
• 
• —
 LUiRICATlON
 AND
 MAINTENANCE
 0 - 1 
 CONTENTS 
page
 page 
CHASSIS
 AND
 BODY
 28
 ENGINE MAINTENANCE
 14 
 DRIVETRAIN
 .,,, 22
 GENERAL INFORMATION
 1 
GENERAL
 INFORMATION INDEl 
page 
Classification
 of
 Lubricants
 . 3 
Components
 Requiring
 No
 Lubrication
 4 
Fuel Requirements
 . 2 
Introduction
 1 
Lubrication
 and
 Replacement Parts  Recommendation
 3 
 page 
Routine Maintenance
 2 
Starting
 Assistance (Jump Starting)
 9 
Vehicle
 Lifting
 Recommendations
 ............ 10 
Vehicle Noise
 Control
 2 
Vehicle Towing Recommendations
 11 
INTRODUCTION 
 Lubrication and maintenance is divided into re
quired and recommended service tasks. The required  service tasks must be completed to verify the emis
sion controls function correctly. The recommended 
service tasks should be completed to maintain safety 
and durability.  This information will assist the service personnel 
in providing maximum protection for each owner's 
vehicle.  Conditions can vary with individual driving habits. 
It is necessary to schedule maintenance as a time in
terval as well as a distance interval.  It is the owner's responsibility to determine the ap
plicable driving condition. Also to have the vehicle  serviced according to the maintenance schedule, and 
to pay for the necessary parts and labor.  Vehicles with a Gross Vehicle Weight Rating 
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform 
to light duty emission standards. Vehicles with a  Gross Vehicle Weight Rating (GVWR) of 3 856 kg 
(8,501 lbs.) or more must conform to heavy duty 
emission standards.  The GVWR for each vehicle is listed on the Safety 
Certification Label. This label is affixed to the driver 
side door pillar (Fig. 1). 
Additional maintenance and lubrication informa
tion is listed in the Owner's Manual. 
 Mm
 rv
 CHRYSLER
 DATE
 OF MFR 
MFD BY CORPORATION 
 GVWR 
GAWR FRONT 
GAWR REAR 
 WITH
 TIRES 
WITH
 TIRES 
 RIMS
 AT 
RIMS
 AT 
PSI
 COLD 
PSI
 COLD  THIS VEHICLE CONFORMS
 TO
 ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY 
STANDARDS
 IN
 EFFECT ON
 THE
 DATE
 OF
 MANUFACTURE SHOWN ABOVE. 
SINGLE 
 DUAL 
BAR
 CODE 
VEHICLE MADE
 IN 
4648503
 J9UN-25 
Fig. 1 Vehicle Safety
 Certification
 Label 
SEVERE DRIVING
 CONDITIONS 
 Vehicles subjected to severe driving conditions 
should decrease the interval between component 
maintenance. Severe driving conditions are defined 
 as: 
• Frequent short trip driving less than 24 km (15 
miles) 
• Frequent driving in dusty conditions 
• Trailer towing 
• Extensive engine idling 
• Sustained high speed operation 
• Desert operation 
• Frequent starting and stopping 
• Cold climate operation 
LUBRICATION
 AND
 MAINTENANCE   

0 - 2
 LUBRICATION
 AND
 MAINTENANCE 
• Commercial service 
When a vehicle is continuously subjected to severe 
driving conditions, lubricate: 
• Body components 
• All the driveline coupling joints 
• Steering linkage  More often than normal driving conditions 
DUSTY
 AREAS 
 With this type of severe driving condition, special 
care should be given to the: 
• Engine air cleaner filter 
• PCV filter 
• Crankcase ventilation system 
• Brake booster control valve air filter.  Verify that the filters and the associated compo
nents are clean. Also verify that they are functioning 
effectively. This will minimize the amount of abra sive particles that enter the engine. 
OFF-ROAD
 (4WD)
 OPERATION 
 After off-road (4WD) operation, inspect the under
side of the vehicle. Inspect the: 
• Tires 
• Body structure 
• Steering components 
• Suspension components  • Exhaust system 
• Threaded fasteners 
HARSH
 SURFACE ENVIRONMENTS 
 After extended operation in harsh environments, 
the brake drums, brake linings, and rear wheel bear ings should be inspected and cleaned. This will pre
vent wear and erratic brake action. 
ROUTINE MAINTENANCE 
 The following routine maintenance is recommended 
on a monthly basis:  TIRES—Inspect the tires for unusual wear/damage. 
Determine if the inflation pressure is adequate for 
the vehicle load.  BATTERY—Inspect and clean the terminals. 
Tighten the terminals if necessary.  FLUIDS—Determine if the component fluid levels 
are acceptable. Add fluid, if necessary.  LIGHTS/ELECTRICAL—Test all the electrical sys
tems in the vehicle for proper operation.  It is also recommended that the engine oil and the 
washer fluid level be determined at each fuel fill-up. 
VEHICLE
 NOISE CONTROL 
 Vehicles with a GVWR of 4 535 kg (10,000 lbs), or 
more, are required to comply with Federal Exterior  Noise Regulations (Fig. 2). 
 VEHICLE
 NOISE
 EMISSION
 CONTROL INFORMATION 
DATE
 OF
 VEHICLE
 MANUFACTURE 
THIS
 VEHICLE CONFORMS
 TO
 U.S. EPA REGULATIONS FOR NOISE EMISSION 
APPLICABLE
 TO
 MEDIUM
 AND HEAVY
 DUTY
 TRUCKS.  THE
 FOLLOWING
 ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT
 OF 1972. (A) THE
 REMOVAL
 OR 
RENDERING
 INOPERATIVE, OTHER
 THAN
 FOR
 PURPOSES
 OF
 MAINTENANCE, 
 REPAIR.
 OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF 
 DESIGN
 (LISTED
 IN
 THE
 OWNERS
 MANUAL)
 INCORPORATED
 INTO
 THIS
 VEHICLE 
IN COMPLIANCE
 WITH
 THE NOISE CONTROL
 ACT:
 (B) THE
 USE
 OF
 THIS
 VEHICLE 
AFTER SUCH DEVICE
 OR
 ELEMENT
 OF
 DESIGN HAS BEEN REMOVED
 OR 
 RENDERED
 INOPERATIVE. 
PU626D 
Fig.
 2 Vehicle
 Noise
 Emission
 Control Information 
 Label 
UNAUTHORIZED
 DEFEAT
 OF
 NOISE 
CONTROL COMPONENTS 
 Federal law prohibits removal, altering or other
wise defeating any noise control component. This in
cludes before or after the vehicle is in use. Federal 
law also prohibits the use of a vehicle after a noise 
control component is defeated. 
REQUIRED MAINTENANCE/SERVICE
 FOR 
NOISE
 CONTROL 
The following maintenance is required after each 
6-month or 9 600 km (6,000 miles) interval. This will 
ensure that the vehicle noise control components are 
operating properly. 
EXHAUST SYSTEM 
 Inspect exhaust system for exhaust leaks and dam
aged components. The exhaust hangers, clamps and 
U-bolts should be attached and in good condition. 
Burned or ruptured mufflers, damaged exhaust pipes  should be replaced. Refer to Group 11—Exhaust Sys
tem/Intake Manifold for service information. 
AIR
 FILTER
 HOUSING/CANISTER 
 Inspect the air filter assembly for proper fit. Verify 
the cover is securely attached to the housing/canis
ter. Inspect all the air filter housing hoses for con nections. The gasket between the air filter housing and throttle body must be in good condition. The air 
filter element should be clean and serviced according 
to the maintenance schedule. 
FUEL
 REQUIREMENTS 
GASOLINE
 ENGINES 
 All engines require the use of unleaded gasoline to 
reduce the effects of lead to the environment. Also  unleaded fuel is necessary to prevent damage to the 
catalytic converter/02 sensor. The fuel must have a 
minimum octane rating of 87 based on the (R + M)/2 
calculation method.   

GASOLINE ENGINE MAINTENANCE SCHEDULE 
LIGHT
 DUTY
 CYCLE 
SCHEDULED
 MAINTENANCE
 FOR
 EMISSIONS
 CONTROL
 -
 PROPER
 VEHICLE
 PERFORMANCE 
Inspection and service is also necessary any
 rime
 a
 malfunction
 is observed or suspected. 
X
 = Scheduled maintenance for all vehicles. 
O
 = Scheduled maintenance for all vehicles, Recommended for proper
 vehicle
 performance. 
Where both
 time
 and mileage Miles (Thousand) are
 shown,
 follow the
 interval 
which
 occurs
 first. Kilometers (Thousand)  7'A 
15 
 22'A 
 30 
37'A 
 45 
52'A 
60 
67'A 
 75 
82'A 
90 97'/2  105 112'A 
120 
Where both
 time
 and mileage Miles (Thousand) 
are
 shown,
 follow the
 interval 
which
 occurs
 first. Kilometers (Thousand)  12 24 
36 48 
60  72 84  96 108  120 
132 144  156 168  180 192 
Coolant
 Condition,
 Coolant
 Hoses/Clomps 
 X  X X  X  X  X 
O  O O  O  O 
O  O  O 
 o 
O 
Exhaust
 System—Check 
 X 
X  X  X  X 
X 
O  O  O 
o 
O 
O  O 
 o  o  o 
Oil—Change
 (6 months) 
 X  X X  X  X  X 
O  O  O 
o o 
O  O 
 o  o 
o 
Oil Filter—Change (2nd Oil Change) 
 X 
X X 
o  o 
 O 
o 
o 
Spark
 Plug—Replace 
 X 
0 
o  o 
Air
 Filter—Replace 
 X 
o 
O 
 o 
Coolant—Flush/Replace
 (36 months) & 
 24
 months/48 000 km
 (30,000
 miles)
 thereafter 
 O 
X 
X 
PCV
 Valve—Replace if
 Necessary 
 O' 
O'  O' 
Battery—Replace 
 O 
This maintenance is recommended by Chrysler Corporation to the owner, but is not
 required
 to
 maintain
 the
 warranty.   

0 - 6
 LUBRICATION
 AND
 MAINTENANCE 
GASOLINE ENGINE MAINTENANCE SCHEDULE 
HEAVY
 DUTY
 CYCLE 
Inspection and service is also necessary anytime
 a
 malfunction is observed or suspected. 
When both
 time
 and mileage
 are
 Miles (Thousand) 
shewn,
 follow
 the
 interval 
which occurs first. Kilometers (Thousand)  6 
12  18 24 
30  36 42  48 54 
60  66  72 
78 
82V2 
84 90 
96 
102  108 
When both
 time
 and mileage
 are
 Miles (Thousand) 
shewn,
 follow
 the
 interval 
which occurs first. Kilometers (Thousand)  9.6 19 29 
38 48  58 67  77 
85 96 106  116 
125 132 
135 
145 
154 164 
174 
Coolant
 Condition, Coolant
 Hoses/Clamps 
 X 
X  X X 
X  X  X  X 
X  X  X  X 
X  X X 
X  X  X 
Exhaust
 System
 —
 Check 
 X X  X  X X X  X  X X  X  X 
X X  X X  X 
X  X 
Oil
 —
 Change
 (6
 Months) 
 X X X  X  X  X  X 
X X 
X 
 X 
 X 
X  X X 
X  X 
 X 
Oil
 Filter
 —
 Change (2nd
 Oil
 Change) 
 X X  X  X 
X  X 
X X 
X 
Drive Belt Tension
 —
 Inspect
 &
 Adjust 
 X' X 
X1 
X  X' X 
Drive Belts (V-Type)
 —
 Replace 
 X 
Air
 Filter/Air
 Pump
 Air
 Filter
 —
 Replace 
 X X  X 
X 
Crankcase
 Inlet
 Air
 Filter
 (6 &
 8
 Cyl.
 Eng.
 Only)
 —
 Clean 
 X X 
X  X 
Spark
 Plug
 —
 Replace 
 X X  X 
Fuel
 Filter
 —
 Replace as necessary 
Coolant
 —
 Flush/Replace
 (36
 months)
 & 24
 months/48
 000 km 
(30,000
 miles)
 thereafter 
 X 
EGR
 Valve
 &
 Tube
 —
 Replace  X2 
EGR
 Tube
 —
 Clean Passengers 
 X2 
PCV
 Valve
 —
 Replace  X2 
Vacuum
 Emission
 Components
 —
 Replace 
 X 
Ignition Timing
 —
 Adjust
 to
 Specs,
 as necessary  X 
Ignition Cables, Distributor Cap
 &
 Rotor
 —
 Replace 
 X 
Manifold Heat Control Valve
 —
 Lubricate 
 X 
Battery
 —
 Replace  X 
Oxygen
 Sensor
 —
 Replace 
 X2 
1 For California vehicles, this maintenance is recommended
 by
 Chrysler Motors
 to the
 owner but, is not
 required
 to
 maintain the
 warranty
 on the
 air
 pump drive
 belt. 
2 Requires
 Emission
 Maintenance Reminder Light.
 If
 so equipped, these parts
 are to be
 replaced
 at the
 indicated mileage,
 or
 when the
 emissions
 maintenance  reminded light remains on continuously
 with
 the key in the
 "on" position, whichever occurs first. 
 J9100-20 
DIESEL
 ENGINE
 MAINTENANCE
 SCHEDULE 
 HEAVY
 DUTY
 CYCLE
 Inspection
 and
 service
 is
 also
 necessary
 any
 time
 a
 malfunction
 is
 observed
 or
 suspected. 
Iff both
 time
 and distance Miles (Thousand) 
are listed, use the
 interval 
that
 ends
 first. Kilometers (Thousand)  6 
12 
18 24 
30 36 42 
4S 
 54 
60  66 
72 78 
84 90  96 
102  108 
Iff both
 time
 and distance Miles (Thousand) 
are listed, use the
 interval 
that
 ends
 first. Kilometers (Thousand)  9,6 19 
29 
38 48  58 67 
77 
85 96 106 
116 125 135 145 154 
164 174 
Coolant
 Condition, Coolant
 Hoses/Clamps
 (12 months) 
Coolant
 Flush/Replace (36 months) & 24 months/ 
48 000 km
 (30,000
 miles)
 thereafter 
 O 
Oil—Change
 (6 months) 
 X X  X 
X X X 
X X X X X 
X  X X X  X X 
X 
Oil Filter—Replace (Every Oil Change) 
 X X X 
X X X 
X X 
X X  X 
X 
X X X X 
X X 
Drive Belts—Replace
 As
 Necessary 
 X X 
X  X X  X 
Air Filter—Replace 
 X X 
X  X 
Air Filter—Clean (California Only)  e 
® 
•  • 
Air
 Filter
 Canister—Clean 
 o o o 
o 
Fuel Filter—Service When Necessary 
Injection
 Pump
 Timing & Engine Idle Speed— 
Check
 & Adjust 
 © 
• 9 •  •  • 
Underhood Rubber/Plastic Components—Inspect/Replace  • • •  • • 
X
 — All vehicles
 O
 — All
 vehicles
 except
 California.
 Recommended
 for
 California.
 •
 — California only.
 Recommended
 for all vehicles.   

CHASSIS LUBRICATION 
For light
 duty
 cycle
 vehicles
 GVW resting
 of
 3 855 Kg (8,500 lbs ) and
 below. 
 Component 
 Truck Models 
Fittings 
 Service Interval  Lubricant 
Center Link 
 AD1
 AD2 
AD
 4 
 2 
36
 000
 km
 (22,500
 miles)
 or 2
 years  Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Mileage Lubricant) 
Drag
 Link
 Bali
 joints 
 AW1 AW 2 
AW
 8 
 2 
12
 000
 km
 (7,500
 miles)
 or 6
 months  Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Mileage Lubricant) 
Gearshift
 Mechanism 
Overdrive
 4 
 AD1 
1 
36
 000
 km
 (22,500
 miles)
 or 2
 years  Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
Parking Brake Ratio 
Lever
 Pivot 
 AD1 AD
 2 AD 4 
AW1 AW 8 
 — 
36
 000
 km
 (22,500
 miles)
 or 2
 years 
Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
Propeller Shaft
 U-joint 
 AW1
 AW2 
AW 8 
 3
 (1
 Piece 
rear 
P/shaft) 
 12
 000
 km
 (7,500
 miles)
 or 6
 months 
Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
Propeller Shaft
 Slip
 Spline 
 AD1 AD
 2 
(2
 piece P/shaft) 
 1 
36
 000
 km
 (22,500
 miles)
 or 2
 years. For severe 
service,
 every
 4
 800
 km
 (3,000
 miles)
 or 3
 months.  Daily,
 if
 vehicle is operated in
 water 
 Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
Suspension
 Ball Joints 
 AD1 AD
 2 
4 
36
 000
 km
 (22,500
 miles) or 2 years
 —
 every
 engine 
oil change
 for
 off-highway operation  Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Mileage Lubricant) 
Tie Rod Ball Joints 
 AD1
 AD2 
AD4 
AW1 AW
 2 
AW8  4 
2 
36
 000
 km
 (22,500
 miles)
 or 2
 years 
12
 000
 km
 (7,500
 miles)
 or 6
 months. Daily,
 if 
vehicle is operated in
 water 
 Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Mileage Lubricant) 
NP-241 Transfer
 Case
 Shift 
Lever Pivot 
 AW1
 AW2 
AW8 
 — 
As
 Required 
Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
Wheel
 Stop 
 AD1 AD
 2
 AD4 
— 
36
 000
 km
 (22,500
 miles)
 or
 as
 required 
 Wax Type Lubricant 
Constant
 Velocity Joint 
 (Front
 P/shaft) 
 AW1
 AW2 
AW8  1 
12
 000
 km
 (7,500
 miles)  Multi-purpose grease
 -
 NGLI
 grade
 2
 EP 
(Multi-Purpose Lubricant) 
> 
J9000-59 
>   

CHASSIS LUBRICATION
 (CONT'D) 
For
 heavy
 duty
 cycle
 vehicles
 GVW
 rating
 of 3 856 Kg
 (8,501
 Sbs.) and
 above. 
 Component 
 Truck
 Models 
Fittings 
 Service
 Interval 
 Lubricant 
Center Link 
 AD2-3 
2 
39 000 km (24,000 miles) or 2 years  Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Mileage Lubricant) 
Drag
 Link Ball Joints 
 AW3 
2 
9
 600 km (6,000 miles) or 6 months 
Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Mileage Lubricant) 
Constant
 Velocity Joint 
 (Front
 P/shaft) 
 AW3 
1 
9
 600 km (6,000 miles)  Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Purpose Lubricant) 
P/shaft
 U-Joints 
 AW3 
3 
9
 600 km (6,000 miles) or 6 months. For severe 
service,
 every
 1
 600 km (1,000 miles). Daily, if 
vehicle is
 operated
 in
 water. 
 Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Purpose Lubricant) 
P/shaft
 Slip
 Spline 
 AW3
 (135" WB) 
1 
39
 000 km (24,000 miles) or 2 years. For severe 
service
 every
 4 800 km (3,000 miles) or 3 months. 
Daily, if vehicle is
 operated
 in
 water. 
 Multi-purpose
 grease -
 NGLI
 grade 2 EP 
(Multi-Purpose Lubricant) 
Suspension
 Ball Joints 
 AD2-3 
4 
39
 000 km (24,000 miles)  Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Mileage Lubricant) 
Tie Rod
 Ball
 Joints 
 AD2-3 
AW2-3 
 4 
2 
 39
 000 km (24,000
 miles)
 or 2 years 
9
 600 km (6,000 miles) or 6 months  Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Mileage Lubricant) 
NP-205
 Transfer
 Case 
Shift
 Linkage 
 AW2-3 
— 
As
 required 
Light
 Engine Oil 
NP-241
 Transfer
 Case
 Shift 
Lever
 Pivot 
 AW2 
— 
As
 required 
Multi-purpose grease -
 NGLI
 grade 2 EP 
(Multi-Purpose Lubricant) 
J9000-60   

• 
LUBRICATION
 AND
 MAINTENANCE
 0 - 15 
DIESEL
 ENGINES 
The Diesel engine oil level indicator is located at 
the left center of the engine, above the
 fuel
 injection 
pump (Fig. 3). 
Fig.
 3
 Diesel
 Engine
 Oil
 Dipstick 
ACCEPTABLE
 OIL
 LEVEL 
 To maintain proper lubrication of an engine, the 
engine oil must be maintained at an acceptable level. 
For gasoline engines, the acceptable levels are indi cated between the ADD and
 FULL
 marks on oil
 dip
stick. For Diesel engines, the acceptable levels are 
indicated between the L (low) and H
 (high) marks
 on 
oil dipstick.  The oil level should be checked periodically. The 
vehicle should be on a level surface. Wait for
 five 
 minutes after stopping the engine. For gasoline en
 gines,
 add oil only when the level indicated on the 
dipstick is at or below the ADD mark. For Diesel en
 gines,
 add oil only when the level indicated on the 
dipstick is between the L and H marks.
 Never oper
ate a Diesel
 engine when
 the oil
 level
 is below 
the L mark. The distance between the L and H 
marks represents 1.9L (2 Qts) engine oil. 
CAUTION:
 Do not
 overfill
 an
 engine crankcase
 with 
oil. This
 will
 cause
 oil
 aeration
 and
 result
 in a de
crease
 in the
 engine
 oil
 pressure. 
ENGINE
 OIL
 CHANGE AND FILTER REPLACEMENT 
WARNING: PROTECTIVE CLOTHING
 AND
 GLOVES  SHOULD
 BE
 WORN. EXPOSED SKIN SHOULD
 BE 
WASHED
 WITH
 SOAP
 AND
 WATER
 TO
 REMOVE 
 USED
 ENGINE
 OIL.
 DO NOT
 USE
 GASOLINE, THIN
NER,
 OR
 SOLVENTS
 TO
 REMOVE ENGINE
 OIL 
FROM
 SKIN.
 DO NOT
 POLLUTE. DISPOSE
 OF
 USED 
ENGINE
 OIL
 PROPERLY. 
 ENGINE
 OIL
 FILTER 
All engines are equipped with a throw-away type 
oil filter. The same type of filter is recommended 
when the filter is changed. 
OIL CHANGE
 AND
 FILTER
 REPLACEMENT 
 Bring engine up to normal operating temperature. 
A more complete drainage of oil will result. 
(1) Remove the drain hole plug and drain the en
gine oil from the crankcase. 
(2) Install the drain hole plug with a replacement 
gasket.  For gasoline engines, the oil filter should be 
replaced during every second engine oil change. 
For Diesel engines, the oil filter should be re
placed during every engine oil change. 
(3) Rotate the oil filter counterclockwise to remove 
it. 
(4) Clean the engine cylinder block oil filter boss. (5) Apply a light coat of new engine oil to the rub
ber seal on the oil filter. 
(6) Install and hand tighten the oil filter 1/2 to 3/4 
of a turn clockwise.  (7) Add new engine oil at the fill hole location on 
top of the engine cylinder head cover. Wipe off any  spilled oil. 
(8) Observe the oil level on the dipstick. 
CAUTION:
 Do not
 overfill
 the
 engine crankcase
 with 
oil. 
(9)
 Start the engine. Observe the oil pressure 
gauge or warning lamp (as applicable). If the oil 
pressure does not increase, stop the engine immedi ately. Check oil level. 
COOLING SYSTEM 
WARNING:
 USE
 EXTREME CAUTION WHEN
 THE 
 ENGINE
 IS
 OPERATING.
 DO NOT PUT
 YOUR 
HANDS NEAR
 THE
 DRIVE BELT(S), PULLEYS
 OR 
FAN BLADE.
 DO NOT
 STAND
 IN A
 DIRECT LINE 
WITH
 THE FAN
 BLADE. 
INSPECTION SCHEDULE 
 Determine the coolant level. Inspect the cooling 
system hoses/clamps after each service interval has 
elapsed. 
COOLANT LEVEL 
 It is recommended that the engine coolant level be 
inspected at least once a month during periods of hot 
weather. 
With the engine at normal operating temperature, 
check the coolant level in the coolant reserve tank. 
The coolant level must be at least above the ADD  mark. Add coolant to the coolant reserve tank only.   

0-18
 LUBRICATION
 AND
 MAINTENANCE 
• 
COOLANT FREEZE PROTECTION 
Cooling systems contain a 50/50 mixture of anti
freeze (ethylene glycol) and distilled water. This is 
the recommended coolant mixture. 
It is recommended that the degree of coolant pro
tection be tested every 12 months. If the coolant is 
contaminated or rusty, the cooling system should be 
drained, flushed. Refill with a 50/50 mixture of fresh 
coolant. Refer to Group 7—Cooling Systems for addi
tional information. 
SYSTEM
 INSPECTION 
WARNING:
 IF THE
 ENGINE
 HAS
 BEEN RECENTLY 
 OPERATED,
 DO NOT
 REMOVE
 THE
 RADIATOR 
CAP.
 THIS WILL AVOID
 YOU
 BEING SCALDED 
WITH
 HOT, PRESSURIZED COOLANT. 
(1) Test the radiator cap for proper sealing and op
eration. Use caution when removing the radiator cap 
to avoid contact with hot coolant. Place a heavy rag 
or towel over the cap and turn to the first stop. Do 
not press down. Pause to allow the pressure to re
lease through the overflow tube. Then press down 
and turn counterclockwise to remove the cap. 
(2) Inspect the coolant overflow tubing and the 
connections at the coolant reserve tank and at the 
radiator. 
(3) Inspect the entire cooling system for leaks. A 
black-light detector can be used as an aid in detect ing the source of coolant leaks. 
(4) Inspect the radiator and air conditioner con
denser fins for debris, etc.  (5) If necessary, refer to Group 7—Cooling Systems 
for additional information and service procedures. 
RADIATOR CAP 
 The radiator cap must be completely tightened to 
provide proper pressure. Inspect and test radiator cap 
when cooling system service is performed. 
MAIN,
 FLUSH
 AND
 FILL 
WARNING: ANTI-FREEZE (ETHYLENE GLYCOL)
 IS 
 POISONOUS.
 KEEP
 OUT OF THE
 REACH
 OF
 CHIL
DREN. 
Drain, flush, and fill the cooling system at the in
terval specified in maintenance schedule. For proper  service instructions see Group 7, Cooling System. 
HOSES AND
 FITTINGS 
 It is recommended that rubber hoses be periodi
cally inspected. Inspect all hose fittings for looseness  and corrosion. 
 ENGINE
 AIR
 CLEANER
 FILTER
 ELEMENT 
MAINTENANCE
 SCHEDULE 
 With normal driving conditions, the engine air 
cleaner filter element should be replaced: 
• Light-Duty Cycle-after each 48 000 km (30,000 
miles) interval has elapsed 
• Heavy-Duty Cycle-after
 each
 38 000 km (24,000 
miles) interval has elapsed 
When the vehicle is operated in dusty areas, the 
filter element should be replaced more often. 
For Diesel engines, the air filter canister should be 
cleaned at the same time the filter is replaced. 
SERVICE/REPLACEMENT 
 (1) Remove the air cleaner cover. 
(2) Remove the air cleaner filter (Fig. 4). 
CAUTION:
 Do not tap the filter or immerse the filter  medium in liquid to remove trapped debris. 
(3) Clean filter by blowing the trapped debris from 
the filter with compressed air (Fig. 5). Direct the air  in the opposite direction of normal intake air flow. 
Keep the air nozzle at least two inches away from 
the filter. 
(4) If the filter has become partially saturated with 
oil,
 replace the filter. Inspect the crankcase ventilat
ing system for proper operation. 
(5) Wash the air cleaner cover and body with 
cleaning solvent. Wipe it dry. 
(6) Install the air cleaner filter element. Attach 
the cover to the body (Fig. 4). 
 Fig,
 4
 Engine
 Air Oeaner—
 Typical