1998 DODGE VIPER Service and Repair Manual

CHRYSLER CORPORATION SERVICE MANUAL 1998 VIPER RT/10® AND VIPER GTS To order the special service tools used and illustrated, please refer to the instructions on inside back cover. NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYS- TEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION. Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli- gations upon itself to install them on its products previously manufactured. Litho in U.S.A. Copyright © 1997 Chrysler Corporation 6M1297 ^CHRYSLER W CORPORATION Paper Content 50% Recycled

FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner's Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly,' and assembly procedures for systems and components. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group.. I f you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR 8G 8P Introduction Lubrication and Maintenance 2 Suspension Differential and Driveline Brakes 6 Clutch 7 Cooling System 8A Battery 8B Starting 80 Charging System 8P Ignition System 8E I nstrument Panel/Gauges 8F Audio Systems Horns 8 J Turn Signal and Flashers 8IN Electrically Heated Systems Power Door Locks 8Q Vehicle Theft/Security System 8S Power Windows 80 Chime/Buzzer Warning System 8W Wiring Diagrams 9 Engine SiC Windshield Wipers and Washers 8L Lamps 811 Passive Restraint Systems 1 j Exhaust System and Intake Manifold i 3 Frame and Bumpers j 4 Fuel System 19 Steering Transmission 22 Tires and Wheels 23 Body 24 Heating and Air Conditioning 25 Emission Control Systems Component and System Index Service Manual Comment Forms (Rear of Manual)

SR INTRODUCTION 1 INTRODUCTION CONTENTS page GENERAL INFORMATION FASTENER IDENTIFICATION 2 GENERAL INFORMATION 1 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 2 page METRIC SYSTEM 5 TORQUE REFERENCES 7 VEHICLE IDENTIFICATION NUMBER 1 VEHICLE SAFETY CERTIFICATION LABEL 1 GENERAL INFORMATION GENERAL INFORMATION The Viper RT/10 and the Viper GTS vehicle family code is designated SR. The vehicle family code does not appear on the vehicle. The SR code may be used in some documents to indicate the Viper. The 1997 Viper does not require a body code plate due to lim- ited optional equipment and colors. VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) is located on the left A-pillar inside the windshield opening. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. VIM CHECK mmiT To protect the consumer from theft and possible fraud the manufacturer is required to include a "Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label is attached to the rear facing of the driver's door. This label indi- cates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included. VIM CODE BREAKDOWN POSITION INTERPRETATION CODE=DESCRIPTION 1 Country of Origin 1-United States 2 Make B=Dodge 3 Vehicle Type 3=Passenger Car 4 Pass. Safety B=Manual Seat Belts E=Active Driver and Passenger Airbags 5 Car Line R=Viper R/T-10 R=Viper GTS 6 Series 7=Performance/lmage 7 Body Style 5=Open Body 9=Speciality Coupe 8 Engine E=8.0L 10 Cylinder 9 Check Digit See explanation in this section. 10 Model Year W=1998 11 Assembly Plant V=Conner Ave. Assembly 12 Thru 17 Sequence Number 6 digit number assigned by the assembly plant.

2 INTRODUCTION GENERAL INFORMATION (Continued) INTERNATIONAL CONTROL AND DISPLAY SYMBOLS SR 10 HIGH BEAM tp FOG LIGHTS HEADLIGHTS, PARKING LIGHTS, PANEL LIGHTS TURN SIGNAL A HAZARD WARNING WINDSHIELD WIPER WINDSHIELD WIPER AND WASHER WINDSCREEN DEMISTING AND DEFROSTING VENTILATING FAN LuD REAR WINDOW DEFOGGER CD i REAR WINDOW WASHER FUEL ENGINE COOLANT TEMPERATURE BATTERY CHARGING CONDITION ENGINE OIL (0) BRAKE FAILURE (0) PARKING BRAKE FRONT HOOD <&> REAR HOOD (TRUNK) HORN r'Y^» WINDSHIELD WASHER REAR WINDOW WIPER A SEAT BELT 1 I 1 LIGHTER SKIP SHIFT 80b34eab All communications or inquiries regarding the vehicle should include the Month-Day-Hour - and Vehicle Identification Number. INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the Interna- tional 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. FASTENER! IDENTIFICATION FASTENER IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt/nut threads are not the same. The difference is described in the Thread Notation chart (Fig. 1). INCH METRIC GRADE/CLASS IDENTIFICATION 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 12.9. 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. 5/16-18 THREAD NUMBER MAJOR OF DIAMETER THREADS IN INCHES PER INCH M8 X 1.25 THREAD DISTANCE MAJOR BETWEEN DIAMETER IN THREADS IN MILLIMETERS MILLIMETERS PR606B Fig. 1 Thread Notation Chart - SAE and Metric

SR INIiODUCIiON 3 GENERAL INFORMATION (Continued) FASTENER IDENTIFICATION Boll Markings and Torque • Metric Commercial Steel Class 8.8 10.9 12.9 Bolt Head Markings Body Size Torque Torque Torque Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft-lb N®m ft -lb N®m ft-lb N®m ft-lb N «m ft-lb N»m ft-lb 6 9 5 7 4 14 9 11 7 14 9 11 7 7 14 9 11 7 18 14 14 11 23 18 18 14 8 25 18 18 14 32 23 25 18 36 27 28 21 10 40 30 30 25 60 45 45 35 70 50 55 40 12 70 55 55 40 105 75 80 60 125 95 100 75 14 115 85 90 65 160 120 125 95 195 145 150 no 16 180 130 140 100 240 175 190 135 290 210 220 165 18 230 170 180 135 320 240 250 185 400 290 310 230 Bolt Markings and Torque Values - U,S. Customary SAE Grade Number 5 Bolt Head Markings 5 (3) line These are a 1 SAE Grade 5 (3) line Bolt Torque - Grade 5 Bolt Bolt Torque - Grade 8 Bolt Body Size Cast Iron Aluminum Cast Iron Aluminum N*m ft -lb N®m ft-lb N«m Mb N«m ft -lb 1/4 - 20 9 7 8 6 15 11 12 9 -28 12 9 9 7 18 13 14 10 5/16 • 18 20 15 16 12 30 22 24 18 - 24 23 17 19 14 33 24 25 19 3/8 - 16 40 30 25 20 55 40 40 30 - 24 40 30 35 25 60 45 45 35 7/16 - 14 60 45 45 35 90 65 65 50 - 20 65 50 55 40 95 70 75 55 1/2 - 13 95 70 75 55 130 95 100 75 - 20 100 75 80 60 150 110 120 90 9/16 - 12 135 100 110 80 190 140 150 no - 18 150 no 115 85 210 155 170 125 5/8 - 11 180 135 150 no 255 190 205 150 - 18 210 155 160 120 290 215 230 170 3/4 - 10 325 240 255 190 460 340 365 270 - 16 365 270 285 210 515 380 410 300 7/8 •9 490 360 380 280 745 550 600 440 - 14 530 390 420 310 825 610 660 490 1 - 8 720 530 570 420 1100 820 890 660 - 14 800 590 650 480 1200 890 960 710 95IN-6

4 INTRODUCTION SR GENERAL INFORMATION (Continued) FASTENER STRENGTH HOW TO DETERMINE BOLT STRENGTH Mark CI lass Mark Class Hexagon head bolt Hexagon flange bolt w / washer hexagon bolt Hexagon head bolt Hexagon flange bolt w / washer hexagon bolt Hexagon head bolt Hexagon head bolt 4- 5- Bolt 6 - head No. 7 - 8- 9- 10- 11 - No mark No mark Two protruding lines Two protruding lines Three protruding Four l^n^lj P r o t r u d i n 9 lines 4T 51 61 71 8T 9T 10T 1 IT 4T 4T 51 61 71 81 Stud bolt Welded bolt No mark 4T Grooved 61 41 95IN-4

SR INTRODUCTION GENERAL INFORMATION (Continued) 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 fMbs x 1.3558 = Newton-Meters (N»m) N*m x 0.7376 = ft-lbs Inches Hg (60°F) x 3.377 SB Kilopascals (kPa) IcPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 - psi Inches x 25.4 SB Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 3S Meters (M) M x 1.0936 = Yards Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles mph x 1.6093 Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec. x 0.3048 ss Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec. Kilometers/Hr. x 0.27778 s Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr. mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 » mph 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 J91IN-1 iETiiC SYSIEi WARNING; USE MAY RESULT IN SONAL INJURY. OF AN INCORRECT FASTENER COMPONENT DAMAGE OR PER- 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 metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvage- able, a fastener of equivalent specification should be used. The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. 2). . Mega - (M) Million Deci (D) Tenth Kilo (K) Thousand Cent! (C) Hundreth Milli (m) Thousandth J901N-2 Fig. 2 Metric Prefixes The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. 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.)

6 INTRODUCTION SR GENERAL INFORMATION (Continued) METRIC CONVERSION in-lbs t o N * m N * m t o in-lbs in- lb N®m in-lb N«m in-lb N®m in-lb N»m in-lb N»m N®m in-lb N»m in-lb N»m in-lb N«m in-lb N«m in-lb 2 .2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2 143.3882 4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4 145.1584 6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6 146.9287 8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8 148.6989 10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 79.6601 13 115.0646 17 150.4691 12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2 152.2393 14 1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4 154.0096 16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6 155.7798 18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8 157.5500 20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 2 17.7022 6 53.1067 10 88.5112 14 123.9157 18 159.3202 22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5 163.7458 24 2.7116 64 7,2309 104 11.7502 144 16.2696 184 20.7889 2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19 168.1714 26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148 2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5 172.5970 28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20 177.0225 30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5 181.4480 32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21 185.8736 34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22 194.7247 36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 3.6 31.8640 7.6 67.2685 11.6 102.6730 15.6 138.0775 23 203.5759 38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24 212.4270 40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4 35.4045 8 70.8090 12 106.2135 16 141.6180 25 221.2781 ft-lbs t o N * m N * m t o ft-lbs ft-lb N»m ft-lb N®m ft-lb N©m ft-lb N®m ft-lb N@m N®m ft-lb N®m ft-lb N®m ft-lb N®m ft-lb N°m ft-lb 1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.2400 61 44.9913 81 59.7425 2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801 3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177 4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552 5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928 6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4333 7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679 8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545 9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430 10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806 11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181 12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557 13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933 14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308 15 20.3373 35 47.4536 55 74.57m 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684 16 21.6931 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.8010 36 26.5522 •56 41.3035 76 56.0547 96 70.8060 17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7923 97 71.5435 18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 57.5298 98 72.2811 19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 59 43.5162 79 58.2674 99 73.0187 20 27.1164 40 54.2327 60 81.3491 80 108.4654 1043 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562 in. to mm mm t o i n . in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in. .01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189 .02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .043866 .42 .01654 .62 .02441 .82 .03228 .03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268 .04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307 .05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346 .06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .02598 .86 .03386 .07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425 .08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465 .09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504 .10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543 .11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .0)433 .31 .01220 .51 .02008 .71 .02795 .91 .03583 .12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622 .13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661 .14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701 .15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .03740 .16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780 .17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819 .18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .03709 .38 .01496 .58 .02283 .78 .03071 .98 .03858 .19 4.826 .39 9.906 .59 14.986 .79 20.066 .99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898 .20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.03 .03937 J901N-10

1998 DODGE VIPER Service and Repair Manual

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