service DODGE CHALLENGER 2009 3.G Workshop Manual

Engine Air Cleaner Filter
Refer to the “Maintenance Schedule” in Section 8 for
proper maintenance intervals.
WARNING!
The air induction system (air cleaner, hoses, etc.) can
provide a measure of protection in the case of engine
backfire. Do not remove the air induction system (air
cleaner, hoses, etc.) unless such removal is necessary
for repair or maintenance. Make sure that no one is
near the engine compartment before starting the
vehicle with the air induction system (air cleaner,
hoses, etc.) removed. Failure to do so can result in
serious personal injury.
Engine Air Cleaner Filter Selection
The quality of replacement engine air cleaner filters
varies considerably. Only high quality filters should be
used to assure most efficient service. MOPARengine air
cleaner filters are a high quality filter and are
recommended.
Maintenance-Free Battery
The top of the maintenance-free battery is permanently
sealed. You will never have to add water, nor is periodic
maintenance required.
NOTE:The battery is stored under an access cover in
the trunk. Remote battery terminals are located in the
engine compartment for jump-starting.
376 MAINTAINING YOUR VEHICLE

WARNING! (Continued)
•The battery in this vehicle has a vent hose that
should not be disconnected and should only be
replaced with a battery of the same type (vented).
CAUTION!
•It is essential when replacing the cables on the
battery that the positive cable is attached to the
positive post and the negative cable is attached to
the negative post. Battery posts are marked posi-
tive (+) and negative (-) and are identified on the
battery case. Cable clamps should be tight on the
terminal posts and free of corrosion.
•If a “fast charger” is used while the battery is in
the vehicle, disconnect both vehicle battery cables
before connecting the charger to the battery. Do
not use a “fast charger” to provide starting voltage.
Air Conditioner Maintenance
For best possible performance, your air conditioner
should be checked and serviced by an authorized dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.
CAUTION!
Do not use chemical flushes in your air conditioning
system as the chemicals can damage your air condi-
tioning components. Such damage is not covered by
the New Vehicle Limited Warranty.
378 MAINTAINING YOUR VEHICLE

WARNING!
•Use only refrigerants and compressor lubricants
approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer to
Section 3 of the Warranty Information Book for
additional warranty information.
•The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced technician.
Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluoro-
carbon (HFC) that is endorsed by the EnvironmentalProtection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by authorized dealers or other
service facilities using recovery and recycling equipment.
NOTE:Use only manufacturer approved A/C system
sealers, stop leak products, seal conditioners, compressor
oil, and refrigerants.
Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, door hinge pivot points and rollers, liftgate,
tailgate, sliding doors and hood hinges, should be lubri-
cated periodically with a lithium based grease such as
MOPARSpray White Lube to assure quiet, easy opera-
tion and to protect against rust and wear. Prior to the
application of any lubricant, the parts concerned should
be wiped clean to remove dust and grit; after lubricating
excess oil and grease should be removed. Particular
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MAINTAINING YOUR VEHICLE 379

attention should also be given to hood latching compo-
nents to ensure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated twice a
year, preferably in the Fall and Spring. Apply a small
amount of a high quality lubricant such as MOPAR
Lock Cylinder Lubricant directly into the lock cylinder.
Windshield Wiper Blades
Clean the rubber edges of the wiper blades and the
windshield periodically with a sponge or soft cloth and a
mild nonabrasive cleaner. This will remove accumula-
tions of salt or road film.
Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.
NOTE:Life expectancy of wiper blades varies depend-
ing on geographical area and frequency of use. Poor
performance of blades may be present with chattering,
marks, water lines or wet spots. If any condition is
present please proceed to clean wiper blades with humid
cloth removing any debris that may be affecting its
function.
Adding Washer Fluid
The windshield washer fluid reservoir is located in the
front of the engine compartment. Be sure to check the
fluid level at regular intervals. Fill the reservoir with
windshield washer solvent (not radiator antifreeze) and
operate the system for a few seconds to flush out the
residual water.
380 MAINTAINING YOUR VEHICLE

WARNING!
Exhaust gases can injure or kill. They contain carbon
monoxide (CO), which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, refer
to “Exhaust Gas” under “Safety Tips” in Section 2.
CAUTION!
The catalytic converter requires the use of unleaded
fuel only. Leaded gasoline will destroy the effective-
ness of the catalyst as an emissions control device
and may seriously reduce engine performance and
cause serious damage to the engine.Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.
CAUTION!
Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.
382 MAINTAINING YOUR VEHICLE

NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this should occur,
safely bring the vehicle to a complete stop, shut the
engine OFF, and allow the vehicle to cool. Thereafter,
obtain service, including a tune-up to manufacturer’s
specifications immediately.To minimize the possibility of catalyst damage:
•Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
•Do not try to start the engine by pushing or towing the
vehicle (automatic transmission only).
•Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
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MAINTAINING YOUR VEHICLE 383

rules for your community. To prevent ingestion by ani-
mals or children, do not store ethylene glycol-based
engine coolant (antifreeze) in open containers or allow it
to remain in puddles on the ground. If ingested by a child
or pet, seek emergency assistance immediately. Clean up
any ground spills immediately.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the engine coolant (antifreeze) level is
adequate. With the engine OFF and cold, the level of the
engine coolant (antifreeze) in the bottle should be be-
tween the ranges indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing en-
gine coolant (antifreeze). Advise your service attendantof this. As long as the engine operating temperature is
satisfactory, the coolant bottle need only be checked once
a month.
When additional engine coolant (antifreeze) is needed to
maintain the proper level, it should be added to the
coolant bottle. Do not overfill.Points to Remember
NOTE:When the vehicle is stopped after a few miles
(kilometers) of operation, you may observe vapor coming
from the front of the engine compartment. This is nor-
mally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot engine
coolant (antifreeze) to enter the radiator.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.
388 MAINTAINING YOUR VEHICLE

WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You would not have your full
braking capacity in an emergency.
Master Cylinder - Brake Fluid Level Check
Check the fluid level in the master cylinder immediately
if the brake system warning light indicates system fail-
ure.
Check the fluid level in the master cylinder when per-
forming underhood services.
Clean the top of the master cylinder area before removing
the cap. Add fluid to bring the level up to the “MAX”
mark on the side of the master cylinder reservoir.Overfilling of fluid is not recommended because it may
cause leaking in the system.
Add enough fluid to bring the level up to the require-
ments described on the brake fluid reservoir. With disc
brakes, fluid level can be expected to fall as the brake
pads wear. However, low fluid level may be caused by a
leak and a checkup may be needed.
Use only manufacturer’s recommended brake fluid. Re-
fer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.
390 MAINTAINING YOUR VEHICLE

Clutch Hydraulic System — Manual Transmission
(If Equipped)
The clutch hydraulic system is fed by a segregated
volume of fluid within the brake system master cylinder
reservoir. In the event of leakage or wear, use only the
manufacturer’s recommended brake fluid. Refer to “Flu-
ids, Lubricants, and Genuine Parts” in this section for the
correct fluid type.
Manual Transmission — If Equipped
Fluid Level Check
Check the fluid level by removing the fill plug on the left
side of the transmission. The fluid level should be at the
bottom of the fill hole. Add fluid, if necessary, to maintain
the proper level. Refer to “Fluids, Lubricants, and Genu-
ine Parts” in this section for the correct fluid type.
CAUTION!
Using a transmission fluid other than the manufac-
turer’s recommended fluid may cause deterioration
in transmission shift quality and/or damage to the
transmission. Refer to “Fluids, Lubricants, and
Genuine Parts” in this section for the correct fluid
type.
Change Transmission Fluid
If contaminated with water, change the fluid immedi-
ately. See your authorized dealer for service.
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.
392 MAINTAINING YOUR VEHICLE

Cavity Car-
tridge
FuseMini-
FuseDescription
39 — 10 Amp
RedHeated Mirrors - if
equipped
40 — 5 Amp
OrangeAuto Inside Rearview
Mirror/Heated Seats - if
equipped/Switch Bank
41———
42 30 Amp
Pink— Front Blower Motor
43 30 Amp
Pink— Rear Window Defroster
44 20 Amp
Blue— Amplifier/Sunroof - if
equipped
*Cavities 11, 12, and 13 contain self-resetting fuses
(circuit breakers) that are only serviceable by an autho-
rized dealer. The cluster and the driver seat switch are
fused by the 25 Amp circuit breaker in cavity 11. Thepassenger seat switch is fused by the 25 Amp circuit
breaker in cavity 12. The door modules, the driver power
window switch, and the passenger power window
switch are fused by the 25 Amp circuit breaker in cavity
13. If you experience temporary or permanent loss of
these systems, see your authorized dealer for service.
VEHICLE STORAGE
If you are leaving your vehicle dormant for more than
21 days, you may want to take these steps to protect your
battery.
•Disconnect the negative cable from the battery.
•Anytime you store your vehicle, or keep it out of
service (i.e., vacation) for two weeks or more, run the
air conditioning system at idle for about five minutes
in the fresh air and high blower setting. This will
ensure adequate system lubrication to minimize the
possibility of compressor damage when the system is
started again.7
MAINTAINING YOUR VEHICLE 407