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Intrepid
Dodge Intrepid User Manual
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Main
Bearing
Remover/Installer
C-3059
Crankshaft
Rear
Seal
Guide
6926-1
&
Installer
6926-2
Driver
Handle
C-4171
Crankshaft
Rear
Seal
Retainer
Alignment
Fixture
8225
Release
Probe
8351
Pressure
Gauge
C-3292
Adapter
8406
DRBIII
T
with
PEP
Module
–
OT
-CH6010A
9
-
108
ENGINE
3.5L
LH
ENGINE
3.5L
(Continued)
342
344
Table of Contents
Table of Contents
94
Body Code Plate
2
Location and Decoding
2
Description
4
Fastener Identification
4
Description Description - Fastener Usage
7
Metric System Description
8
Digit
11
Vehicle Safety Certification Label
12
C101
103
C104
105
C105
105
C106
106
C120 (Police Package/Special Service)
109
C200
110
C201
111
C204
113
C300
115
C301
116
C302
117
C303
118
C304
119
C305
119
C306
120
C307
120
C308
121
C309
121
C310
122
C311
122
C312
122
C313 (Concorde/Dodge/300M)
123
C313 (Ltd/Built-Up-Export) - (Tail Lamps
123
C313 (Ltd/Concorde/Built-Up-Export)
123
C314 (Concorde/Dodge/300M)
124
C314 (Ltd/Built-Up-Export) - (Tailamps
124
C314 (Ltd/Concorde/Built-Up-Export)
124
C315 (Concorde/Ltd)
125
C316
125
C317
126
C319 (Memory)
128
C320 (Concorde/Ltd)
128
Grounds
205
Splices
206
8W-97 Power Distribution
230
Cigar Lighter/Power Outlet Description
231
Operation
232
Removal
232
Installation
232
Power Distribution
231
Description
231
Operation
231
Standard Procedure - Cigar Lighter/ Power Outlet Customer Preference
231
Iod Fuse Description
232
Operation
233
Removal
233
Installation
233
Junction Block Description
233
Operation
234
Removal
234
Installation
234
Power Distribution Center Description
234
Removal
235
Installation
235
Engine
236
Engine 2.7L
238
Engine 2.7L Description
238
Diagnosis - Introduction
240
Diagnosis and Testing
240
Diagnosis and Testing - Engine
240
Diagnosis and Testing - Engine Diagnosis - Performance
241
Diagnosis and Testing - Engine Diagnosis - Mechanical
243
Diagnosis and Testing - Cylinder Combustion Pressure Leakage Test
245
Diagnosis and Testing - Cylinder Compression Pressure Test
245
Standard Procedure - Engine Gasket Surface Preparation
246
Standard Procedure Standard Procedure - Form-In- Place Gaskets and Sealers
246
Standard Procedure - Engine Core and Oil Gallery Plugs
247
Standard Procedure - Repair of Damaged or Worn Threads
247
Removal - Engine Assembly
248
Standard Procedure - Hydrostatic Locked Engine
248
Standard Procedure - Measuring Bearing Clearance Using Plastigage
248
Installation - Engine Assembly
250
2.7L Engine
252
Specifications
252
Torque
254
2.7L Engine
255
Special Tools
255
Air Cleaner Element Removal
258
Engine 3.5L
258
Installation
258
Cylinder Head
259
Description
259
Diagnosis and Testing-Cylinder Head Gasket
259
Removal
260
Cleaning
261
Inspection
262
Installation
262
Camshaft(S) Description
263
Operation
263
Standard Procedure - Camshaft End Play
263
Removal
263
Inspection
263
Installation
264
Cylinder Head Cover(S) Removal
265
Installation
266
Intake/Exhaust Valves & Seats Description
266
Operation
266
Standard Procedure - Valve and Valve Seat Refacing
266
Removal
267
Inspection
268
Installation
268
Valve Springs Description
269
Operation
269
Removal
269
Removal - in Vehicle
269
Removal - off Vehicle
269
Inspection
269
Installation
270
Installation - in Vehicle
270
Installation - off Vehicle
271
Valve Stem Seals Removal
271
Installation
272
Hydraulic Lash Adjusters
272
Diagnosis and Testing - Hydraulic
272
Lash Adjuster Noise Diagnosis
272
Removal
273
Installation
273
Rocker Arms Description
273
Operation
273
Inspection
274
Installation
274
Engine Block Description
274
Standard Procedure - Cylinder Bore Honing
274
Cleaning
274
Connecting Rod Bearings
276
Standard Procedure - Connecting
276
Rod and Bearing Fitting
276
Crankshaft Description
277
Operation
277
Standard Procedure - Crankshaft End Play
277
Removal
277
Installation
278
Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting
280
Crankshaft Oil Seal - Front
282
Removal
282
Installation
282
Crankshaft Oil Seal - Rear
283
Removal
283
Installation
283
Crankshaft Rear Oil Seal Retainer
284
Removal
284
Installation
284
Assembly
306
Installation
306
Intake Manifold Description
307
Operation
307
Diagnosis and Testing - Intake Manifold Leaks
307
Intake Manifold - Upper
307
Standard Procedure - Intake
307
Manifold Vacuum Port Repair
307
Removal - Upper
307
Inspection
308
Installation
308
Intake Manifold - Lower Removal
309
Inspection
309
Installation
309
Exhaust Manifold Description
310
Exhaust Manifold - Right Removal
310
Inspection
310
Installation
310
Exhaust Manifold - Left Removal
311
Inspection
311
Installation
311
Valve Timing
311
Description
311
Standard Procedure Engine Timing - Verification
313
Timing Chain Cover Removal
313
Installation
314
Engine 3.5L
322
Description
325
Timing Belt/Chain and Sprockets Removal Removal - Timing Chain
314
Removal - Crankshaft Sprocket
315
Installation Installation - Timing Chain
317
Installation - Crankshaft Sprocket
321
Diagnosis and Testing Diagnosis and Testing - Engine Diagnosis - Introduction
325
Engine 3.5L Description
325
Even Numbered (Fig. 2). the Firing Order Is
325
The Cylinders Are Numbered from Front to Rear
325
The Engine Identification Number Is Located on the
325
With the Right Bank Odd Numbered, and the Left Bank
325
Diagnosis and Testing - Engine Diagnosis - Mechanical
327
Diagnosis and Testing - Engine Diagnosis - Performance
329
Diagnosis and Testing - Cylinder Combustion Pressure Leakage Test
331
Diagnosis and Testing - Cylinder Compression Pressure Test
331
Standard Procedure Standard Procedure - Form-In- Place Gaskets and Sealers
331
Standard Procedure - Engine Gasket Surface Preparation
332
Standard Procedure - Repair of Damaged or Worn Threads
332
Standard Procedure - Engine Core and Oil Gallery Plugs
333
Standard Procedure - Hydrostatic Locked Engine
333
Removal - Engine Assembly
334
Standard Procedure - Measuring Bearing Clearance Using Plastigage
334
Installation - Engine Assembly
335
3.5L Engine
337
Specifications
337
Torque
340
3.5L Engine
341
Special Tools
341
Air Cleaner Element Removal
344
Installation
344
Cylinder Head Description
344
Diagnosis and Testing-Cylinder Head Gasket
344
Cleaning
345
Removal
345
Inspection
346
Installation
346
Camshaft Oil Seal(S) Removal
347
Installation
348
Camshaft(S) Description
348
Operation
348
Standard Procedure - Measuring Camshaft End Play
348
Cleaning
349
Inspection
349
Installation
349
Removal
349
Cylinder Head Cover(S) Removal
350
Installation
350
Intake/Exhaust Valves & Seats Description
351
Operation
351
Standard Procedure - Valve and Valve Seat Refacing
351
Cleaning
352
Removal
352
Inspection - Valve Guides
353
Inspection Inspection - Valves
353
Installation
353
Rocker Arm / Adjuster Assembly Description Description - Rocker Arm
354
Description - Rocker Arm Shafts
354
Diagnosis and Testing Lash Adjuster (Tappet) Noise Diagnosis
354
Operation
354
Removal
356
Standard Procedure - Hydraulic Lash Adjuster Bleeding
356
Disassembly
357
Inspection
357
Assembly
358
Installation
358
Spark Plug Tube Removal
359
Installation
359
Valve Stem Seals Removal
359
Valve Springs Description
360
Operation
360
Removal
360
Removal - Cylinder Head off
360
Removal - Cylinder Head on
360
Inspection
361
Installation
361
Installation - Cylinder Head off
361
Installation - Cylinder Head on
362
Engine Block Description
362
Standard Procedure - Cylinder Bore Honing
362
Cleaning
363
Inspection
363
Connecting Rod Bearings
364
Crankshaft Description
365
Operation
365
Removal
365
Standard Procedure - Crankshaft End Play
365
Inspection
366
Installation
367
Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting
368
Removal
369
Installation
370
Crankshaft Oil Seal - Front Removal
371
Installation
371
Crankshaft Oil Seal - Rear Removal
372
Installation
372
Crankshaft Rear Oil Seal Retainer Removal
373
Installation
373
Flex Plate Removal
374
Installation
374
Piston & Connecting Rod Description
374
Operation
374
Removal
374
Standard Procedure - Fitting Pistons
374
Installation
375
Piston Rings
377
Removal
377
Standard Procedure - Piston Ring Fitting
377
Installation
378
Structural Collar / Cover Removal
379
Installation
379
Vibration Damper Removal
380
Installation
380
Removal
381
Engine Mounting Description
381
Inspection
381
Left Mount Removal
381
Installation
381
Rear Mount Removal
382
Installation
382
Right Mount Removal
382
Lubrication Description
383
Diagnosis and Testing Diagnosis and Testing - Engine Oil Leak Inspection
383
Operation
383
Diagnosis and Testing - Checking Engine Oil Pressure
384
Oil Description
385
Standard Procedure - Engine Oil and Filter Change
385
Standard Procedure Standard Procedure - Engine Oil Level Check
385
Oil Cooler & Lines Description
386
Operation
386
Removal
386
Installation
387
Oil Filter Removal
387
Oil Pan Removal
387
Installation
388
Oil Pressure Relief Valve Removal
389
Inspection
389
Installation
389
Oil Pressure Switch Description
389
Description
389
Operation
389
Removal
389
Installation
390
Oil Pump Removal
390
Cleaning
390
Disassembly
390
Inspection
390
Assembly
393
Installation
393
Intake Manifold Description
393
Diagnosis and Testing - Intake Manifold Leaks
394
Intake Manifold - Upper Removal
394
Inspection
395
Installation
396
Intake Manifold - Lower Removal
396
Inspection
397
Installation
397
Exhaust Manifold Description
399
Exhaust Manifold - Right Removal
400
Inspection
400
Installation
400
Exhaust Manifold - Left Removal
400
Inspection
401
Installation
401
Standard Procedure - Valve Timing
401
Valve Timing Description
401
Verification
401
Timing Belt Cover(S) - Front Removal
402
Timing Belt Cover(S) - Rear Removal
403
Installation
403
Timing Belt Tensioner & Pulley Removal Removal - Tensioner Pulley Assembly
405
Inspection - Tensioner
405
Inspection - Tensioner Pulley Assembly
405
Installation Installation - Tensioner Pulley Assembly
405
Removal - Tensioner
405
Installation - Tensioner
406
Timing Belt and Sprockets Removal Removal - Timing Belt
406
Removal - Camshaft Sprockets
407
Inspection - Timing Belt
409
Installation Installation - Timing Belt
409
Removal - Crankshaft Sprocket
409
Installation - Camshaft Sprockets
410
Installation - Crankshaft Sprocket
412
Engine 2.7L
325
Exhaust System
414
Exhaust System
416
Inspection
417
Installation - Exhaust System
417
Removal - Exhaust System
417
Adjustments
418
Specifications Torque
418
Catalytic Converter(S) Description
419
Operation
419
Inspection
420
Exhaust System
419
Special Tools
419
Catalytic Converter - Right
420
Removal - Right Side
420
Installation - Right Side
421
Heat Shields Description
421
Operation
421
Catalytic Converter - Left
421
Installation - Left Side
421
Removal - Left Side
421
Muffler/Front Resonator Assembly Removal
422
Installation
422
Resonator - Left Rear Removal
422
Resonator - Right Rear (300M Special) Removal
422
Frame & Bumpers
424
Front Fascia Removal Removal
425
Front Bumper Reinforcement
425
Installation Installation
425
Installation - Intrepid
426
Removal - Intrepid
425
Rear Bumper Removal
426
Installation
427
Rear Fascia
427
Removal
427
Removal - Intrepid
427
Rear Fascia - Intrepid Installation - Intrepid
427
Frame Specifications Frame Dimensions
428
Specifications - Torque
432
Engine Cradle Crossmember Removal
432
Installation
432
Rear Crossmember Description
433
Operation
433
Removal
433
Disassembly
435
Assembly
436
Installation
436
Front Tow Hook Bracket Removal
433
Front Tow Eye Removal
433
Installation
433
Rear Tow Eye Removal
438
Installation
438
Installation
425
Fuel System
440
Fuel Delivery Description
441
Diagnosis and Testing - Fuel Delivery System
441
Fuel Delivery
441
Operation
441
Standard Procedure
441
Pressure Release Procedure
441
Standard Procedure - Draining Fuel Tank
441
Standard Procedure - Fuel System
441
Fuel System Pressure
442
Fuel Tank Capacity
442
Torque
442
Special Tools
442
Fuel
442
Fuel Level Sending Unit / Sensor Description
443
Removal
443
Installation
445
Flow Management Valve Description
443
Operation
443
Fuel Lines
445
Description - Fuel Lines/Hoses and Clamps
445
Standard Procedure - Hoses and Clamp
445
Fuel Pressure Regulator Description
446
Installation
446
Operation
446
Removal
446
Fuel Pump Module Description
447
Installation
448
Removal
448
Fuel Pump Description
447
Operation
447
Fuel Rail Description
449
Installation Installation - 2.7L
449
Operation
449
Removal - 2.7/3.5L
449
Installation - 3.5L
450
Fuel Tank Description
450
Operation
450
Removal
450
Installation
452
Fuel Tank Filler Tube Removal
453
Installation
453
Fuel Tank Vent Tube Removal
453
Inlet Filter Removal
453
Quick Connect Fitting Standard Procedure - Quick-Connect Fittings
454
Fuel Injection
457
Fuel Injection
458
Operation - Injection System
458
Operation - Modes of Operation
458
FUEL CORRECTION or ADAPTIVE MEMORIES
460
Programmable Communications Interface (Pci) Bus
461
Specifications Torque
462
Torque Management
462
Accelerator Pedal
463
Removal
463
Installation
464
Special Tools
463
Fuel
463
Crankshaft Position Sensor
464
Description
464
Installation
465
Operation
465
Removal
465
Engine Speed Sensor Description
465
Fuel Injector Description
466
Operation
466
Removal Removal - 2.7L
466
Installation - 3.5L
467
Installation Installation - 2.7L
467
Removal - 3.5L
467
Fuel Pump Relay Description
467
Operation
467
Idle Air Control Motor Description
468
Installation Installation - 2.7L
468
Operation
468
Removal - 3.5L
468
Removal Removal - 2.7L
468
Installation - 3.5L
469
Intake Air Temperature Sensor Removal
469
Installation
469
Map Sensor Description
469
Operation
470
Installation - 3.5L
471
Installation Installation - 2.7L
471
O2 Sensor Description
471
Removal - 3.5L
471
Removal Removal - 2.7L
471
Operation
472
Removal - Downstream 1/2, 2/2
473
Removal - Upstream 1/1, 2/1
473
Installation - Downstream 1/2, 2/2
474
Installation Installation - Upstream
474
Manifold Tune Valve Removal - 3.5L
469
O2 Sensor
472
Short Runner Valve Description
474
Installation - 3.5L
474
Operation
474
Removal - 3.5L
474
Throttle Body Description
475
Operation
475
Removal - 3.5L
475
Removal Removal - 2.7L
475
Installation - 3.5L
476
Installation Installation - 2.7L
476
Throttle Control Cable Removal
476
Installation
476
Throttle Position Sensor Description
476
Operation
476
Installation - 2.7L
477
Installation - 3.5L
477
Removal - 2.7L
477
Removal - 3.5L
477
Steering
478
Diagnosis and Testing Diagnosis and Testing - Power Steering Flow and Pressure Test
479
Diagnosis and Testing - Steering Diagnosis Charts
481
Diagnosis and Testing - Speed Proportional Power Steering
486
Power Steering Fastener Torque
486
Specifications
486
Power Steering
487
Special Tools
487
Column
488
Column
489
Operation
500
Diagnosis and Testing - Steering
500
Ignition Switch Removal
500
Intermediate Shaft
500
Column Intermediate Shaft
500
Key/Lock Cylinder Description
501
Operation
501
Removal
501
Steering Coupling
502
Column Shaft Upper Coupler
502
Diagnosis and Testing - Steering
502
Removal
502
Steering Wheel Removal
503
Installation
503
Steering Column Gear Shift Lever Removal
503
Table of Contents
507
Operation - Power Steering Gear
509
Operation - Speed Proportional Steering Gear
509
Removal - Power Steering Gear
509
Steering Gear
509
Assembly- Power Steering Gear (Housing Bushings)
515
Disassembly - Power Steering Gear (Housing Bushings)
515
Installation - Power Steering Gear
515
Description - Solenoid Control Valve
517
Operation - Solenoid Control Valve
517
Removal - Solenoid Control Valve
517
Speed Proportional Steering Solenoid
517
Installation - Solenoid Control Valve
518
Tie Rod - Inner
519
Removal - Inner Tie Rod
519
Installation - Inner Tie Rod
521
Tie Rod - Outer
522
Diagnosis and Testing - Outer Tie Rod Socket End Play
522
Installation - Outer Tie Rod
523
Removal - Outer Tie Rod
523
Bushing - Inner Tie Rod
524
Removal - Inner Tie Rod Bushing
524
Installation - Inner Tie Rod Bushing
527
Fluid Cooler Description/Assembly - Pump (Pulley)
530
Pump
531
Operation
531
Standard Procedure - Power Steering Pump Initial Operation
531
Removal - Pump (2.7L Engine)
532
Removal - Pump (3.5L Engine)
533
Assembly - Pump (Pulley)
535
Installation - Pump (2.7L Engine)
536
Installation - Pump (3.5L Engine)
536
Disassembly - Pump (Pulley)
535
Specifications
536
Power Steering Pump Flow
536
Fluid Cooler Description
537
Standard Procedure - Power Steering Fluid Level Checking
537
Installation
538
Removal
538
Hoses Description
539
Removal - Pressure and Return Hoses
539
Installation - Pressure and Return Hoses
543
Removal - Reservoir (2.7L Engine)
544
Removal - Reservoir (3.5L Engine)
544
Engine)
545
Installation - Reservoir
545
Installation - Reservoir (3.5L Engine)
546
Transaxle
548
42Le Automatic Transaxle
550
Diagnosis and Testing
551
Diagnosis and Testing - Hydraulic
552
Diagnosis and Testing - Clutch Air Pressure Tests
555
Pressure Tests
555
Diagnosis and Testing - Fluid Leakage
556
Operation
551
Removal
557
Standard Procedure - Aluminum Thread Repair
557
Disassembly
558
Assembly
575
Installation
594
Schematics and Diagrams - 42Le Transaxle
595
Specifications
608
42Le Automatic Transaxle
608
Special Tools
610
42Le Automatic Transaxle
610
Accumulator Description
616
Autostick Switch Description
617
Bearing Adjustment Procedures
618
Master Shim Chart
618
Driving Clutches Description
620
Final Drive
620
Disassembly
620
Assembly / Bearing Adjustment Procedure
628
Standard Procedure - Fluid/Filter Service
645
Standard Procedure - Differential Sump Drain and Refill
646
Gear Shift Cable - Column Removal
647
Installation
649
Adjustment
650
Gear Shift Cable - Floor Removal
651
Installation
651
Adjustment
653
Holding Clutches Description
653
Input Clutch Assembly Disassembly
654
Assembly
661
Oil Pump Description
671
Standard Procedure - Oil Pump Volume Check
671
Disassembly
672
Assembly
673
Planetary Geartrain Description
673
Seal - Stub Shaft (Long) Removal
674
Installation
675
Seal - Stub Shaft (Short) Removal
676
Seal - Oil Pump
678
Shift Interlock Cable Removal
679
Installation
680
Adjustment - Interlock Cable
681
Shift Interlock Mechanism Removal
682
Installation
682
Shift Interlock Solenoid Removal
683
Installation
684
Operation
686
Diagnosis and Testing - Brake/ Transmission Shift Interlock System
687
Shift Mechanism
689
Solenoid/Pressure Switch Assy
690
Speed Sensor - Input Description
692
Speed Sensor - Output Description
693
Torque Converter
695
Transfer System Inspection
697
Drive Sprocket Height Adjustment Procedure
698
Transmission Control Relay
699
Transmission Range Sensor
699
Removal
700
Valve Body Description
701
Removal
703
Disassembly
705
Installation
715
Tire Pressure Monitoring
725
Wheel Cover
734
Lock Cylinder
753
Door Glass
756
Window Regulator
763
Front Fender
774
Glove Box
783
Instrument Panel Assembly
783
Instrument Panel
788
Rear View Mirror
809
Sun Visor
811
Front Armrest
816
Front Seat
818
Lumbar Support
827
Rear Armrest
829
Rear Seat Cushion
832
Glass Panel
842
Wind Deflector
846
Opening Dimensions
855
Heater Core
977
Fuel Filler Cap
994
Pcv Valve
998
Torque References Description
1016
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Dodge Intrepid Specifications
General
Brand
Dodge
Model
Intrepid
Category
Automobile
Language
English
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