Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

repair and service manual covers all Chrysler LHS, Concorde, 300M and Dodge Intrepid models, from 1998 through 2003.
Table of Contents
Introductory pages
About this manual | Introduction to the Chrysler LHS, Concorde, 300M, and Dodge Intrepid | Vehicle identification numbers | Buying parts | Maintenance techniques, tools and working facilities | Jacking and towing | Booster battery (jump) starting | Automotive chemicals and lubricants | Conversion factors | Fraction/decimal/millimeter equivalents | Safety first! | Troubleshooting

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1. Remove the air cleaner outlet tube (6B659). For additional information, refer to Section 303-12. 2. Disconnect the electrical connector from the ignition coil (12029). 3. Remove the bolt. 4. Remove the ignition coil. 1. To install, reverse the removal procedure.

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SERPENTINE BELT SLIPS OFF IDLER PULLEY Model(s): 1996-1999 Chrysler (NS) Town & Country 1996-1999 Dodge (NS) Caravan 1996-1999 Plymouth (NS) Voyager 1996-1999 Chrysler (GS) Voyager (International Market) SYMPTOM/CONDITION Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt off of the idler pulley. DIAGNOSIS Visually inspect the serpentine belt and idler pulley to determine if mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Fig. 1 ) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Fig. 2 , perform the REPAIR PROCEDURE . REPAIR PROCEDURE This repair is compatible with DaimlerChrysler’s Mobile Service Program and does not require hoists or other full service facility special equipment. 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Fig. 3 ). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Fig. 4 ). 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Fig. 3 ). 7. Remove the engine mounting bracket. 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 N.m (30-50 ft-lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 N.m (30-50 ft-lbs.). 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 N.m (50 ft-lbs.), vertical fastener 102 N.m (75 ft-lbs.), and horizontal fastener 150 N.m (111 ft-lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Fig. 1 ).

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REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the HVAC unit housing from the vehicle. See: Housing Assembly HVAC\Service and Repair 2. Remove the heater core tubes from the heater core. 3. Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. 4. Remove the expansion valve from the evaporator inlet and outlet tube fittings. 5. Disconnect the HVAC wire harness connector for the blower motor from the motor connector receptacle on the bottom of the outboard end of the evaporator housing. 6. Disengage the HVAC wire harness from the routing clips molded into the outside of the HVAC housing components.Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. 8. Pull the top of the distribution housing away from the evaporator housing far enough to disengage the two hook formations on the bottom of the distribution housing from the two receptacles on the evaporator housing. 9. Remove the two screws that secure the upper intake air housing to the lower intake air housing. 10. Remove the three screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening.

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rePaIr Procedure/InformatIon Step 1) Ignition Coil Inspection Check the tower portion of the ignition coil for carbon tracks (leakage). If leakage is more than 5mm long, the ignition coil and high tension cables should be replaced (see Figure 1). Figure 1 Example of leakage on ignition coil tower. Step 2) High Tension Cable Inspection Check the high tension cables for carbon tracks (leakage). If leakage is evident, the high ten- sion cables should be replaced and the ignition coil cleaned (see figure 2 and refer to Step 3). Figure 2 Leakage on cable. Step 3) Ignition Coil Cleaning Procedure (if carbon track is less than 5mm) • • • • note: Do not insert the high tension cables until the ignition coil is dry. If there is any evidence of carbon, clean the surface of the ignition coil using a clean, soft rag dampened with water. Permit the ignition coil to dry. Clean the same area of the ignition coil using a clean soft rag dampened with Isopropyl alcohol. Permit the ignition coil to dry.