2005 DODGE STRATUS Service and Repair Manual

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Compass/Mini-Trip Computer 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission/Transaxle 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE DESCRIPTION .......................... 1 FASTENER IDENTIFICATION DESCRIPTION .......................... 2 FASTENER USAGE DESCRIPTION .......................... 5 THREADED HOLE REPAIR DESCRIPTION .......................... 5 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS ...5 METRIC SYSTEM DESCRIPTION .......................... 6 TORQUE REFERENCES DESCRIPTION .......................... 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 9 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION ......................... 10 E-MARK LABEL DESCRIPTION ......................... 10 VECI LABEL DESCRIPTION ......................... 10 MANUFACTURE PLATE DESCRIPTION ......................... 11 BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 1) is located in the engine compartment on the driver side strut tower. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate. BODY CODE PLATE LINE 2 DIGITS 1, 2, AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for Body Color Codes. DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint DIGIT 13 AND 14 Open Space Fig. 1 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN JR INTRODUCTION 1

DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • ECC = 2.0L Four Cylinder 16 Valves DOHC Gasoline • EDZ = 2.4L Four Cylinder 16 Valves DOHC Gas- oline • EER = 2.7L Six Cylinder 24 Valves DOHC Gas- oline DIGIT 23 Open Space BODY CODE PLATE LINE 1 DIGITS 1, 2, AND 3 Transaxle Codes • DGL = 41TE 4-Speed Electronic Automatic Transaxle • DD5 = NV T350 5-Speed Manual Transaxle DIGIT 4 Open Space DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code. IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be fol- lowed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates. FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3). 2 INTRODUCTION JR BODY CODE PLATE (Continued)

Fig. 2 FASTENER IDENTIFICATION JR INTRODUCTION 3 FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH 4 INTRODUCTION JR FASTENER IDENTIFICATION (Continued)

FASTENER USAGE DESCRIPTION WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR DESCRIPTION Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures. INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. INTERNATIONAL SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter JR INTRODUCTION 5

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in. lbs. x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in. lbs. ft. lbs. x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft. lbs. Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards m.p.h. x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = m.p.h. Feet/Sec. x 0.3048 = Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec. m.p.h. x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 = m.p.h. Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 4). 6 INTRODUCTION JR

Fig. 4 METRIC CONVERSION CHART JR INTRODUCTION 7 METRIC SYSTEM (Continued)

TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- tions Chart for torque references not listed in the individual torque charts (Fig. 5). Fig. 5 TORQUE SPECIFICATIONS 8 INTRODUCTION JR

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) is located on the upper left corner of the instrument panel, near the left windshield pillar (Fig. 6). The VIN con- sists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown table for decoding information. VIN CODE BREAKDOWN POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Built in United States by DaimlerChrysler Corporation. 2 Make B = Dodge C = Chrysler 3 Vehicle Type2 3 = Passenger Car 4 Passenger Safety A = Active Front and Side Airbag E = Active Driver and Passenger Airbag 5 Car Line J = Stratus L = Sebring 6 Series 4 = High line 5 = Premium 6 = Special Transmission Table For Bux w/ABB, ABJ N = 5-Speed Manual B = 4 Speed Automatic 7 Body Style 5 = Convertible / Open Body 6 = 4 Door Sedan 8 Engines Y = 2.0L 4 Cyl. 16V DOHC Gasoline S = 2.4L 4 Cyl. 16V DOHC Gasoline R = 2.7L 6 Cyl. 24V DOHC Gasoline 9 Check Digit 0 through 9 or X 10 Model Year 2 = 2002 11 Plant N = Sterling Heights Assembly Plant 12 through 17 Sequence Number 6 digit number assigned by assembly plant. Fig. 6 Vehicle Identification Number (VIN Plate) 1 - V.I.N. PLATE 2 - DASH PANEL 3 - 17 DIGITS 4 - WINDSHIELD OPENING JR INTRODUCTION 9

2005 DODGE STRATUS Service and Repair Manual

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