Primary Coverage:
Mechanical, Electrical, Bodywork, Maintenance, Diagnostics, Troubleshooting, Repair Procedures
Specific Systems:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Fuel System, Exhaust System, Electrical System, Body & Interior, Body Control Modules (BCM), Powertrain Control Modules (PCM)
Estimated Page Count:
Over 2000 pages (typical for comprehensive service manuals of this era)
Type:
Service and Repair Manual
Content Source:
Factory Service Manual (FSM) equivalent
Digital Format:
PDF Download
Engine Mechanical:
V6 (3.5L, 2.7L) and V8 (5.7L HEMI) engine assembly, disassembly, inspection, repair, torque specifications, timing, seals, gaskets, pistons, rings, bearings, cylinder heads, camshafts, crankshafts
Engine Electrical:
Ignition system, fuel injection system, emission control systems, engine sensors (MAP, TPS, CKP, CMP), PCM diagnostics, starting and charging system
Transmission Manual:
4-speed automatic (42RLE) and 5-speed automatic (NAG1/722.6) transmission repair, overhaul, torque converter, valve body, solenoids, clutches, bands, fluid specifications, capacity, and refill procedures
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, driveshafts, CV joints, differentials, axle shafts, repair and maintenance
Suspension Steering:
Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), steering system (rack and pinion, power steering pump, steering column), alignment specifications, diagnosis of wear and tear
Brakes:
Hydraulic brake system, ABS system, disc brake components (rotors, pads, calipers), parking brake system, brake fluid specifications, bleeding procedures, component replacement
Body Electrical:
Lighting system (headlights, taillights, interior), power windows, power locks, power seats, mirrors, door modules, keyless entry, security system, horn, wipers, wash system
HVAC:
Air conditioning system (refrigerant type, charge, components), heating system, climate control modules, blower motor, heater core, evaporator, condenser, diagnostic procedures
Fuel Exhaust:
Fuel tank, fuel pump, fuel lines, fuel injectors, fuel filter replacement, exhaust system components (manifold, catalytic converter, mufflers, pipes), oxygen sensors
Routine Maintenance:
Oil change procedures, filter replacement (oil, air, cabin), fluid level checks and top-offs, spark plug replacement, belt replacement, tire rotation
Diagnostic Troubleshooting:
Step-by-step diagnostic flowcharts for common symptoms, OBD-II (On-Board Diagnostics) system interpretation, DTC (Diagnostic Trouble Code) lookup and resolution
Component Replacement:
Detailed instructions for replacing individual components such as alternators, starters, water pumps, radiators, fuel pumps, brake pads, rotors, suspension parts, interior trim, exterior body panels
Rebuilding Overhauls:
Complete engine and transmission rebuilding procedures, including disassembly, cleaning, inspection, part measurement, and reassembly with specifications
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems, power distribution, component locations, connector pinouts
Depth:
Comprehensive, covering basic to advanced repair and diagnostic procedures, suitable for professional technicians and experienced DIYers
Data Precision:
Includes precise torque specifications, clearances, fluid capacities, diagnostic parameters, and wiring information
NHTSA Front Impact:
5-star (driver), 5-star (passenger) for 2005-2008 models
NHTSA Side Impact:
5-star (front), 5-star (rear) for 2005-2008 models
IIHS Side Impact:
Good (2005-2008 models)
IIHS Rear Impact And Head Restraints:
Good (2005-2008 models)
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Electronic Stability Control:
Available Electronic Stability Program (ESP)
Airbags:
Standard front airbags, optional front side-impact airbags, optional side curtain airbags
Seat Belts:
Three-point seat belts for all occupants, pretensioners and load limiters for front seats
Service Intervals General
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first, with synthetic oil. Consult manual for specific engine/oil type.
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 15,000-30,000 miles depending on environment.
Spark Plug Replacement:
2.7L V6/3.5L V6: Platinum plugs, 100,000 miles. 5.7L HEMI: MDS operation may require specific plugs, check manual.
Transmission Fluid Flush:
42RLE: 60,000 miles. NAG1/722.6: Check manual, often specified as 'lifetime' but fluid change recommended every 60,000-100,000 miles for longevity.
Coolant Flush:
Every 100,000 miles or 5 years with HOAT coolant.
Engine Oil Capacity:
2.7L V6: 5.0 qts (4.7 L); 3.5L V6: 5.0 qts (4.7 L); 5.7L V8 HEMI: 7.0 qts (6.6 L)
Engine Oil Viscosity:
5W-20 or 5W-30 (refer to oil cap/manual for exact spec)
Power Steering Fluid:
ATF+4 (Chrysler specification)
Common Problems Powertrain:
Water pump leaks, intake manifold gasket leaks (3.5L V6), camshaft position sensor issues, early transmission valve body issues (NAG1), HEMI lifter tick (MDS related).
Common Problems Suspension Steering:
Worn ball joints, tie rod ends, front control arm bushings, power steering pump noise.
Common Problems Electrical:
Window motor failures, door lock actuator failures, BCM (Body Control Module) glitches, headlight condensation.
Common Problems HVAC:
Blend door actuator failures, A/C compressor issues, evaporator leaks.