rail pinch flange above door openings. 3. Starting at the bottom of the A-pillar, push the drip rail weatherstrip on to the windshield side molding. 4. Position splash shield. 5. Install two screws. 6. Close front and rear doors. A - Pillar Weatherstrip Retainer and Molding A - PILLAR WEATHERSTRIP RETAINER AND MOLDING REMOVAL 1. Partially raise convertible top. 2. Remove header and A-pillar weatherstrip as necessary to gain access. Fig. 1 3. Remove screws holding A-pillar weatherstrip retainer to A-pillar (Fig. 1). 4. Remove retainer from vehicle. 5. Remove screws attaching A-pillar molding to A-pillar. 6. Remove A-pillar molding from vehicle. INSTALLATION Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6029 1. Clean A-pillar of any seal material residue. 2. Position A-pillar molding to vehicle. 3. Install screws attaching A-pillar molding to A-pillar. 4. Position A-pillar weatherstrip retainer on A-pillar. 5. Install screws attaching retainer to A-pillar. Install middle screw first and then work outward. 6. Install header and A-pillar weatherstrip. 7. Lower and secure convertible top. Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Quarter Panel Weatherstrip QUARTER PANEL WEATHERSTRIP REMOVAL 1. Remove door sill trim panel. 2. Remove push in fasteners holding weatherstrip to B-pillar. 3. Remove weatherstrip from door opening flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6030 Fig. 17 4. Remove quarter panel weatherstrip from vehicle (Fig. 17). INSTALLATION 1. Position panel weatherstrip onto vehicle. 2. Install weatherstrip to door opening flange. 3. Install push in fasteners attaching weatherstrip to B-pillar. 4. Install door sill trim panel. Secondary Sill Weatherstrip SECONDARY SILL WEATHERSTRIP REMOVAL 1. Open door. 2. Using fork tool C-4829, disengage push in fasteners attaching secondary sill weatherstrip to bottom of door. Fig. 23 3. Remove secondary sill weatherstrip from vehicle (Fig. 23). INSTALLATION 1. Place secondary sill weatherstrip into position. 2. Install push in fasteners attaching secondary sill weatherstrip to bottom of door. 3. Close door. Side View Mirror Flag / Door Glass Channel Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6031 SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > A - Pillar Seal > Page 6032 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6037 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6038 Front Door Window Glass Weatherstrip: Service and Repair Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6039 Front Door Window Glass Weatherstrip: Service and Repair Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6040 INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6041 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6042 Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6043 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6044 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6045 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL Fig. 10 1. Remove screw attaching rearward end of molding to front door (Fig. 10). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6046 Fig. 11 2. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 11). 3. Lift up on the rear of the belt molding and pull rearward to remove. INSTALLATION 1. Place belt molding in position. 2. Using your hand press downward at each clip attaching belt molding to door till in position. 3. Install screw attaching rearward end of molding to front door. Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. 2. Remove bolt attaching bottom of front lower run channel to inner door panel. 3. Pull glass run weatherstrip from door glass opening frame. Fig. 8 4. Remove lower run channel through opening at top of door (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6047 INSTALLATION 1. Install lower run channel through opening at top of door. 2. Push glass run weatherstrip to door glass opening frame. 3. Install bolt attaching bottom of front lower run channel to inner door panel. 4. Install door glass. Door Glass Inner Belt Stabilizer DOOR GLASS INNER BELT STABILIZER REMOVAL 1. Remove door trim panel. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Remove nut attaching inner belt stabilizer to door panel. Fig. 17 4. Remove inner belt stabilizer from door (Fig. 17). INSTALLATION 1. Place inner belt stabilizer into position. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Install nut attaching inner belt stabilizer to door panel. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. 4. Install door trim panel. Door Inner Belt Weatherstrip DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6048 Fig. 3 2. Pull upward on rear edge of inner belt weatherstrip (Fig. 3). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Start leading edge of weatherstrip on vehicle. 2. Press the leading edge of the weatherstrip forward until edge is tight to the mirror flag. 3. Press weatherstrip into position on door panel. 4. Install door trim panel. Header / A - Pillar Weatherstrip HEADER / A - PILLAR WEATHERSTRIP REMOVAL 1. Partially raise convertible top. 2. Remove inside rear view mirror. 3. Remove sun visors. 4. Remove header trim panel. 5. Remove both door sill trim panels. Fig. 12 6. Remove nuts holding header and A-pillar weatherstrip at upper corners of windshield (Fig. 12). 7. Remove push in fasteners at lower corners of windshield holding weatherstrip to A-pillar. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6049 8. Remove header and A-pillar weatherstrip from vehicle. 9. Clean any residual seal material from header panel. INSTALLATION Fig. 13 CAUTION: Ensure that the butyl patch and butyl rope at each corner of the windshield is present and in good condition (Fig. 13). The butyl is critical for the water management system. Replace as necessary. 1. Install new L foam starting at upper screw on A-pillar retainer. Fig. 14 2. Install new L foam starting at upper screw on A-pillar retainer (Fig. 14). 3. Position header and A-pillar weatherstrip on vehicle. 4. Secure weatherstrip into retainers at header and A-pillar. 5. Install nuts at upper corners of windshield. 6. Install push in fasteners at lower corners of windshield. 7. Install door sill trim panels. 8. Install header trim panel. 9. Install sun visors. 10. Install inside rear view mirror. 11. Lower and secure convertible top. Outer Door Belt Weatherstrip Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6050 OUTER DOOR BELT WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 16 2. Remove screws attaching outer belt weatherstrip to outer door panel (Fig. 16). 3. Remove outer belt weatherstrip from the vehicle. INSTALLATION 1. Position outer belt weatherstrip on vehicle. 2. Install screws to hold outer weatherstrip to outer door panel. 3. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Front And Rear Door Opening Weatherstrip Rear Door Weatherstrip: Service and Repair Front And Rear Door Opening Weatherstrip FRONT & REAR DOOR OPENING WEATHERSTRIP REMOVAL 1. Open door. 2. Remove door sill plate. Fig. 7 3. Pull weatherstrip from pinch flange around door opening (Fig. 7). INSTALLATION Position the splice in the door opening weatherstrip in the center of the bottom of the opening and reverse the preceding operation. 1. Push weatherstrip on to pinch flange around door opening. 2. Install door sill plate. 3. Close door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Front And Rear Door Opening Weatherstrip > Page 6055 Rear Door Weatherstrip: Service and Repair Rear Door B - Pillar Door Seal REAR DOOR B - PILLAR DOOR SEAL REMOVAL 1. Using a suitable heat gun, warm seal to approximately 100 degrees F to ease adhesive separation. Fig. 18 2. Peel B-pillar seal from upper door frame, top to bottom (Fig. 18). 3. Clean adhesive residue from door frame. INSTALLATION 1. If original seal is reused, clean adhesive residue from back of seal. 2. Apply body side molding tape to back of seal. 3. Peel protective paper from back of tape. 4. Place cutout in seal around screw head at bottom of seal location. 5. Align seal to edge of door frame. 6. Press adhesive onto door frame. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove rear door trim panel. 2. Pull upward at front end of inner belt weatherstrip. Fig. 20 3. Remove inner belt weatherstrip from vehicle (Fig. 20). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Push downward on the inner belt weatherstrip. 3. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 6060 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL Fig. 21 1. Remove screw attaching forward end of molding to rear door (Fig. 21). 2. Disengage clips attaching rearward end of belt molding to rear door. Fig. 22 3. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 22). 4. Remove belt molding from door. INSTALLATION 1. Place belt molding into position. 2. Push or tap downward at each clip attaching belt molding to door. 3. Engage clips attaching rearward end of belt molding to rear door. 4. Install screw attaching forward end of molding to rear door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 6061 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 19 2. Pull glass run weatherstrip from door glass opening frame (Fig. 19). INSTALLATION 1. Install glass run weatherstrip to door glass opening frame. 2. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures Sunroof / Moonroof Weatherstrip: Procedures OPENING TRIM LACE REMOVAL Fig.8 Sunroof Opening Trim Lace Remove lace by starting at the joint and pull one end of the lace away from the headliner until the entire lace is removed. INSTALLATION Install lace by starting at the spot of the previous joint, fully seat the lace in place around the sunroof opening, cut to fit if necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 6066 Sunroof / Moonroof Weatherstrip: Removal and Replacement SUNROOF GLASS PANEL SEAL REMOVAL 1. Remove sunroof glass panel. 2. Grasp the seal and pull seal away from the glass panel. The seal is a one piece seal. INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Install seal on glass. Using care working the seal around the glass, being careful not to over stretch the seal while installing. 2. Install sunroof glass panel. 3. Test sunroof operation, adjust as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair DECKLID OPENING WEATHERSTRIP REMOVAL 1. Release decklid latch and open decklid. 2. Disconnect and isolate the battery negative cable. 3. Remove four push pins and remove the latch cover. 4. Disconnect the three harness electrical connectors and remove the ground strap screw. 5. Tape the wires together and tape in one chase wire. 6. Route the wires through the decklid. Fig. 2 7. Pull decklid opening weatherstrip from decklid opening flange (Fig. 2). 8. Remove decklid opening weatherstrip from vehicle. INSTALLATION 1. Position decklid opening weatherstrip on vehicle (Fig. 2). 2. Starting at center weatherstrip over decklid latch striker and press weatherstrip firmly onto decklid opening flange. Ensure that the weatherstrip seats properly along the entire length. 3. Route the wire harness through the decklid and remove the tape and chase wire. 4. Connect the three harness connectors and install the ground strap screw. 5. Install the latch cover and install the four push pins. 6. Connect the battery negative cable. 7. Verify decklid operation and sealing. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Servo Mounting Bracket Nuts .............................................................................................................. .................................................. 5.1 Nm (45 In. Lbs) Servo Mounting Nuts ........................................................................................................................... .................................................. 6.7 Nm (60 In. Lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6074 Vehicle Speed Control Servo Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6075 Cruise Control Servo: Description and Operation The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded by the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6076 Cruise Control Servo: Service and Repair REMOVAL Fig.2 Negative Battery Cable 1. Disconnect the negative battery cable. 2. Remove 2 nuts attaching servo bracket to shocktower. 3. Disconnect electrical connectors and vacuum hose. 4. Remove two nuts attaching speed control cable and mounting bracket to servo. Fig.3 Speed Control Cable And Bracket 5. Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo. 6. Remove servo mounting bracket. INSTALLATION 1. With throttle in full open position feed cable sleeve through hole in bracket, then align hole in speed control cable sleeve with hole in servo pin and install retaining clip. 2. Connect vacuum hose to servo. 3. Connect electrical connector. 4. Insert servo studs through holes in speed control cable and mounting bracket. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6077 5. Install nuts, tighten to 6.7 Nm (60 in. lbs.). 6. Install servo and bracket to stud plate in shocktower and tighten nuts. 7. Connect negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed control switches are located on the steering wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6081 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM. The switch names are: ON, OFF, SET COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST RESUME, ACCEL, TAP-UP TAP-DOWN, COAST and CANCEL. Refer to the Speed Control for more information. Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6082 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO the RESTRAINT SYSTEMS for more information. 1. Remove the negative battery cable. 2. Turn OFF ignition. Fig.4 Speed Control Switch 3. Remove screw from back of the switch. 4. Rock switch away from airbag and steering wheel. 5. Disconnect two-way electrical connector. 6. Repeat for the other switch. INSTALLATION 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw into the back of the switch. 4. Repeat for the other switch. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications Cruise Control Vacuum Reservoir: Specifications Vacuum Reservoir Screws .................................................................................................................. .................................................. 10.2 Nm (90 In. Lbs) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6086 Cruise Control Vacuum Reservoir: Locations The vacuum reservoir is located under the left front headlamp, in front of the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6087 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is located under the left front headlamp, in front of the battery. It is made of plastic and does not contain any other parts, such as a check valve. The reservoir stores engine vacuum. Manifold vacuum is supplied from the brake booster check valve. The speed control vacuum supply hose has a check valve at the source (brake booster) to maintain the highest available vacuum level in the servo, reservoir and vacuum hoses. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Specifications > Page 6088 Cruise Control Vacuum Reservoir: Service and Repair Fig.5 Vacuum Reservoir REMOVAL The vacuum reservoir is located below the left front headlamp. 1. Remove the front fascia, refer to the Frames and Bumper/Front Fascia for more information. 2. Remove bolt from reservoir. 3. Disconnect vacuum hose from reservoir. 4. Remove the vacuum reservoir by sliding it up slightly and separating the nail head pegs (molded into the reservoir) from the frame rail. INSTALLATION 1. Connect vacuum hose to reservoir by inserting nail head pegs on reservoir into the keyhole slots in the frame rail and slide down to lock it into place. 2. Install the vacuum reservoir. 3. Install bolt through to reservoir to frame rail. 4. Install the front fascia, refer to the Frames and Bumper/Front Fascia for more information. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed control switches are located on the steering wheel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6093 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM. The switch names are: ON, OFF, SET COAST, RESUME, ACCEL, TAP-UP, COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST RESUME, ACCEL, TAP-UP TAP-DOWN, COAST and CANCEL. Refer to the Speed Control for more information. Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6094 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO the RESTRAINT SYSTEMS for more information. 1. Remove the negative battery cable. 2. Turn OFF ignition. Fig.4 Speed Control Switch 3. Remove screw from back of the switch. 4. Rock switch away from airbag and steering wheel. 5. Disconnect two-way electrical connector. 6. Repeat for the other switch. INSTALLATION 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw into the back of the switch. 4. Repeat for the other switch. 5. Install the negative battery cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Chime System Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6119 Audible Warning Device: Description and Operation CHIME SYSTEM The chime system is comprised of an audible chime located internal to the BCM; and is dependent on various inputs to the BCM to operate. These inputs to the BCM include key-in ignition switch, exterior lamps as well as requests for the Mechanical Instrument Cluster from the seat belt switch input or whenever certain indicators are turned ON. CHIME/BUZZER The chime warning/reminder system includes signals for fasten seat belts, certain warning indicators, exterior lamps left ON, key left in ignition and door ajar. For diagnosis and testing, use the DRB III scan tool and the proper Body Diagnostic Procedures. Door Ajar Chime The BCM will sound an audible chime when the key is in the ignition and the drivers door is open. This is to prevent partial closing of vehicle doors. An audible chime will sound when the vehicle begins to move and the transmission range indicator display will indicate DOOR. Fasten Seat Belts At power up, a seat belt lamp bulb check will be conducted by the instrument cluster. If the driver side seat belt buckle is unbuckled during the bulb check, an accompanying chime will sound within the duration of the bulb check. Single Warning Chime After bulb check at power-up, if any of the following indicators are still activated, the cluster will request a single chime from the BCM. ABS, Air Bag, Check Engine, Charging System, Engine Temperature, Low Fuel (after 10 sec. for accurate fuel info), and BRAKE (if speed is greater than 2 mph). Exterior Lamps Left ON An audible chime tone that indicates the exterior lamps were left ON. Key Left In Ignition An audible chime tone that indicates the key was left in ignition. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6120 Audible Warning Device: Testing and Inspection For Removal and Installation of Junction Block (JB) (Refer to POWER DISTRIBUTION/JUNCTION BLOCK - REMOVAL). For Removal and Installation of Body Control Module (BCM), refer to Electrical, Electronic Control Modules, Body Control Modules, Removal, and Installation. No Tone When Ignition Switch Is Turned On And Drivers Seat Belt Is Unbuckled And Fully Retracted 1. Check driver's seat belt retractor switch for a ground when belt is retracted. 2. Use DRB III scan tool to perform PCI data bus diagnostics on the BCM for battery, ignition and seat belt switch inputs. 3. Use DRB III scan tool to perform actuator diagnostics on BCM Chime. 4. Check for tone in any other function. Fig.1 Junction Block Connector To The BCM 5. Remove BCM from Junction Block. Check for battery voltage at terminal JB-12 and ignition feed at terminal JB-6 of BCM (Fig. 1). Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 6. If voltage not OK, repair as necessary. No Fasten Seat Belt Lamp When Ignition Switch Is Turned ON 1. At power-up, the cluster will turn ON the seat belt warning indicator for 6 ± 1 seconds as required regardless of the driver side seat belt buckle status. If the warning indicator does not turn ON, verify if the socketted red LED is seated properly and good contact with the PC-board is present. If not seated properly, then seat the LED properly by twisting the socket counterclockwise. If seated properly, replace the LED. Seat Belt Lamp ON For More Than 7 Seconds After Driver Seat Belt Buckle Switch Is Fastened And Ignition ON 1. Use a DRB III scan tool to verify status of the driver seat belt buckle switch as received by the instrument cluster. Compare to the actual seat belt buckle status: If buckled, lamp is OFF or if unbuckled, lamp is ON. If the status received by the instrument cluster does match the actual buckle seat belt switch status (buckled/unbuckled), then check the driver seat belt switch and wiring for proper connection. No Tone Or Door Indicated In Place Of Odometer When A Door Is Ajar And Vehicle Begins Moving The vehicle must be moving for the chime to occur. However the door indicator will come ON regardless of the vehicle movement. The PCI data bus, Transmission Control Module (TCM) and Powertrain Control Module (PCM) must be operational. 1. Check all door jamb switches. 2. Use DRB III scan tool to perform PCI data bus diagnostics on BCM for battery and ignition switch input 3. Inspect BCM connectors and wires for proper connection. 4. Remove BCM from Junction Block. Check for battery voltage at terminal JB-12 and ignition feed at terminal JB-6 of BCM. Refer to the Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6121 appropriate wiring information. 5. If voltage not OK, repair as necessary No Tone When Headlamps Are ON, Ignition Switch Is OFF And Driver's Door Is Open. 1. Check left door jamb switch for good ground when driver's door is open. 2. Use DRB III scan tool to perform PCI data bus diagnostics on BCM for battery, ignition switch input, headlamp and driver's door input and Chime Output Test. 3. Check headlamp switch. 4. Inspect BCM connectors and wires for proper connection. 5. Remove BCM from Junction Block. Check for battery voltage at terminal JB-12 and ignition feed at terminal JB-6 of BCM. 6. If voltage not OK, repair as necessary. No Tone When Ignition Key Is Left In Ignition Switch And It Is In The OFF Position With Driver's Door Is Open 1. Check left door jamb switch for good ground when drivers door is open. 2. Use DRB III scan tool to perform PCI data bus diagnostics on BCM for battery, ignition switch input, key-in-switch and driver's door input and Chime Output Test. 3. Check key-in switch. 4. Inspect BCM connectors and wires for proper connection. 5. Remove BCM from Junction Block. Check for battery voltage at terminal JB-12 and ignition feed at terminal JB-6 of BCM. Refer to the appropriate wiring information. 6. If voltage not OK, repair as necessary. Chimes Continue When Headlamps Are Turned OFF And/or Key Is Removed From Ignition 1. Use DRB III scan tool to perform PCI data bus diagnostics on BCM for headlamp or key-in-ignition inputs. 2. Check wiring for a grounded condition between key-in switch and BCM. Check headlamp switch to BCM wiring for short to battery. 3. Inspect BCM connectors and wires for proper connection. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Application and ID Brake Warning Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Brake Warning ..................................................................................................................................... .............................................................. PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Application and ID > Page 6125 Brake Warning Indicator: Service and Repair CLUSTER ILLUMINATION AND WARNING LAMPS REPLACEMENT REMOVAL 1. Remove the Instrument Cluster. 2. Turn over cluster and expose the illumination bulbs or warning indicator bulbs/socketed LEDs by removing the cluster cardboard back cover. For accurate identification of the defective bulb or LED, see the labels on the PC board. 3. After Identifying the defective bulb or LED, twist it out of the cluster using a counterclockwise motion. INSTALLATION 1. Install the new bulb/LED socket into the cluster using a clockwise motion. 2. Install the cluster cardboard back cover. 3. Install the Instrument Cluster. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Compass: Locations The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Compass: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Compass/Mini-Trip Computer Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Compass/Mini-Trip Computer (CMTC) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6173 Compass: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table CMTC/Traveler .................................................................................................................................... ......................................................... 04798364 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6174 Compass: Description and Operation COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located between the center A/C ducts. The CMTC is an electronic control module with a vacuum fluorescent display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. An "all segments" test can be performed by pressing both the "step" and "US/M" switches and then turning the ignition ON. The functions that are available via actuation of the STEP switch are as follows: Compass and ambient temperature - Average Fuel Economy (AVE ECO) - Distance To Empty (DTE) - Present Fuel Economy (ECO) - Trip odometer (ODO) - Elapsed ignition time (ET) - Blank screen (OFF) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6175 Compass: Adjustments Setting The Compass The compass in the CMTC module is self-calibrating and requires no manual adjustment. If calibration is required, the word CAL will be displayed to indicate that the compass is in the fast calibrating mode. "CAL" will turn OFF after the calibration is completed. A manual calibration can be invoked by holding down the "step" and US/M buttons until the "CAL" lamp is lit. Setting The Compass Variance Variance is the difference between north and geographic north. To determine the variance for the area you are in, refer to the zone map below and follow the instructions provided. The number shown for your area is the variance number for your area. 1. With ignition ON, use the STEP button to select the Compass/Temperature display. 2. Press and hold the US/M and STEP buttons until VAR is displayed. CMTC displays the last variance zone and the word VAR. All other display segments are OFF. 3. Use the STEP button to select the proper variance zone number (1-15). Each variance zone represents a 4-degree shift in magnetic variation from central zone 8, which has no variation from true north. 4. After selecting the proper variance zone number, press the STEP and US/M buttons or wait several seconds. The new variance zone is then set and the CMTC will resume normal operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6176 Compass: Service and Repair REMOVAL 1. Remove the CMTC/Traveler from the instrument panel. Refer to Body, Instrument Panel, Compass Mini-Trip Computer, Removal. 2. With the CMTC removed from the cluster bezel, remove the tape from the lamp access opening at the bottom of the CMTC/Traveler. 3. With a screwdriver, twist the bulb assembly 1/4 turn counterclockwise. Remove bulb and replace. INSTALLATION 1. With a screwdriver, twist the bulb 1/4 turn clockwise. 2. Install the tape to the access opening at the bottom of the CMTC/Traveler to prevent any light leaking. 3. Install the CMTC/Traveler. Refer to Body, Instrument Panel, Compass Mini-Trip Computer, Installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Application and ID Cruise Control Indicator Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Speed Control ...................................................................................................................................... ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6184 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6188 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement Technical Service Bulletin # 899 Date: 001001 Recall - Traveler Module/PCM Replacement October 2000 Dealer Service Instructions for: Customer Satisfaction Notification No. 899 Traveler Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 00-50 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with the Traveler option (Sales Code LET) and NOT equipped with a Smart Key Immobilizer Module (SKIM) (Sales Code - GXX) built through September 25, 2000 (MDH 092512). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The traveler module on about 6,900 of the above vehicles may transmit an erroneous "security system" signal to the Powertrain Control Module (PCM) if the vehicle is facing West when started. This will prevent the engine from starting. Repair: The traveler module must be replaced. If the no-start problem has already occurred, the PCM must also be replaced. Parts Information Due to the small number of involved vehicles expected to require PCM replacement, no parts will be distributed initially. PCM's should be ordered only if a vehicle has experienced a no-start condition. Very few vehicles are expected to require PCM replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6197 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD899". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by mail. They are requested a schedule appointments for this service with their dealers. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling cut the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Replace Traveler Module 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the left instrument panel end cover. 3. Using a trim stick, gently pry up on the power mirror switch bezel; then disconnect the switch electrical connector and remove the switch and bezel assembly. 4. Using the trim stick, gently pry up on the instrument panel center trim bezel. 5. Disconnect the HVAC control electrical connectors and set the bezel assembly aside. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6198 6. Remove the one screw from the passenger side trim bezel and then remove the passenger side bezel by unsnapping the clips. 7. Remove the one screw from the driver side trim bezel and then remove the driver side bezel by unsnapping the clips. 8. Remove the five (5) screws from the left lower instrument panel, trim/knee blocker. 9. Remove the four (4) cluster bezel screws. 10. Using a trim stick, unsnap the cluster bezel. 11. Disconnect the traveler module electrical connector. 12. Remove the cluster bezel assembly. 13. Remove the two (2) screws that attach the traveler module to the cluster bezel. 14. Remove the traveler module from the cluster bezel. 15. If the bezel on the removed traveler module is not Slate colored, transfer the old traveler bezel to the new traveler module. To remove the bezel, pull up on the two bezel mounting tabs on the bottom of the module. 16. Install the new traveler module into the cluster bezel. Tighten the attaching screws securely. 17. Connect the traveler module electrical connector. 18. Install the cluster bezel. Tighten the four (4) cluster bezel screws securely. 19. Install the left lower instrument trim panel/knee blocker. Tighten the five (5) trim panel screws securely. 20. Install the driver side trim bezel. Tighten the driver side trim bezel screw securely. 21. Install the passenger side trim bezel. Tighten the passenger side trim bezel screw securely. 22. Connect the HVAC control electrical connectors. 23. Install the instrument panel center trim bezel. 24. Connect the power mirror switch electrical connector; then install the switch and bezel assembly. 25. Install the left instrument panel end cover. 26. If the vehicle has experienced a no-start condition due to the erroneous traveler signal, the PCM must be replaced. Continue with Section B - Replace PCM. If the vehicle could be started normally prior to the traveler module replacement, connect the negative battery cable and then return the vehicle to the customer. B. Replace PCM IMPORTANT: Only those vehicles that have experienced a no-start condition require PCM replacement. Very few vehicles are expected to require PCM replacement. 1. Remove the air cleaner box. 2. Disconnect the PCM electrical connectors and move the wiring harness aside. 3. Remove the two (2) bolts and one (1) nut from the PCM bracket. 4. Remove the PCM and Bracket assembly. 5. Remove the PCM from the PCM bracket. 6. Install the new PCM onto the bracket. Tighten the screws to 35 in-lbs (4 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6199 7. Install the PCM and bracket assembly. Tighten the two (2) bolts and one (1) nut to 35 in-lbs (4 Nm) 8. Connect the PCM electrical connectors. 9. Install the air cleaner box. 10. Connect the negative battery cable. 11. Using the DRB III scan tool, program the new PCM with the vehicle's Vehicle Identification Number (VIN) and current vehicle mileage. NOTE: Failure to reprogram the new PCM with VIN information and mileage may cause a Diagnostic Trouble Code (DTC) to be set. a. Connect the DRB III to the underdash diagnostic connector. b. Select "DRB III STANDALONE" (1) and then press "Enter". c. Select "1998 - 2001 DIAGNOSTICS" (1) and then press "Enter". d. Select "ENGINE" (1) and press "Enter" three times. e. Select "FUNCTION SCREEN" and scroll to page two (press the right arrow key once) f. Select "MISCELLANEOUS". g. Select "CHECK VIN" (4) and then press "Enter". h. Follow the instructions on the DRB III screen to enter the VIN. CAUTION: Verify that the correct VIN is displayed on the DRB III before pressing the "Enter" key. The VIN cannot be changed once it is entered. If an incorrect VIN is entered, the module must be replaced to correct the VIN error. i. Press the "PAGE BACK" button on the DRB III key pad. j. Select "SRI MEMORY CHECK" (3) and then press "Enter". k. Follow the instructions on the DRB III to enter the current vehicle mileage. 12. After entering the VIN and mileage, check for any additional software updates. Continue with Section C - Check for PCM Software Updates. C. Check for PCM Software Updates: NOTE: The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at the latest release is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON" 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request an MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6200 NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button; then continue with Step E. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped) .Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after-all other modules have had their trouble codes erased. 9. Continue with Section D - Install Authorized Software Update Label. D. Install Authorized Software Update Label: Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label, and attach it to the PCM. Cover the label with the clear plastic portion of the label. Continue with Section E - Install the Authorized Modifications Label. E. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label. Then attach the label near the VECI label. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Recalls for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6201 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement Technical Service Bulletin # 899 Date: 001001 Recall - Traveler Module/PCM Replacement October 2000 Dealer Service Instructions for: Customer Satisfaction Notification No. 899 Traveler Module Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 00-50 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models: 2001 (JR) Dodge Stratus Sedan and Chrysler Sebring Sedan (Four-Door) NOTE: This notification applies only to the above vehicles equipped with the Traveler option (Sales Code LET) and NOT equipped with a Smart Key Immobilizer Module (SKIM) (Sales Code - GXX) built through September 25, 2000 (MDH 092512). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The traveler module on about 6,900 of the above vehicles may transmit an erroneous "security system" signal to the Powertrain Control Module (PCM) if the vehicle is facing West when started. This will prevent the engine from starting. Repair: The traveler module must be replaced. If the no-start problem has already occurred, the PCM must also be replaced. Parts Information Due to the small number of involved vehicles expected to require PCM replacement, no parts will be distributed initially. PCM's should be ordered only if a vehicle has experienced a no-start condition. Very few vehicles are expected to require PCM replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6207 Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD899". Owner Notification and Service Scheduling All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement by mail. They are requested a schedule appointments for this service with their dealers. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Not Available If a vehicle is not available for service, let us know by filling cut the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Replace Traveler Module 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the left instrument panel end cover. 3. Using a trim stick, gently pry up on the power mirror switch bezel; then disconnect the switch electrical connector and remove the switch and bezel assembly. 4. Using the trim stick, gently pry up on the instrument panel center trim bezel. 5. Disconnect the HVAC control electrical connectors and set the bezel assembly aside. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6208 6. Remove the one screw from the passenger side trim bezel and then remove the passenger side bezel by unsnapping the clips. 7. Remove the one screw from the driver side trim bezel and then remove the driver side bezel by unsnapping the clips. 8. Remove the five (5) screws from the left lower instrument panel, trim/knee blocker. 9. Remove the four (4) cluster bezel screws. 10. Using a trim stick, unsnap the cluster bezel. 11. Disconnect the traveler module electrical connector. 12. Remove the cluster bezel assembly. 13. Remove the two (2) screws that attach the traveler module to the cluster bezel. 14. Remove the traveler module from the cluster bezel. 15. If the bezel on the removed traveler module is not Slate colored, transfer the old traveler bezel to the new traveler module. To remove the bezel, pull up on the two bezel mounting tabs on the bottom of the module. 16. Install the new traveler module into the cluster bezel. Tighten the attaching screws securely. 17. Connect the traveler module electrical connector. 18. Install the cluster bezel. Tighten the four (4) cluster bezel screws securely. 19. Install the left lower instrument trim panel/knee blocker. Tighten the five (5) trim panel screws securely. 20. Install the driver side trim bezel. Tighten the driver side trim bezel screw securely. 21. Install the passenger side trim bezel. Tighten the passenger side trim bezel screw securely. 22. Connect the HVAC control electrical connectors. 23. Install the instrument panel center trim bezel. 24. Connect the power mirror switch electrical connector; then install the switch and bezel assembly. 25. Install the left instrument panel end cover. 26. If the vehicle has experienced a no-start condition due to the erroneous traveler signal, the PCM must be replaced. Continue with Section B - Replace PCM. If the vehicle could be started normally prior to the traveler module replacement, connect the negative battery cable and then return the vehicle to the customer. B. Replace PCM IMPORTANT: Only those vehicles that have experienced a no-start condition require PCM replacement. Very few vehicles are expected to require PCM replacement. 1. Remove the air cleaner box. 2. Disconnect the PCM electrical connectors and move the wiring harness aside. 3. Remove the two (2) bolts and one (1) nut from the PCM bracket. 4. Remove the PCM and Bracket assembly. 5. Remove the PCM from the PCM bracket. 6. Install the new PCM onto the bracket. Tighten the screws to 35 in-lbs (4 Nm) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6209 7. Install the PCM and bracket assembly. Tighten the two (2) bolts and one (1) nut to 35 in-lbs (4 Nm) 8. Connect the PCM electrical connectors. 9. Install the air cleaner box. 10. Connect the negative battery cable. 11. Using the DRB III scan tool, program the new PCM with the vehicle's Vehicle Identification Number (VIN) and current vehicle mileage. NOTE: Failure to reprogram the new PCM with VIN information and mileage may cause a Diagnostic Trouble Code (DTC) to be set. a. Connect the DRB III to the underdash diagnostic connector. b. Select "DRB III STANDALONE" (1) and then press "Enter". c. Select "1998 - 2001 DIAGNOSTICS" (1) and then press "Enter". d. Select "ENGINE" (1) and press "Enter" three times. e. Select "FUNCTION SCREEN" and scroll to page two (press the right arrow key once) f. Select "MISCELLANEOUS". g. Select "CHECK VIN" (4) and then press "Enter". h. Follow the instructions on the DRB III screen to enter the VIN. CAUTION: Verify that the correct VIN is displayed on the DRB III before pressing the "Enter" key. The VIN cannot be changed once it is entered. If an incorrect VIN is entered, the module must be replaced to correct the VIN error. i. Press the "PAGE BACK" button on the DRB III key pad. j. Select "SRI MEMORY CHECK" (3) and then press "Enter". k. Follow the instructions on the DRB III to enter the current vehicle mileage. 12. After entering the VIN and mileage, check for any additional software updates. Continue with Section C - Check for PCM Software Updates. C. Check for PCM Software Updates: NOTE: The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at the latest release is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON" 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request an MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6210 NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button; then continue with Step E. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped) .Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after-all other modules have had their trouble codes erased. 9. Continue with Section D - Install Authorized Software Update Label. D. Install Authorized Software Update Label: Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label, and attach it to the PCM. Cover the label with the clear plastic portion of the label. Continue with Section E - Install the Authorized Modifications Label. E. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label. Then attach the label near the VECI label. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Driver/Vehicle Information Display: > 899 > Oct > 00 > Recall - Traveler Module/PCM Replacement > Page 6211 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6215 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6216 Fuel Gauge Sender: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 1). Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6217 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector (Fig. 3). 4. Push level sensor signal and ground terminals out of the connector (Fig. 3). Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove (Fig. 4). 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6222 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL 1. Remove the Instrument Cluster. Refer to Electrical, Instrument Cluster, Removal. 2. Turn over cluster and expose the illumination bulbs or warning indicator bulbs/socketed LEDs by removing the cluster cardboard back cover. For accurate identification of the defective bulb or LED, see the labels on the PC board. 3. After Identifying the defective bulb or LED, twist it out of the cluster using a counterclockwise motion. INSTALLATION 1. Install the new bulb/LED socket into the cluster using a clockwise motion. 2. Install the cluster cardboard back cover. 3. Install the Instrument Cluster. Refer to Electrical, Instrument Cluster, Installation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection To test the key left in ignition function: - The ignition switch must be in the OFF position with key in ignition. - Driver's door open. - Chime should sound until key is removed from ignition or drivers door is closed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Application and ID Low Fuel Lamp/Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Low Fuel .............................................................................................................................................. ...................................................... Amber LED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Check Engine ...................................................................................................................................... ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 6238 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Sender: All Technical Service Bulletins Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: Customer Interest Engine Oil Pressure Light - ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Warning Lamp/Indicator: > 08-36-99 > Oct > 99 > Engine Oil Pressure Light - ON/Flickers Oil Pressure Warning Lamp/Indicator: All Technical Service Bulletins Engine Oil Pressure Light ON/Flickers NUMBER: 08-36-99 GROUP: Electrical DATE: Oct. 15, 1999 SUBJECT: Engine Oil Pressure Light Flicker OVERVIEW: This bulletin involves adding a terminal/wire/vent to the oil pressure switch connector. MODELS: 1998 - 1999 (LH) Concorde/Intrepid NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.7L ENGINE. SYMPTOM/CONDITION: With a hot engine the oil pressure light may be on or flicker on at idle. DIAGNOSIS: Verify engine oil pressure as described on page 9-21 of the 1999 Concorde/Intrepid/LHS/300M service manual (Publication No. 81-270-9140). If engine oil pressure is within specification perform the Repair Procedure. PARTS REQUIRED: 1 05017800AA Wire Terminal/Vent REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove engine oil pressure switch connector from switch. 3. Remove sealing dart from the empty cavity at the rear of the connector. 4. Pull terminal locking ring outward from front (switch) side of connector to gain access to terminal locking tabs. 5. Install wire terminal/vent, p/n 05017800AA, in place of the removed sealing dart. Slide locking ring back into place. 6. Attach the connector back on the oil pressure switch. 7. Spot tape the wire/vent to follow the harness towards the top of the engine compartment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-65-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Technical Service Bulletins > Page 6265 Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Engine Oil Pressure ............................................................................................................................. ............................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Seat Belt .............................................................................................................................................. ........................................................... Red LED Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6273 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge level sending unit is attached to the side of fuel pump module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6277 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT/SENSOR The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6278 Fuel Gauge Sender: Service and Repair REMOVAL Remove fuel pump module. Refer to Fuel Pump Module. Fig. 1 Fuel Pump/Level Sensor Electrical Connector 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 1). Fig. 2 Wire Terminal Locking Wedge 2. Pull off locking wedge (Fig. 2). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6279 Fig. 3 Removing Wires From Connector 3. Using a small screwdriver lift locking finger away from terminal and push level sensor and ground terminals out of connector (Fig. 3). 4. Push level sensor signal and ground terminals out of the connector (Fig. 3). Fig. 4 Loosening Level Sensor 5. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove (Fig. 4). 6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of installation channel in module. INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor. 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Testing and Inspection Key Reminder Switch: Testing and Inspection To test the key left in ignition function: - The ignition switch must be in the OFF position with key in ignition. - Driver's door open. - Chime should sound until key is removed from ignition or drivers door is closed. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Application and ID Shift Indicator: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Shift Indicator ....................................................................................................................................... ...................................................... VF Display Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Application and ID > Page 6286 Shift Indicator: Service and Repair REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of transmission range indicator bezel from floor console. 3. Pull upward carefully on transmission range indicator bezel and disengage tabs from rear floor console bezel. 4. Disconnect wire connector to lamp assembly. 5. Remove transmission range indicator bezel and lamp assembly from vehicle. INSTALLATION 1. Position transmission range indicator bezel and lamp assembly to vehicle. 2. Connect wire connector to lamp assembly. 3. Engage tabs on transmission range indicator bezel to slots in rear floor console bezel. 4. Push downward on transmission range indicator bezel to engage to bezel to floor console. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Application and ID Backup Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Back-up ............................................................................................................................................... ..................................................... 921 (W16W) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams Brake Lamp: Diagrams Left Tail/Stop Lamp Right Tail/Stop Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 6294 Brake Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Brake ................................................................................................................................................... ............................................................... 3175K Tail/Brake/Turn Signal .............................................. ......................................................................................................................................... 3175K Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations The brake lamp switch is located under the instrument panel at the brake pedal arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6298 Brake Light Switch: Description and Operation The brake lamp switch is located under the instrument panel at the brake pedal arm. It controls operation of the vehicle's brake lamps. Also, if the vehicle is equipped with speed control, the brake lamp switch will deactivate speed control when the brake pedal is depressed. When the brake pedal is depressed, the plunger on the outside of the switch extends outward. This action closes the electrical contacts within the switch, completing the circuit to the brake lamps at the rear of the vehicle, thus illuminating the brake lamps and the Center-High-Mounted Stop Lamp (CHMSL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6299 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. Refer to ADJUSTMENTS. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Refer to REMOVAL for the proper procedure. Fig.2 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. Refer to INSTALLATION for the proper procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6300 Brake Light Switch: Adjustments 1. Remove the brake lamp switch from its bracket. The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch if necessary. 3. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Connect the wiring harness connector to the brake lamp switch if previously disconnected. 5. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 6. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 7. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6301 Brake Light Switch: Service and Repair REMOVAL 1. Remove the brake lamp switch from its bracket . The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch. INSTALLATION NOTE: Prior to installing brake lamp switch into the mounting bracket, the plunger must be moved to its fully extended position using the procedure in Step 1. 1. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the brake lamp switch. 3. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6302 CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 4. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 5. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Application and ID Center Mounted Brake Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Center High Mounted Stop Lamp ............................................................................................................................................................ 921 (W16W) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp (CHMSL) Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove fasteners from trunk latch cover by prying under the head of the fastener with a flat bladed tool. 3. Remove trunk latch cover. 4. Rotate socket counterclockwise one quarter turn. 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into back of lamp. 3. Rotate socket clockwise one quarter turn. 4. Install trunk latch cover. Insert fasteners and press into place 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center High Mounted Stop Lamp (CHMSL) Replacement > Page 6308 Center Mounted Brake Lamp: Service and Repair Center High Mounted Stop Lamp Unit (CHMSL) Replacement REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove fasteners from trunk latch cover by prying under the head of the fastener with a flat bladed tool. 3. Remove trunk latch cover. 4. Remove socket from CHMSL. Fig.9 Center High Mounted Stop Lamp 5. Remove screws attaching CHMSL to decklid. 6. Remove CHMSL from decklid. INSTALLATION 1. Install CHMSL to decklid. 2. Install screws attaching CHMSL to decklid. 3. Install socket into CHMSL. 4. Install trunk latch cover. Insert fasteners and press into place. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Ash Receiver Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Glove Box Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Open glove box door. 3. Push switch through from behind. 4. Disconnect wire harness from switch. 5. Remove bulb from switch. INSTALLATION 1. Install bulb to switch. 2. Connect wire harness to switch. 3. Install switch to instrument panel. 4. Close glove box door. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6323 Daytime Running Lamp Control Unit: Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6324 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. From the left side of the vehicle, insert a flat bladed pry tool under the lens. 3. Remove bulb. INSTALLATION 1. Insert bulb into lamp. 2. Push lens into place 3. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6332 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams Left Fog Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Page 6336 Fog/Driving Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Fog Lamp ............................................................................................................................................ .................................................................... 899 Front And Rear Fog Lamp ....................................... .......................................................................................................................................... PC161 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Page 6337 Fog/Driving Lamp: Testing and Inspection Fog Lamp Diagnosis (Part 1 Of 2) Fog Lamp Diagnosis (Part 2 Of 2) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Page 6338 Fog/Driving Lamp: Adjustments Fog Lamp Alignment Prepare a alignment screen. (Refer to LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT ADJUSTMENTS). A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp center line and straight ahead. Fig.14 Fog Lamp Adjuster To adjust fog lamp alignment, rotate alignment screw to achieve the specified low beam hot spot pattern. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Service and Repair > Fog Lamp Replacement Fog/Driving Lamp: Service and Repair Fog Lamp Replacement REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove fog lamp unit. (Refer to LAMPS/LIGHTING - EXTERIOR/FOG LAMP UNIT - REMOVAL). 3. Disconnect wire connector from back of fog lamp. 4. Rotate bulb base counterclockwise one quarter turn. 5. Pull bulb from back of lamp. INSTALLATION 1. Install bulb and twist clockwise. 2. Connect the fog lamp harness connector. 3. Install foglamp unit. (Refer to LAMPS/LIGHTING - EXTERIOR/FOG LAMP UNIT - INSTALLATION). 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Service and Repair > Fog Lamp Replacement > Page 6341 Fog/Driving Lamp: Service and Repair Fog Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove screw attaching fog lamp to front bumper fascia. 3. Remove fog lamp from fascia. 4. Disconnect wire connector from fog lamp bulb. Fig.12 Fog Lamp Unit 5. Remove fog lamp from vehicle. INSTALLATION 1. Place fog lamp into position. 2. Connect wire connector to fog lamp bulb. 3. Install fog lamp to fascia. 4. Install screw attaching fog lamp to front bumper fascia. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions Fuse Panel Lamp: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Fuse Panel Lamp: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Fuse Panel Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Panel Lamps Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Fig.10 Combination Flasher Location Fig.11 Combination Flasher Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6369 Hazard Warning Flasher: Description and Operation Fig.10 Combination Flasher Location COMBINATION FLASHER The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). An inoperative or incomplete turn signal circuit will result in an increase in flasher speed. The flasher is mounted to the back side of the multi-function switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6370 Hazard Warning Flasher: Testing and Inspection Combination Flasher Diagnosis (Part 1 Of 2) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6371 Combination Flasher Diagnosis (Part 2 Of 2) For combination flasher Diagnosis and Testing, refer to the table. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 6372 Hazard Warning Flasher: Service and Repair Fig.10 Combination Flasher Location REMOVAL The flasher is mounted to the back side of the multi-function switch. To gain access, the upper steering column cover must be removed. The flasher can be removed by pulling it forward. The flasher is serviced separately from the multi-function switch. The flasher is black in color for ease of identification. INSTALLATION The flasher is mounted to the back side of the multi-function switch. To gain access, the upper steering column cover must be removed. Push the flasher toward the rear of the vehicle. The flasher is black in color for ease of identification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6376 Hazard Warning Switch: Description and Operation Fig.15 Hazard Warning Switch HAZARD WARNING SWITCH The hazard warning switch push button protrudes from the top of the steering column. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The hazard warning system is actuated by a push button located on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on top of the button. Push and release the button to turn the hazard function ON or OFF. The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position. Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6377 The multi-function switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6382 Head Lamp Delay Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6383 Headlamp Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 6384 Headlamp Delay Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Leveling Switch (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Application and ID Hi-Beam Indicator Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table High Beam ........................................................................................................................................... .............................................................. PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6395 Horn Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6396 Horn Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6397 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6398 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6399 Horn Relay: Description and Operation The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6400 Horn Relay: Testing and Inspection 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn switch is molded into the airbag trim cover. The horn switch can not be serviced separately. For service procedures, refer to RESTRAINTS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams License Plate Lamp: Diagrams Left License (JR-41) (Built-up Export) License Lamp (JR-41) (Except Built-up Export) Right License Lamp (JR-41) (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 6407 License Plate Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application License Plate ....................................................................................................................................... ..................................................... 2825 (WSW) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement License Plate Lamp: Service and Repair License Plate Lamp Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove screws attaching license plate lamp to rear bumper fascia. Fig.19 License Plate Lamp Bulb 3. Remove license plate lamp. 4. Rotate socket counterclockwise one quarter turn. 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION 1. Place bulb into socket. 2. Push socket into back of lamp. 3. Rotate socket clockwise one quarter turn. 4. Install license plate lamp. 5. Install screws attaching license plate lamp. 6. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > License Plate Lamp Replacement > Page 6410 License Plate Lamp: Service and Repair License Plate Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.20 License Plate Lamp 2. Remove screws attaching license plate lamp. 3. Remove license plate lamp from fascia. 4. Remove socket from lamp. INSTALLATION 1. Install socket to lamp. 2. Install license plate lamp to fascia. 3. Install screws attaching license plate lamp. 4. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Recalls for Map Light: > NHTSA00V278000 > Sep > 00 > Recall 00V278000: Silencer Pad May Fall onto Map Light Map Light: Recalls Recall 00V278000: Silencer Pad May Fall onto Map Light Through degradation of the bond between the silencer Pad and a sheet metal panel (quarter inner upper), the pad may fall onto the map light located in the rear seating area near the C-pillar trim panel (LH and RH). This contact could cause the pad to melt, creating a hot smell and/or smoke during long periods of illumination. DaimlerChrysler has not yet provided a remedy for this campaign. DaimlerChrysler has not yet provided an owner notification schedule for this campaign. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Light: > NHTSA00V278000 > Sep > 00 > Recall 00V278000: Silencer Pad May Fall onto Map Light Map Light: All Technical Service Bulletins Recall 00V278000: Silencer Pad May Fall onto Map Light Through degradation of the bond between the silencer Pad and a sheet metal panel (quarter inner upper), the pad may fall onto the map light located in the rear seating area near the C-pillar trim panel (LH and RH). This contact could cause the pad to melt, creating a hot smell and/or smoke during long periods of illumination. DaimlerChrysler has not yet provided a remedy for this campaign. DaimlerChrysler has not yet provided an owner notification schedule for this campaign. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Page 6424 Overhead Map/Courtesy Lamps (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Page 6425 Map Light: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Reading Lamp ..................................................................................................................................... .................................................................... 906 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Page 6426 Map Light: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. Fig,2 Reading Lamp 2. Using a trim stick, pry lamp from headliner. 3. Disconnect wire harness connector. 4. Pull bulb socket from lamp. 5. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Install bulb socket to lamp. 3. Install wire harness connector. 4. Install reading lamp to headliner. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams Marker Lamp: Diagrams Left Tail/Side Marker Lamp Right Tail Side Marker Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams Parking Lamp: Diagrams Left Park/Turn Signal Lamp (Except Built-up Export) Right Park/Turn Signal Lamp (Except Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 6433 Parking Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Park/Turn Signal .................................................................................................................................. ...................................... 3157NA or 3157NAK Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 6434 Parking Lamp: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove headlamp retaining screws. 3. Remove headlamp to expose back of unit. 4. Rotate socket counterclockwise one quarter turn. Fig.24 Park And Turn Signal Lamp Bulb 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Twist socket into headlamp. 3. Install headlamp retaining screws. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6439 Daytime Running Lamp Control Unit: Diagrams 8w-12-3 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6440 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6444 Head Lamp Delay Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6445 Headlamp Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 6446 Headlamp Delay Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6450 Horn Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6451 Horn Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6452 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6453 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6454 Horn Relay: Description and Operation The horn relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6455 Horn Relay: Testing and Inspection 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations The brake lamp switch is located under the instrument panel at the brake pedal arm. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6460 Brake Light Switch: Description and Operation The brake lamp switch is located under the instrument panel at the brake pedal arm. It controls operation of the vehicle's brake lamps. Also, if the vehicle is equipped with speed control, the brake lamp switch will deactivate speed control when the brake pedal is depressed. When the brake pedal is depressed, the plunger on the outside of the switch extends outward. This action closes the electrical contacts within the switch, completing the circuit to the brake lamps at the rear of the vehicle, thus illuminating the brake lamps and the Center-High-Mounted Stop Lamp (CHMSL). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6461 Brake Light Switch: Testing and Inspection NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. Refer to ADJUSTMENTS. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. Refer to REMOVAL for the proper procedure. Fig.2 Switch Test - Released Position 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. 3. Gently push the plunger on the brake lamp switch in until it stops. Fig.4 Switch Test - Depressed Position 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as listed in the figure. If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. Refer to INSTALLATION for the proper procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6462 Brake Light Switch: Adjustments 1. Remove the brake lamp switch from its bracket. The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch if necessary. 3. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Connect the wiring harness connector to the brake lamp switch if previously disconnected. 5. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 6. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 7. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6463 Brake Light Switch: Service and Repair REMOVAL 1. Remove the brake lamp switch from its bracket . The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30 degrees. Pull the switch rearward and remove it from its mounting bracket. 2. Disconnect the wiring harness connector from the switch. INSTALLATION NOTE: Prior to installing brake lamp switch into the mounting bracket, the plunger must be moved to its fully extended position using the procedure in Step 1. 1. Hold the brake lamp switch firmly in one hand. Using the other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the brake lamp switch. 3. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure: - Depress the brake pedal as far down as possible. - Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. - When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30 ° to lock the switch into place. It should be aligned straight up and down. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6464 CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If too much force is used, the switch or striker can be damaged. 4. Gently release/pull back on the brake pedal until the pedal stops moving. This will ratchet the switch plunger backward to the correct adjustment position. 5. Check the brake lamps to verify they are operating properly and not staying on when the pedal is in the released position. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: Customer Interest Trip Computer/Radio Display/IP/Dome Lights - Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 6473 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: All Technical Service Bulletins Trip Computer/Radio Display/IP/Dome Lights Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 6479 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 6480 Combination Switch: Testing and Inspection 1. Remove multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-function Switch, Removal and Installation. Multi-Function Switch Continuity Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 6481 Fig.22 Multi-Function Switch Connectors 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the table and. The switch assembly is mounted over the center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Page 6482 Combination Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove the upper steering column shroud. Refer to Steering, Column, Shroud, Removal. Fig.23 Multi-Function Switch Mounting 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION Position the switch on the steering column and install the retaining screws. 1. Tighten multi-function switch to column retaining screws to 2.3 Nm (20 in. lbs.) torque. 2. Install the steering shrouds and screws. Refer to Steering, Column, Shroud, Installation. 3. Tighten steering column cover retaining screws to 2 Nm (17 in. lbs.) torque. 4. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Decklid Release Solenoid/Ajar Switch Driver Door Lock Motor/Ajar Switch Left Rear Door Lock Motor/Ajar Switch (JR-41) Passenger Door Lock Motor/Ajar Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6486 Right Rear Door Lock Motor/Ajar Switch (JR-41) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Open glove box door. 3. Push switch through from behind. 4. Disconnect wire harness from switch. 5. Remove bulb from switch. INSTALLATION 1. Install bulb to switch. 2. Connect wire harness to switch. 3. Install switch to instrument panel. 4. Close glove box door. 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 6493 Hazard Warning Switch: Description and Operation Fig.15 Hazard Warning Switch HAZARD WARNING SWITCH The hazard warning switch push button protrudes from the top of the steering column. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The hazard warning system is actuated by a push button located on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on top of the button. Push and release the button to turn the hazard function ON or OFF. The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position. Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 6494 The multi-function switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Leveling Switch (Built-up Export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn switch is molded into the airbag trim cover. The horn switch can not be serviced separately. For service procedures, refer to RESTRAINTS. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6504 Turn Signal Switch: Description and Operation Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH The multi-flinction switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams Tail Lamp: Diagrams Left Tail/Side Marker Lamp Left Tail/Stop Lamp Left Tail/Turn Signal Lamp (JR-41) (Dodge) Right Tail/Stop Lamp Right Tail/Turn Signal Lamp (JR-41) (Dodge) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 6508 Tail Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Tail Lamp ............................................................................................................................................. ................................................... 2825 (WSW) Tail/Brake/Turn Signal ............................................... ........................................................................................................................................ 3175K Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement Tail Lamp: Service and Repair Tail Lamp Replacement REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the tail lamp unit (Refer to LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT - REMOVAL). 3. Rotate socket counterclockwise one quarter turn. 4. Pull socket from back of lamp. 5. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into back of lamp. 3. Rotate socket counterclockwise one quarter turn. 4. Install the tail lamp unit (Refer to LAMPS/LIGHTING - EXTERIOR/TAILLAMP UNIT - INSTALLATION). 5. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Service and Repair > Tail Lamp Replacement > Page 6511 Tail Lamp: Service and Repair Tail Lamp Unit Replacement REMOVAL 1. Disconnect and isolate battery negative cable. 2. Disconnect wire harness connector from tail lamp unit by sliding the red lock, then pressing release tab. 3. Remove wing-nuts attaching tail lamp. Fig.25 Tail Lamp 4. Remove lamp from opening in quarter panel. INSTALLATION 1. Place tail lamp into position. 2. Connect wire connector to back of tail lamp (left side). 3. Install lamp to opening in quarter panel. 4. Install wing-nuts attaching tail lamp to rear closure panel. 5. Reconnect wire harness connector to the tail lamp. Slide lock into position. 6. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams Trunk Lamp Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Page 6515 Trunk Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Trunk ................................................................................................................................................... .................................................................... 906 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Page 6516 Trunk Lamp: Service and Repair Trunk Lamp Unit Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a flat bladed tool, pry lamp housing from rear shelf. 3. Disconnect wire harness connector. 4. Remove bulb. INSTALLATION 1. Install bulb. 2. Connect wire harness connector to the lamp. 3. Install housing into rear shelf. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: Customer Interest Trip Computer/Radio Display/IP/Dome Lights - Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 6526 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering Combination Switch: All Technical Service Bulletins Trip Computer/Radio Display/IP/Dome Lights Flickering NUMBER: 08-026-01 GROUP: Electrical DATE: Dec. 14, 2001 SUBJECT: Trip Computer And/Or Radio Display And/Or Instrument Panel And/Or Overhead/Dome Lights Flicker OVERVIEW: This bulletin involves diagnosing the root cause of the flickering trip computer or radio display and/or instrument panel illumination and/or overhead/dome lights and replacing the multifunction switch. MODELS: 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 2002 (KJ) Liberty SYMPTOM/CONDITION: Some subject vehicles may exhibit a flickering trip computer and/or radio display, instrument panel illumination, and/or overhead/dome lights. This condition occurs intermittently but is usually noticed while the driver operates the turn signals or beam change on the left stalk switch. This condition will not adversely affect vehicle operation and can be temporarily corrected by adjusting the instrument panel illumination dimmer setting. DO NOT change the position of the dimmer switch on the multifunction switch prior to Diagnosis. DIAGNOSIS: 1. Physically check to ensure the instrument panel cross car beam ground is good. The left kick panel must be removed to see if the ground is loose. 2. Next check the dimmer switch output voltage with a DRBIII(R). This function is located in: Body, Body Computer, Sensor Display, Dimming Level. DO NOT change the position of the dimmer switch before monitoring the voltage across the switch. 3. While monitoring the voltage, activate the turn signal and beam change and look for output voltage fluctuations on the DRBIII(R) and instrument panel lamps or trip computer display flicker. If the voltage varies more than 0.2 volts perform the Repair Procedure. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 08-026-01 > Dec > 01 > Trip Computer/Radio Display/IP/Dome Lights - Flickering > Page 6532 PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: DO NOT REPLACE THE TRIP COMPUTER, INSTRUMENT CLUSTER, RADIO, OR BODY CONTROL MODULE (BCM) FOR A TRIP COMPUTER AND/OR RADIO DISPLAY, INSTRUMENT PANEL ILLUMINATION OR OVERHEAD/DOME LIGHT FLICKER CONDITION UNLESS PROPERLY DIAGNOSED AS BEING THE CAUSE OF THE CONDITION. 1. Use the procedures outlined in the appropriate service manual to replace the multifunction switch. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Page 6533 Combination Switch: Testing and Inspection 1. Remove multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-function Switch, Removal and Installation. Multi-Function Switch Continuity Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Page 6534 Fig.22 Multi-Function Switch Connectors 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the table and. The switch assembly is mounted over the center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Page 6535 Combination Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove the upper steering column shroud. Refer to Steering, Column, Shroud, Removal. Fig.23 Multi-Function Switch Mounting 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION Position the switch on the steering column and install the retaining screws. 1. Tighten multi-function switch to column retaining screws to 2.3 Nm (20 in. lbs.) torque. 2. Install the steering shrouds and screws. Refer to Steering, Column, Shroud, Installation. 3. Tighten steering column cover retaining screws to 2 Nm (17 in. lbs.) torque. 4. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Fig.10 Combination Flasher Location Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6539 Turn Signal Flasher: Description and Operation Fig.10 Combination Flasher Location COMBINATION FLASHER The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). An inoperative or incomplete turn signal circuit will result in an increase in flasher speed. The flasher is mounted to the back side of the multi-function switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6540 Turn Signal Flasher: Testing and Inspection Combination Flasher Diagnosis (Part 1 Of 2) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6541 Combination Flasher Diagnosis (Part 2 Of 2) For combination flasher Diagnosis and Testing, refer to the table. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 6542 Turn Signal Flasher: Service and Repair Fig.10 Combination Flasher Location REMOVAL The flasher is mounted to the back side of the multi-function switch. To gain access, the upper steering column cover must be removed. The flasher can be removed by pulling it forward. The flasher is serviced separately from the multi-function switch. The flasher is black in color for ease of identification. INSTALLATION The flasher is mounted to the back side of the multi-function switch. To gain access, the upper steering column cover must be removed. Push the flasher toward the rear of the vehicle. The flasher is black in color for ease of identification. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams Turn Signal Lamp: Diagrams Left Park/Turn Signal Lamp (Except Built-up Export) Left Tail/Turn Signal Lamp (JR-41) (Dodge) Right Park/Turn Signal Lamp (Except Built-up Export) Right Tail/Turn Signal Lamp (JR-41) (Dodge) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 6546 Turn Signal Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Park/Turn Signal .................................................................................................................................. ...................................... 3157NA or 3157NAK Tail/Brake/Turn Signal ............................................... ........................................................................................................................................ 3157K Trun Signal ................................................................................................................................................... ...................................................... PC194 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 6547 Turn Signal Lamp: Service and Repair REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove headlamp retaining screws. 3. Remove headlamp to expose back of unit. 4. Rotate socket counterclockwise one quarter turn. Fig.24 Park And Turn Signal Lamp Bulb 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Twist socket into headlamp. 3. Install headlamp retaining screws. 4. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Multi-Function Switch C1 Multi-Function Switch C2 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6551 Turn Signal Switch: Description and Operation Multi-Function/Exterior Lamp Switch MULTI-FUNCTION SWITCH The multi-flinction switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers, one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn sighals are canceled. A canceling cam is molded to the clock spring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the OFF position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. In this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. The windshield wiper and wash system is covered in Wipers/Washers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Application and ID Vanity Lamp: Application and ID CAUTION: - Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. - Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Table Visor Vanity ......................................................................................................................................... ........................................................... 6501966 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Application and ID > Page 6555 Vanity Lamp: Service and Repair REMOVAL The vanity lamp is incorporated into the visor assembly. If the vanity lamp needs to be replaced, the entire visor must be replaced. The bulbs are serviced separately. 1. Disconnect and isolate the battery negative cable. Fig.3 Vanity Lamp 2. Using a pick or other suitable tool, pry the lens from the lamp. 3. Remove bulb. INSTALLATION 1. Install bulb. 2. Snap lamp lens into position. 3. Connect the battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6561 Rear Window Defogger Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6562 Heated Glass Element Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6563 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6564 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6565 Heated Glass Element Relay: Description and Operation The rear window defogger relay is an electromechanical device that switches fused battery current to the rear glass heating grid and the Light-Emitting Diode (LED) indicator of the rear window defogger switch, when the Body Control Module (BCM) rear window defogger timer and logic circuitry grounds the relay coil. The rear window defogger relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The rear window defogger relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. when the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6566 Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. 40 amp EBL fuse in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay (EBL) from the Junction Block. 3. Using voltmeter, test battery voltage: a Test rear window defogger relay terminals 13 for battery voltage. If voltage is OK, go to Step b. If voltage is not OK, repair A4 circuit. b Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step c. If voltage is not OK, repair A31 circuit. c Use a known good relay. If not OK, repair circuits as necessary. Refer to Wiring Diagrams. If OK, replace relay. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 6567 Heated Glass Element Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Open the driver's door and remove instrument panel end cover. 3. Remove Rear Window Defogger (EBL) relay from the Junction Block. INSTALLATION 1. Install Rear Window Defogger (EBL) relay in the Junction Block. 2. Install the instrument panel end cover. 3. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation REAR WINDOW DEFOGGER SWITCH The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C-Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. The rear window defogger control switch and circuit are integrated into the HVAC control assembly. Refer to the HVAC control assembly for additional information. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for 15 minutes upon initial actuation. Then 10 minutes with each subsequent actuation or until either the switch or ignition is turned OFF. An indicating lamp illuminates the rear window defogger switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Page 6571 Heated Glass Element Switch: Testing and Inspection The rear window defogger control switch and timer circuit may be tested in the vehicle with or without a scan tool, such as the DRB III. Testing With Scan Tool Using a scan tool, refer to the proper Body Diagnostic Procedures. Testing Without Scan Tool 1. Remove the HVAC control head from the instrument panel however, do not disconnect any of the electrical connectors if possible. 2. Using a ohmmeter, check leads between Pins 5 and 1 of the HVAC electrical connector. Depress the rear window defogger button and the resistance reading should be 360 ohms (± 10%). If not OK, replace HVAC. If OK, check for the following possible causes: Rear window relay (EBL) - Blown fuse - Cut wire - Poor ground - Poor connection - Defective BCM - Bulkhead connector inoperative Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6576 Rear Window Defogger Relay is located in the Junction Block. Junction Block (JB) Junction Block (JB) is located in the left endcap of the instrument panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6577 Heated Glass Element Relay: Diagrams Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6578 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6579 8w-12-6 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6580 Heated Glass Element Relay: Description and Operation The rear window defogger relay is an electromechanical device that switches fused battery current to the rear glass heating grid and the Light-Emitting Diode (LED) indicator of the rear window defogger switch, when the Body Control Module (BCM) rear window defogger timer and logic circuitry grounds the relay coil. The rear window defogger relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The rear window defogger relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. when the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6581 Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. 40 amp EBL fuse in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay (EBL) from the Junction Block. 3. Using voltmeter, test battery voltage: a Test rear window defogger relay terminals 13 for battery voltage. If voltage is OK, go to Step b. If voltage is not OK, repair A4 circuit. b Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step c. If voltage is not OK, repair A31 circuit. c Use a known good relay. If not OK, repair circuits as necessary. Refer to Wiring Diagrams. If OK, replace relay. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6582 Heated Glass Element Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Open the driver's door and remove instrument panel end cover. 3. Remove Rear Window Defogger (EBL) relay from the Junction Block. INSTALLATION 1. Install Rear Window Defogger (EBL) relay in the Junction Block. 2. Install the instrument panel end cover. 3. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation REAR WINDOW DEFOGGER SWITCH The Rear Window Defogger Switch is a momentary contact switch. Toggling the switch results in the A/C-Heater Control sending a signal to the BCM to provide rear window defogger activation or deactivation respectively. The switch LED illuminates when the switch is ON. The rear window defogger control switch and circuit are integrated into the HVAC control assembly. Refer to the HVAC control assembly for additional information. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for 15 minutes upon initial actuation. Then 10 minutes with each subsequent actuation or until either the switch or ignition is turned OFF. An indicating lamp illuminates the rear window defogger switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Page 6587 Heated Glass Element Switch: Testing and Inspection The rear window defogger control switch and timer circuit may be tested in the vehicle with or without a scan tool, such as the DRB III. Testing With Scan Tool Using a scan tool, refer to the proper Body Diagnostic Procedures. Testing Without Scan Tool 1. Remove the HVAC control head from the instrument panel however, do not disconnect any of the electrical connectors if possible. 2. Using a ohmmeter, check leads between Pins 5 and 1 of the HVAC electrical connector. Depress the rear window defogger button and the resistance reading should be 360 ohms (± 10%). If not OK, replace HVAC. If OK, check for the following possible causes: Rear window relay (EBL) - Blown fuse - Cut wire - Poor ground - Poor connection - Defective BCM - Bulkhead connector inoperative Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Master Power Window Switch Passenger Power Window Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 6591 Power Window Switch: Testing and Inspection Master Window Switch Continuity Test Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 6592 Passenger Window Switch Continuity Test For switch testing, remove the switch. (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL) Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct and. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 6593 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch mounting fasteners. INSTALLATION 1. Install switch and mounting fasteners. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams Power Window Motor: Diagrams Driver Power Window Motor Passenger Power Window Motor Right Rear Power Window Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 6598 Power Window Motor: Service Precautions WARNING: - FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOVING THE MOTOR CAN RESULT IN INJURY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 6599 Power Window Motor: Testing and Inspection 1. Remove door trim panel. 2. Connect positive (+) lead from a test battery to either of the two motor terminals. 3. Connect negative (-) lead from test battery to remaining motor terminal. 4. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed. b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in Step 1 and Step 2 and window should now move. If window does not move, replace motor. 5. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. 6. If window does not move, check to make sure that it is free. 7. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. 8. To determine if the glass is free, disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 6600 Power Window Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the window regulator. WARNING: FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOVING THE MOTOR CAN RESULT IN INJURY. 3. Secure the sector and mounting plate with a C clamp or similar clamping tool. This will prevent a sudden and forceful movement of the regulator when the motor is removed. 4. Remove the motor from the regulator. INSTALLATION 1. Install motor on regulator by positioning motor gearbox so that it engages regulator sector teeth. A slight rotational or rocking movement may be necessary to bring the motor gearbox mounting holes into proper position. 2. Install the motor fasteners. Tighten to 8 Nm (70 in. lbs.). 3. Install regulator. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Master Power Window Switch Passenger Power Window Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 6604 Power Window Switch: Testing and Inspection Master Window Switch Continuity Test Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 6605 Passenger Window Switch Continuity Test For switch testing, remove the switch. (Refer to POWER WINDOWS/POWER WINDOW SWITCH REMOVAL) Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct and. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 6606 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch mounting fasteners. INSTALLATION 1. Install switch and mounting fasteners. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair BACKLITE REMOVAL For a description of tools and adhesive systems that are recommended for use in this procedure. WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. BE SURE TO REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. CAUTION: Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured. Water leaks can result. 1. Remove rear window moldings. 2. Remove upper quarter trim panel. 3. Disengage wire connectors from rear window defogger, and rear window mounted radio antenna, if so equipped. 4. Remove C-pillar applique, if so equipped. WARNING: WEAR EYE AND HAND PROTECTION WHEN HANDLING SAFETY GLASS. PERSONAL INJURY CAN RESULT. CAUTION: Do not damage body or trim finish when cutting out glass or applying fence primer. 5. Cut the urethane around the perimeter of the rear window glass. 6. Remove the rear window from the vehicle. INSTALLATION For a description of tools and adhesive systems that are recommended for use in this procedure. WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. BE SURE TO REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. CAUTION: Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured. Water leaks can result. 1. Prepare the work area, window fence, and glass the same way as described in the Windshield section of this group. Fig. 11 2. Place fence spacers at the locations shown (Fig. 11). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 6611 3. Install the rear window molding on glass. 4. Apply a 10 mm (0.4 in.) bead of urethane along center line of window fence. 5. Install the glass in the same manner described in the Windshield section of this group (Fig. 11). 6. Connect rear window defogger wiring, and rear window mounted radio antenna, if so equipped. 7. Install C-pillar applique, and interior trim. 8. After urethane has cured, water test rear window to verify repair. Verify rear window defogger operation. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6617 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6618 Front Door Window Glass Weatherstrip: Service and Repair Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6619 Front Door Window Glass Weatherstrip: Service and Repair Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6620 INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6621 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6622 Front Door Window Glass Weatherstrip: Service and Repair Side View Mirror Flag / Door Glass Channel SIDE VIEW MIRROR FLAG / DOOR GLASS CHANNEL REMOVAL 1. Remove side view mirror. 2. Partially lower the door glass. 3. Remove inner belt line glass seal. Fig. 28 4. Remove attaching fasteners (Fig. 28). 5. Remove the adjustment stud. Count the number of turns to aid installation. 6. Remove mirror flag. INSTALLATION 1. Align glass into the guide and position the mirror flag on door. (Fig. 28). 2. Install the adjustment stud and tighten the number of turns counted in the removal procedure. 3. Install attaching fasteners and tighten to 7 N.m (62 in.lbs.). 4. Install the inner glass seal. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6623 Fig. 13 5. Verify glass fit at mirror flag. Upper edge of the glass should be flush with the mirror flag top edge. Adjust the mirror flag position as necessary. (Fig. 13). 6. Install side view mirror. Door Opening Trim Welt DOOR OPENING TRIM WELT REMOVAL 1. Using trim stick, special tool C-4755, remove one end of door opening trim welt from door opening flange. Fig. 4 2. Remove welt from vehicle (Fig. 4). INSTALLATION 1. Position door opening trim welt on vehicle. 2. Butt end of welt to edge of header/A-pillar weatherstrip. 3. Push door opening welt onto door opening flange. Rear Vertical Guide Bar REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6624 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6625 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove front door trim panel. 2. Pull upward at rear end of inner belt weatherstrip. Fig. 9 3. Remove inner belt weatherstrip from vehicle (Fig. 9). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Start weatherstrip at the front and rear edge door. Press downward on the inner belt weatherstrip till it is fully seated. 3. Install front door trim panel. Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL Fig. 10 1. Remove screw attaching rearward end of molding to front door (Fig. 10). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6626 Fig. 11 2. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 11). 3. Lift up on the rear of the belt molding and pull rearward to remove. INSTALLATION 1. Place belt molding in position. 2. Using your hand press downward at each clip attaching belt molding to door till in position. 3. Install screw attaching rearward end of molding to front door. Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. 2. Remove bolt attaching bottom of front lower run channel to inner door panel. 3. Pull glass run weatherstrip from door glass opening frame. Fig. 8 4. Remove lower run channel through opening at top of door (Fig. 8). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6627 INSTALLATION 1. Install lower run channel through opening at top of door. 2. Push glass run weatherstrip to door glass opening frame. 3. Install bolt attaching bottom of front lower run channel to inner door panel. 4. Install door glass. Door Glass Inner Belt Stabilizer DOOR GLASS INNER BELT STABILIZER REMOVAL 1. Remove door trim panel. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Remove nut attaching inner belt stabilizer to door panel. Fig. 17 4. Remove inner belt stabilizer from door (Fig. 17). INSTALLATION 1. Place inner belt stabilizer into position. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Install nut attaching inner belt stabilizer to door panel. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. 4. Install door trim panel. Door Inner Belt Weatherstrip DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6628 Fig. 3 2. Pull upward on rear edge of inner belt weatherstrip (Fig. 3). 3. Remove weatherstrip from vehicle. INSTALLATION 1. Start leading edge of weatherstrip on vehicle. 2. Press the leading edge of the weatherstrip forward until edge is tight to the mirror flag. 3. Press weatherstrip into position on door panel. 4. Install door trim panel. Header / A - Pillar Weatherstrip HEADER / A - PILLAR WEATHERSTRIP REMOVAL 1. Partially raise convertible top. 2. Remove inside rear view mirror. 3. Remove sun visors. 4. Remove header trim panel. 5. Remove both door sill trim panels. Fig. 12 6. Remove nuts holding header and A-pillar weatherstrip at upper corners of windshield (Fig. 12). 7. Remove push in fasteners at lower corners of windshield holding weatherstrip to A-pillar. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6629 8. Remove header and A-pillar weatherstrip from vehicle. 9. Clean any residual seal material from header panel. INSTALLATION Fig. 13 CAUTION: Ensure that the butyl patch and butyl rope at each corner of the windshield is present and in good condition (Fig. 13). The butyl is critical for the water management system. Replace as necessary. 1. Install new L foam starting at upper screw on A-pillar retainer. Fig. 14 2. Install new L foam starting at upper screw on A-pillar retainer (Fig. 14). 3. Position header and A-pillar weatherstrip on vehicle. 4. Secure weatherstrip into retainers at header and A-pillar. 5. Install nuts at upper corners of windshield. 6. Install push in fasteners at lower corners of windshield. 7. Install door sill trim panels. 8. Install header trim panel. 9. Install sun visors. 10. Install inside rear view mirror. 11. Lower and secure convertible top. Outer Door Belt Weatherstrip Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Side View Mirror Flag / Door Glass Channel > Page 6630 OUTER DOOR BELT WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 16 2. Remove screws attaching outer belt weatherstrip to outer door panel (Fig. 16). 3. Remove outer belt weatherstrip from the vehicle. INSTALLATION 1. Position outer belt weatherstrip on vehicle. 2. Install screws to hold outer weatherstrip to outer door panel. 3. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove rear door trim panel. 2. Pull upward at front end of inner belt weatherstrip. Fig. 20 3. Remove inner belt weatherstrip from vehicle (Fig. 20). INSTALLATION 1. Place inner belt weatherstrip into position. 2. Push downward on the inner belt weatherstrip. 3. Install rear door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 6636 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL Fig. 21 1. Remove screw attaching forward end of molding to rear door (Fig. 21). 2. Disengage clips attaching rearward end of belt molding to rear door. Fig. 22 3. Using a rubber mallet and block of wood, tap upward at each clip attaching belt molding to door (Fig. 22). 4. Remove belt molding from door. INSTALLATION 1. Place belt molding into position. 2. Push or tap downward at each clip attaching belt molding to door. 3. Engage clips attaching rearward end of belt molding to rear door. 4. Install screw attaching forward end of molding to rear door. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip > Page 6637 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door glass. Fig. 19 2. Pull glass run weatherstrip from door glass opening frame (Fig. 19). INSTALLATION 1. Install glass run weatherstrip to door glass opening frame. 2. Install door glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove door trim panel. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector. 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. Front Door Regulator 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator in door through access hole in door panel. 2. Position regulator on door panel. 3. Tighten bolts attaching regulator to door panel. 4. Position screw and bolt heads in keyhole slots in door panel. 5. Tighten screw attaching regulator scissor channel to door panel. 6. Connect power window motor wire electrical connector. 7. Position glass in regulator roller channel. 8. Tighten fasteners attaching door glass to roller channel. 9. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6643 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector. 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. Fig. 33 7. Remove regulator from door panel (Fig. 33). 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. REMOVAL - JR-27 (Convertible) ONLY 1. Remove door trim panel and water shield. 2. Disconnect wire connector to power window motor. 3. Remove nuts attaching regulator lift channel to door glass. 4. Secure door glass in upward position. 5. Mark position of rear bolt of roller channel to inner door panel to aid in installation. 6. Remove bolt attaching rear of roller channel to door panel. 7. Loosen bolt attaching front of roller channel to door panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6644 Fig. 34 8. Remove roller channel from door panel (Fig. 34). 9. Loosen bolts attaching window regulator to inner door panel reinforcement. 10. Remove bolt heads from key hole slots in inner door panel. 11. Remove window regulator through large hole in inner door panel (Fig. 34). 12. Remove power window motor from regulator. INSTALLATION 1. Position regulator in door through access hole in door panel. 2. Position regulator on door panel. 3. Tighten bolts attaching regulator to door panel. 4. Position screw and bolt heads in keyhole slots in door panel. 5. Tighten screw attaching regulator scissor channel to door panel. 6. Connect power window motor wire electrical connector. 7. Position glass in regulator roller channel. 8. Tighten fasteners attaching door glass to roller channel. 9. Install door trim panel. INSTALLATION - JR-27 (Convertible) ONLY 1. Install power window motor on regulator. 2. Move window regulator into position in door and engage bolt heads into key hole slots in inner door panel reinforcement and tighten bolts. 3. Install roller channel to door panel. 4. Install bolt at rear of roller channel. Make sure that bolt is aligned to mark on inner door panel made previously. 5. Tighten front and rear bolts of roller channel. 6. Install nuts attaching regulator lift channel to door glass. 7. Verify glass fit and operation. Adjust door glass, if necessary. 8. Connect wire connector to power window motor. 9. Install door water dam and trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove door waterdam. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector, if equipped. Rear Door Regulator 4. Loosen screw attaching regulator scissor channel to door panel. 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator on door panel through access hole in door panel. 2. Tighten bolts attaching regulator to door panel. 3. Install screw and bolt heads on scissor channel to keyhole slots in door panel. 4. Tighten screw attaching regulator scissor channel to door panel. 5. Connect power window motor wire connector, if equipped. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door waterdam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6649 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door waterdam. 2. Remove glass from regulator roller channel. Secure glass in the up position in the door frame. 3. Disconnect power window motor wire connector, if equipped. Fig. 14 4. Loosen screw attaching regulator scissor channel to door panel (Fig. 14). 5. Remove screw and bolt heads from keyhole slots in door panel. 6. Loosen bolts attaching regulator to door panel. 7. Remove regulator from door panel. 8. Slide regulator rearward and rotate forward end of roller channel through access hole in door panel. INSTALLATION 1. Position regulator on door panel through access hole in door panel. 2. Tighten bolts attaching regulator to door panel. 3. Install screw and bolt heads on scissor channel to keyhole slots in door panel. 4. Tighten screw attaching regulator scissor channel to door panel. 5. Connect power window motor wire connector, if equipped. 6. Position glass to regulator roller channel. 7. Tighten fasteners attaching door glass to roller channel. 8. Install door waterdam. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top Window Seal: Customer Interest Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 6658 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 6659 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top Window Seal: All Technical Service Bulletins Front Door Trim Panel - Loose/Warped Along Top NUMBER: 23-001-02 GROUP: Body DATE: Jan. 11, 2002 SUBJECT: Front Door Trim Panel Retention/Warped Along Belt Line OVERVIEW: This bulletin involves installing a metal clip to the front door inner belt line weather seal that is on the weld flange of the front door. This TSB should be performed any time a front door trim panel is removed and a metal clip is not present on the belt line weather seal. MODELS: 2001 - 2002 (JR41) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Front door trim panel is loose at rear of door or warped along the belt line/top of trim panel. Trim panel flange is not engaging belt seal channel properly. DIAGNOSIS: Visually inspect the rear edge and belt line area of the front door trim panel, if loose and/or warped perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: THIS REPAIR PROCEDURE SHOULD BE PERFORMED IF THE STEEL RETENTION CLIP IS NOT PRESENT ON THE INNER BELT LINE WEATHER SEAL ANYTIME A FRONT DOOR TRIM PANEL IS REMOVED 1. Lower the front door glass. 2. Remove the three screws at the bottom of the door trim panel. 3. Remove the screw in the door trim panel pull cup. 4. Remove the screw in the door latch handle cup. 5. Pry oft the mirror/flag trim cover. 6. Remove the inner belt line weather seal from the upper door weld flange. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 6665 7. Measure 248 mm (9 3/4 in.) from the rear edge of the inner belt line weather seal and place a mark on the lip used for door trim panel retention. (Fig. 1) 8. Cut off the rear most 248 mm (9 3/4 in.) of the lip of the inner belt line weather seal used for door trim panel retention. 9. Install the retention clip, p/n 05056222AA, to the inner belt weather seal so the forward edge of the clip is flush with the edge of the cut made in the weather seal. 10. Install the inner belt weather seal to the weld flange of the front door. 11. Replace the three rear edge door trim panel retention pins, pin 06506853AB and grommets, p/n O6506852AB. NOTE: NOTE: IF ANY GROMMET FRAGMENTS FALL INTO THE DOOR, TO PREVENT POTENTIAL RATTLES, REMOVE THE WATER SHIELD FOLLOWING THE REMOVAL AND INSTALLATION INSTRUCTIONS ON MDS2, PAGE 23-40 OF THE 2002 JR INFORMATION, WHICH ALSO APPLIES TO THE 2001 MODEL YEAR. REMOVE ANY FRAGMENTS AND REINSTALL WATER SHIELD MAKING SURE THE ADHESIVE BEAD IS NOT BROKEN. FOLLOWING THIS PROCEDURE WILL AVOID ANY WATER INTRUSION. 12. Place door trim panel into the retention lip of belt line weather seal and clip so the door trim panel retention pins align with the grommet holes and press on the trim panel until the pins are fully engaged into the grommets. 13. Install the mirror/flag trim cover. 14. Install the five door trim panel retaining screws. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-001-02 > Jan > 02 > Front Door Trim Panel - Loose/Warped Along Top > Page 6666 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front Strut / Shock Tower: All Technical Service Bulletins Body/Suspension - Clunk/Pop Sound From Vehicle Front NUMBER: 23-039-04 GROUP: Body DATE: September 24, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-03, DATED May 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR. SUBJECT: Pop/Clunk Sound From Front Of Vehicle OVERVIEW: This bulletin involves installing two rivets in each front shock tower/wheel well area. MODELS: 2001 - **2005** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: Vehicle produces an intermittent front end popping or clunk type sound while driving over road inputs that cause the body to come under a twisting load. This sound may also be produced when in park & idle by turning the steering wheel quickly, 90 degrees, to the left and back to the right. DIAGNOSIS: If the vehicle operator describes the above Symptom, turn the steering wheel quickly, 90 degrees, to the left and back to the right while the transmission is in park and the engine is at idle. If a popping or clunk type sound is heard, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove both front tire/wheel assemblies. 3. Remove wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6672 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6673 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6679 4. Drill two 17/64 in. (6.8 mm) diameter holes from inside the shock tower/wheel well area into the inside of the wet plenum, (Fig. 1) and (Fig. 2). 5. Apply Mopar Corrosion Inhibitor, p/n 82300508, to the bare metal surface of drilled holes. 6. Install rivets, p/n 06033864, in the holes drilled in step 4 using Pentastar Service Equipment W-HK150F or W-AK175ACH riveter or equivalent. 7. Install the wheel well splash shield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-039-04 > Sep > 04 > Body/Suspension - Clunk/Pop Sound From Vehicle Front > Page 6680 8. Repeat steps 2 through 7 for the other side of the vehicle. 9. Install the front tire/wheel assemblies. 10. Torque the lug nuts to 135 Nm (100 ft.lbs.) using a criss-cross pattern. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 23-014-03 > Jun > 03 > Body - Front Door Glass Clicking Sound Window Track: Customer Interest Body - Front Door Glass Clicking Sound NUMBER: 23-014-03 GROUP: Body DATE: June 6, 2003 SUBJECT: Front Door Glass Clicking Sound OVERVIEW: This bulletin involves torquing the front door glass liftplate attaching nuts and on some vehicle adding a spacer washer. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: When cycling door glass up and down, a clicking noise can be heard when changing directions of window travel. DIAGNOSIS: Cycle the front window up and down, if a clicking sound is heard when the window travel changes direction, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove front door trim panel and watershield using the procedures outlined in the appropriate service manual or the information on TechCONNECT/MDS2. CAUTION: WHEN HANDLING THE WATERSHIELD KEEP THE ADHESIVE BEAD FREE OF DIRT/FOREIGN MATERIAL. 2. Lower the front door glass to gain access to glass liftplate attach nuts. For 2004 JR41 (sedan) vehicles built prior to March 24, 2003 and after May 16, 2003 (MDH 0324XX - 0516XX) and all JR27 (convertible) vehicles skip to step 6. 3. For 2004 JR41 (sedan) vehicles built on March 24, 2003 through and including May 16, 2003 (MDH 0324XX - 0516XX), remove one front door glass liftplate attaching nut (2 per glass). 4. Add a washer (as specified in the Parts Required Section) to the liftplate stud and install the liftplate attaching nut. 5. Repeat steps 3 and 4 for the other front door glass liftplate attachment. 6. Torque the glass liftplate attach nuts to 10-14 Nm (90-120 in. lbs.). 7. Torque all remaining window regulator and glass channel attachments to 6.2-8.5 Nm (55-75 in. lbs.). 8. Reinstall watershield and front door trim panel using the procedures outlined in the appropriate service manual or the information on Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 23-014-03 > Jun > 03 > Body - Front Door Glass Clicking Sound > Page 6689 TechCONNECT/MDS2. NOTE: INSURE THE WATERSHIELD IS COMPLETELY SEALED TO THE DOOR, OTHERWISE WATER LEAKAGE INTO THE PASSENGER COMPARTMENT WILL OCCUR. 9. Repeat steps I through 8 for other side front door glass. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 23-014-03 > Jun > 03 > Body - Front Door Glass Clicking Sound Window Track: All Technical Service Bulletins Body - Front Door Glass Clicking Sound NUMBER: 23-014-03 GROUP: Body DATE: June 6, 2003 SUBJECT: Front Door Glass Clicking Sound OVERVIEW: This bulletin involves torquing the front door glass liftplate attaching nuts and on some vehicle adding a spacer washer. MODELS: 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: When cycling door glass up and down, a clicking noise can be heard when changing directions of window travel. DIAGNOSIS: Cycle the front window up and down, if a clicking sound is heard when the window travel changes direction, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Remove front door trim panel and watershield using the procedures outlined in the appropriate service manual or the information on TechCONNECT/MDS2. CAUTION: WHEN HANDLING THE WATERSHIELD KEEP THE ADHESIVE BEAD FREE OF DIRT/FOREIGN MATERIAL. 2. Lower the front door glass to gain access to glass liftplate attach nuts. For 2004 JR41 (sedan) vehicles built prior to March 24, 2003 and after May 16, 2003 (MDH 0324XX - 0516XX) and all JR27 (convertible) vehicles skip to step 6. 3. For 2004 JR41 (sedan) vehicles built on March 24, 2003 through and including May 16, 2003 (MDH 0324XX - 0516XX), remove one front door glass liftplate attaching nut (2 per glass). 4. Add a washer (as specified in the Parts Required Section) to the liftplate stud and install the liftplate attaching nut. 5. Repeat steps 3 and 4 for the other front door glass liftplate attachment. 6. Torque the glass liftplate attach nuts to 10-14 Nm (90-120 in. lbs.). 7. Torque all remaining window regulator and glass channel attachments to 6.2-8.5 Nm (55-75 in. lbs.). 8. Reinstall watershield and front door trim panel using the procedures outlined in the appropriate service manual or the information on Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 23-014-03 > Jun > 03 > Body - Front Door Glass Clicking Sound > Page 6695 TechCONNECT/MDS2. NOTE: INSURE THE WATERSHIELD IS COMPLETELY SEALED TO THE DOOR, OTHERWISE WATER LEAKAGE INTO THE PASSENGER COMPARTMENT WILL OCCUR. 9. Repeat steps I through 8 for other side front door glass. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Inner Belt Stabilizer Window Track: Service and Repair Door Glass Inner Belt Stabilizer DOOR GLASS INNER BELT STABILIZER REMOVAL 1. Remove door trim panel. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Remove nut attaching inner belt stabilizer to door panel. Fig. 17 4. Remove inner belt stabilizer from door (Fig. 17). INSTALLATION 1. Place inner belt stabilizer into position. 2. Lift inner belt weatherstrip as necessary to access nut. 3. Install nut attaching inner belt stabilizer to door panel. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. 4. Install door trim panel. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Inner Belt Stabilizer > Page 6698 Window Track: Service and Repair Front Door REAR VERTICAL GUIDE BAR REMOVAL - JR-27 (Convertible) 1. Remove door trim panel and watershield. Fig. 31 2. Remove the lift plate attaching screws (Fig. 31). 3. Remove nut attaching top of guide bar to inner door panel. 4. Using a suitable allen wrench, hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel. Fig. 32 5. Remove guide bar from vehicle and remove through access hole in inner door panel (Fig. 32). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Inner Belt Stabilizer > Page 6699 INSTALLATION - JR-27 (Convertible) 1. If a new guide bar is being installed, preset bottom jack screw using old guide bar as a reference. 2. Position rear guide bar on vehicle. 3. Using a suitable allen wrench, hold jack screw stationary while installing nut attaching bottom of guide bar to inner door panel. 4. Install nut attaching top of rear guide bar to inner door panel. 5. Verify glass fit and operation. Adjust door glass as necessary. 6. Install door trim panel and watershield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield Windshield: Customer Interest Body - Wind Noise From Top of Windshield NUMBER: 23-040-02 REV. A GROUP: Body DATE: Sept. 16, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-040-02, DATED SEPT. 9, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A CORRECTION TO THE LABOR OPERATION NUMBER. SUBJECT: Windnoise Occurring At Highway Speeds In High Ambient Temperature Conditions OVERVIEW: This bulletin involves replacing the windshield reveal molding. MODELS: 2001 - 2003 (JR) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: A whistling or buzzing sound may be heard coming from the top of the windshield at highway speeds (105 Km/h+ / 65 mph+) during high ambient temperature (27°C+ / 80°F+) conditions. DIAGNOSIS: If the vehicle operator describes the above Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the front doors and pull back the drip-rail seal from the bottom of the "A" pillar to the top to gain access to the five "A" pillar molding fasteners, right and left side. 2. Remove the "A" pillar molding fasteners and separate the "A" pillar moldings from the vehicle. 3. Remove the windshield reveal molding from the top of windshield glass. CAUTION: USE CARE TO PREVENT CHIPPING THE EDGE OF THE WINDSHIELD WHILE REMOVING THE REVEAL MOLDING AND ANY EXCESS URETHANE. 4. Remove any excess urethane that has squeezed out from under the windshield glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield > Page 6708 5. Add bead of urethane along entire top edge of windshield per (Fig. 1). 6. Install revised windshield reveal molding, p/n 04806123AA, to the top of the windshield. 7. Press along entire length of windshield reveal molding with fiber stick per (Fig. 2) to ensure proper bond to glass. Finesse as necessary to ensure proper appearance of molding. Leading edge and "tail" of molding should not be wavy in appearance. The tail of the reveal molding should be slightly underflush to the top of the roof. If the tail of the reveal molding is grossly overflush the gap between the windshield and the downstanding surface of the roof is too small and the windshield must be removed and refitted to achieve a larger windshield to roof gap. It is also important that the gap be consistent all the way across in order to achieve an optimum appearance. 8. Install the "A" pillar moldings. Tighten the fasteners to 2 Nm (18 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield > Page 6709 9. Install the drip-rail seals. NOTE: ALLOW A MINIMUM OF 24 HOURS CURE TIME AFTER INSTALLATION BEFORE USING A CAR WASH. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield Windshield: All Technical Service Bulletins Body - Wind Noise From Top of Windshield NUMBER: 23-040-02 REV. A GROUP: Body DATE: Sept. 16, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-040-02, DATED SEPT. 9, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A CORRECTION TO THE LABOR OPERATION NUMBER. SUBJECT: Windnoise Occurring At Highway Speeds In High Ambient Temperature Conditions OVERVIEW: This bulletin involves replacing the windshield reveal molding. MODELS: 2001 - 2003 (JR) Sebring Sedan/Stratus Sedan SYMPTOM/CONDITION: A whistling or buzzing sound may be heard coming from the top of the windshield at highway speeds (105 Km/h+ / 65 mph+) during high ambient temperature (27°C+ / 80°F+) conditions. DIAGNOSIS: If the vehicle operator describes the above Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open the front doors and pull back the drip-rail seal from the bottom of the "A" pillar to the top to gain access to the five "A" pillar molding fasteners, right and left side. 2. Remove the "A" pillar molding fasteners and separate the "A" pillar moldings from the vehicle. 3. Remove the windshield reveal molding from the top of windshield glass. CAUTION: USE CARE TO PREVENT CHIPPING THE EDGE OF THE WINDSHIELD WHILE REMOVING THE REVEAL MOLDING AND ANY EXCESS URETHANE. 4. Remove any excess urethane that has squeezed out from under the windshield glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield > Page 6715 5. Add bead of urethane along entire top edge of windshield per (Fig. 1). 6. Install revised windshield reveal molding, p/n 04806123AA, to the top of the windshield. 7. Press along entire length of windshield reveal molding with fiber stick per (Fig. 2) to ensure proper bond to glass. Finesse as necessary to ensure proper appearance of molding. Leading edge and "tail" of molding should not be wavy in appearance. The tail of the reveal molding should be slightly underflush to the top of the roof. If the tail of the reveal molding is grossly overflush the gap between the windshield and the downstanding surface of the roof is too small and the windshield must be removed and refitted to achieve a larger windshield to roof gap. It is also important that the gap be consistent all the way across in order to achieve an optimum appearance. 8. Install the "A" pillar moldings. Tighten the fasteners to 2 Nm (18 in. lbs.). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-040-02A > Sep > 02 > Body - Wind Noise From Top of Windshield > Page 6716 9. Install the drip-rail seals. NOTE: ALLOW A MINIMUM OF 24 HOURS CURE TIME AFTER INSTALLATION BEFORE USING A CAR WASH. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6717 Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. - URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. - DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. - BE SURE TO REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. - VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. - SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. - ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6718 Windshield: Service and Repair WINDSHIELD DESCRIPTION The windshield is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier. REMOVAL - JR-27 (Convertible) ONLY EXTERIOR METHOD 1. Open convertible top. 2. Remove header/A-pillar weatherstrip from weatherstrip retainers. 3. Remove A-pillar weatherstrip retainer and molding. 4. Remove header weatherstrip/molding. 5. Mark top edge of the windshield glass at three locations on the header. 6. Remove windshield wiper arms. 7. Remove cowl cover. 8. Place protective covers over instrument panel and hood. Fig. 1 9. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, header and cowl pinch weld fences (Fig. 1). A power cutting device can be used if available. 10. Remove windshield from vehicle. INTERIOR METHOD 1. Remove cowl cover. 2. Open convertible top. 3. Remove header/A-pillar weatherstrip from weatherstrip retainers. 4. Remove A-pillar weatherstrip retainer and molding. 5. Remove header weatherstrip/molding. 6. Mark top edge of the windshield glass at three locations on the header. 7. Remove header panel trim cover. 8. Remove header panel weatherstrip from channel. 9. Remove instrument panel top cover. 10. Remove A-pillar trim covers. 11. Place protective covers over instrument panel and hood. 12. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used. 13. Remove windshield from vehicle. REMOVAL The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6719 of the vehicle using a reciprocating or oscillating power knife is recommended. 1. Remove inside rear view mirror. 2. Remove cowl cover. Refer to Trim Panel. 3. Remove drip rail weatherstrips as necessary to gain access to screws holding windshield side moldings to A-pillars. 4. Remove screws holding windshield side moldings to A-pillars. Fig. 2 5. Remove windshield moldings. (Fig. 2) Pull outward on molding at the bottom of A-pillars using pliers. Fig. 3 6. Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available. (Fig. 3) 7. Separate windshield from vehicle. INSTALLATION - JR-27 (Convertible) CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. NOTE: The JR 27 uses adjustable support spacers along the bottom. Once the support spacers are set, use care not to move them. 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. 2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6720 3. Move the support spacers as necessary so that the top of the windshield aligns with the marks on the header, from the original windshield. 4. Place a piece of tape over the ratcheting portion of the bottom support spacer to prevent them from moving. 5. Repeat Step 3 and Step 4 for the opposite side of the windshield. Fig. 4 6. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. 4). 7. Remove replacement windshield from windshield opening. Fig. 5 8. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 5). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 9. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. 10. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible. 11. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. 12. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. 13. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6721 Fig. 6 14. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening at original locations (Fig. 6). 15. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. 16. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. Fig. 7 17. Slowly lower windshield glass to windshield opening fence. Push windshield inward until glass is flush to A-pillars (Fig. 7). 18. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent. 19. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 20. Install cowl cover and wipers. 21. Install inside rear view mirror to header. 22. After urethane has cured, remove tape strips and water test windshield to verify repair. INSTALLATION CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. 1. Place replacement windshield into position and center in the opening against the support spacers. 2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6722 Fig. 8 3. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. 8). 4. Remove replacement windshield from windshield opening. Fig. 9 5. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 9). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 6. Clean inside of windshield with ammonia based glass cleaner and lint free cloth. 7. Apply molding to perimeter of windshield. 8. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint free cloth until no streaks are visible. 9. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. 10. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. 11. Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 6723 Fig. 10 12. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening (Fig. 10). 13. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. 14. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. 15. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward molding is flush to roof line and A-pillars. 16. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent. 17. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 18. Install windshield side moldings and drip rail weatherstrips. 19. Install cowl cover and wipers. 20. Install inside rear view mirror. 21. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Pump > Component Information > Diagrams Headlamp Washer Pump Motor (JR-41) (Built-up-export) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center (PDC) Front Wiper On/Off and High/Low Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 6732 Wiper Relay: Diagrams Power Distribution Center (PDC) Front Wiper ON/OFF Relay Front Wiper High/Low Relay Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Motor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Fig.17 Terminal Removal Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig.23 Splice Clip 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 23). Fig.24 Crimping Tool 4. Using crimping tool, Miller p/n 8272, crimp the splice clip and wires together (Fig. 24) Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Fig.25 Solder 5. Solder the connection together using rosin core type solder only (Fig. 25) CAUTION: DO NOT USE ACID CORE SOLDER. Fig.26 Heat Shrink Tubing 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 26). Special Tools Probing Tool Package 6807 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Windshield Washer Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Front Washer Pump Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Front Washer Pump Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 6766 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Partially remove the bumper fascia as needed to gain access to the reservoir pump. Refer to Frame & Bumpers, Bumpers, Front Fascia, Removal. 3. Place a drain bucket below the reservoir to catch any washer solvent that may leak out. 4. Firmly grasping pump by hand twist and pull away from reservoir and out of grommet. Care must be taken riot to puncture reservoir. 5. Remover rubber grommet from reservoir and throw away. INSTALLATION 1. A new grommet is required for installation. 2. Firmly grasping pump by hand twist and push into reservoir. Care must be taken not to tear grommet or puncture reservoir. 3. If fascia was partially removed, reinstall bumper fascia as needed Refer to Frame & Bumpers, Bumpers, Front Fascia, Installation. 4. Refill reservoir with the washer solvent. 5. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Reservoir Replacement Windshield Washer Reservoir: Service and Repair Washer Reservoir Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Disconnect washer fluid hose at in-line connector on top of the right shock tower. 3. Partially remove bumper fascia as needed to gain access to the reservoir. Refer to Frame & Bumpers, Bumpers, Front Fascia, Removal. Fig.2 Reservoir Removal 4. Disconnect wire connector from washer pump and harness mounting tab. 5. Remove washer reservoir mounting bolts. 6. Slide rearward and drop down and away from vehicle. 7. Drain washer fluid from reservoir into an appropriate container. 8. Disconnect the washer hose from the reservoir. INSTALLATION 1. Connect the washer hose to the reservoir. 2. Install the washer fluid reservoir. 3. Connect wire connector to washer pump and harness mounting tab. 4. If fascia was partially removed, reinstall bumper fascia as needed. Refer to Frame & Bumpers, Bumpers, Front Fascia, Installation. 5. Connect washer fluid hose at in-line connector on top of the right shock tower. 6. Fill washer fluid. 7. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Reservoir Replacement > Page 6771 Windshield Washer Reservoir: Service and Repair Washer Reservoir Pump Replacement REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Partially remove the bumper fascia as needed to gain access to the reservoir pump. Refer to Frame & Bumpers, Bumpers, Front Fascia, Removal. 3. Place a drain bucket below the reservoir to catch any washer solvent that may leak out. 4. Firmly grasping pump by hand twist and pull away from reservoir and out of grommet. Care must be taken riot to puncture reservoir. 5. Remover rubber grommet from reservoir and throw away. INSTALLATION 1. A new grommet is required for installation. 2. Firmly grasping pump by hand twist and push into reservoir. Care must be taken not to tear grommet or puncture reservoir. 3. If fascia was partially removed, reinstall bumper fascia as needed Refer to Frame & Bumpers, Bumpers, Front Fascia, Installation. 4. Refill reservoir with the washer solvent. 5. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair Windshield Washer Spray Nozzle: Service and Repair REMOVAL To replace nozzle, disconnect washer fluid hose. Using needle nose pliers, squeeze together the locking tabs on the nozzle and remove. INSTALLATION For installing make sure that both locking tabs are securely snapped into position. Connect washer fluid hose. If no washer spray, check fluid hoses for kinks or leaks. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments High speed, wet windshield operation, the right blade tip may override the cowl screen slightly. This is normal and should not affect wiper system performance. 1. Lift arms and blade assemble to a over centered position. 2. Turn ignition switch to ON or ACC position. 3. Use LOW speed setting and cycle the wiper motor to the PARK position. 4. Turn ignition OFF. 5. Carefully lower arm and blades to the windshield. 6. Measure the distance from the blade tip to the cowl screen edge. The blade should be 18 to 42 mm (0.75 to 1.60 inches.). 7. If not OK, check for worn parts. Arm Adjustment 8. In the event the blade tip strikes the cowl screen or molding remove arm. Position arm on windshield and tighten to 33 to 40 Nm (23 to 29 ft. lbs.) torque. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 6778 Wiper Arm: Service and Repair REMOVAL 1. Place the wiper arm/blades in the PARK position and turn ignition OFF. 2. Unsnap arm cover. By hand rock gently side to side and slide away from arm pivot. To remove the left side raise hood for clearance 3. Loosen retention nut. 4. Remove the arm from the pivot by using a universal claw puller or by hand rock gently side to side and slide. Raise blade and arm off glass and rock side to side while applying pressure with the puller till loose. Ensure that the puller is not on the collar below the arm. 5. Remove arm retention nut and arm. INSTALLATION 1. Place arm on pivot shaft, align blade with wiper location made on windshield 2. Start retention nut. 3. Raise arm and blade off windshield while tightening retention nut. Tighten nut to 33 to 40 Nm (23 to 29 ft. lbs). 4. Install arm head cover. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6792 Wiper Blade: Description and Operation Wiper Blade - Typical The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the windshield wiper arm and sweep across the front windshield to clear it of water, snow, and debris. When the wiper blade rubber element is exposed to the weather for a long period of time, it tends to lose wiping ability. Periodic cleaning of the wiper blade element is suggested to remove the accumulation of salt and road film. The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and a mild detergent or non-abrasive cleaner. If the blades continue to streak or smear, they should be replaced. The driver and the passenger blade elements are 550 mm (21.65 in.) in length. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement Wiper Blade: Service and Repair Wiper Blade Replacement REMOVAL 1. Turn wiper switch ON, position blades to a convenient place on the windshield by turning the ignition switch ON and OFF. Turn ignition switch OFF when blade is in the desirable position. 2. Lift wiper arm to raise blade off glass. Wiper Blade And Element Remove Blade From Arm 3. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip and. Wiper Blade - Typical 4. The driver's side wiper blade has a air foil on it and the air foil points downward as in. 5. Gently place wiper arm tip on windshield. CLEANING Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement > Page 6795 recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper Arm Alignment paragraph. INSTALLATION 1. Gently lift the wiper arm tip off windshield. 2. The driver's side wiper blade has a air foil on it and the air foil points downward. 3. Install the blade assembly onto the wiper arm by firmly snapping it onto the the arm tip and. 4. Lower blade to glass 5. When complete turn ignition switch ON. Turn wiper switch OFF allowing the wiper blades to PARK. Then turn ignition switch OFF. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement > Page 6796 Wiper Blade: Service and Repair Wiper Blade Element Replacement REMOVAL 1. Lift wiper arm to raise blade off the windshield. Wiper Blade And Element Remove Blade From Arm 2. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip and. Gently place wiper arm tip on windshield. Fig.7 Wiper Blade And Element Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Replacement > Page 6797 3. Remove wiping rubber element by pulling stopper of the rubber element, out of the claws of blade assemble. The wiper rubber element and two vertebra will be removed. INSTALLATION 1. Slide the rubber element into the blade assembly through the claws. 2. Slide the metal vertebra into the top element slot, with the vertebra curved to match the windshield 3. Ensure that the final blade claw is locked into the slot at the end of the rubber element. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams Front Wiper Motor Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 6801 Wiper Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Remove wiper arms and blades. 3. Remove the cowl screen. 4. Remove the four wiper motor assembly mounting screws then lift assembly to gain access to wire harness clip. 5. Disconnect harness clip from the forward mounting leg. 6. Disconnect wire connector at motor and remove assembly. INSTALLATION 1. Connect wire connector at motor and remove assembly. 2. Connect harness clip to the forward mounting leg. 3. Place assembly into position, install the mounting bolts, and tighten the mounting bolts to 10 to 12 Nm (89 to 106 in. lbs.) torque. 4. Install the cowl screen. 5. Install the wiper arms and blades. 6. Connect the battery negative remote cable. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly. 4. Disconnect wiper arm linkage by using an ball joint/tie rod separator. Separate the right and left ball cap from the ball. 5. Disconnect drive link from the motor crank. Using an ball joint/tie rod separator and separate the ball cap from the ball. INSTALLATION 1. Connect the drive link to the motor crank. If motor output crank nut was removed, tighten nut to 25 to 30 Nm (19 to 23 ft. lbs.). 2. Align link ball cap over ball and gently press fit against shoulder of cap to lock cap into position. 3. Install the wiper motor assembly. 4. Install the cowl screen. 5. Install the wiper arms. Dodge Stratus Sedan Workshop Manual (V6-2.7L (2001)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center (PDC) Front Wiper On/Off and High/Low Relays are located in the Power Distribution Center (PDC). Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery.
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