service DODGE CHARGER 2007 6.G Service Manual

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 ex-
haust system. Do not park or operate your vehicle in
areas where your exhaust system can contact any-
thing 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 engine by pushing or towing the
vehicle.
•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.
302 MAINTAINING YOUR VEHICLE

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 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 battery is in
vehicle, disconnect both vehicle battery cables
before connecting the charger to 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.
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
further 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.
304 MAINTAINING YOUR VEHICLE

Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluorocar-
bon (HFC) that is endorsed by the Environmental Pro-
tection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by dealers or other service facilities
using recovery and recycling equipment.
NOTE:Use only manufacturer approved A/C System
Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, and Refrigerants.
A/C Air Filter — If Equipped
The filter is located in the fresh air inlet under the hood,
behind a removable panel in the cowl on the passenger
side of the vehicle, next to the windshield wipers. When
installing a new filter, ensure its proper orientation. To
replace the filter, remove the access door in the cowl
screen by pressing the retaining clips. Slide the lid on the
filter adapter forward and down and remove used filter.
Install new filter with arrows pointing in the direction of
airflow, which is toward the rear of the vehicle (text and
arrows on the filter indicate this).Refer to the “Maintenance Schedule” in this manual for
the recommended air conditioning filter replacement
intervals.
Power Steering — Fluid Check
Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.
WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturer’s recommended
power steering fluid.
MAINTAINING YOUR VEHICLE 305
7

If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type.
Front & Rear Suspension Ball Joints
The suspension ball joints should be inspected for exter-
nal leakage or damage when other maintenance is per-
formed.
Steering Linkage
The tie rod end ball joints should be inspected for
external leakage or damage when other maintenance is
performed.
Body Lubrication
Locks and all body pivot points, including seat tracks,
door hinges, trunk hinges, and hood hinges, should be
lubricated periodically to assure quiet, easy operation
and to protect against rust and wear. Prior to the appli-
cation 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
attention should also be given to hood latching compo-
nents to insure proper function. When performing otherunderhood 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 MoparLock
Cylinder Lubricant or equivalent directly into the lock
cylinder.
Windshield Wiper Blades
The rubber edges of the wiper blades and the windshield
should be cleaned periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove accu-
mulations 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.
306 MAINTAINING YOUR VEHICLE

WARNING!
•The warning words “DO NOT OPEN HOT” on
the cooling system pressure cap are a safety pre-
caution. Never add coolant when the engine is
overheated. Do not loosen or remove the cap to
cool an overheated engine. Heat causes pressure
to build up in the cooling system. To prevent
scalding or injury, do not remove the pressure cap
while the system is hot or under pressure.
•Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or
engine damage may result.
Disposal of Used Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. To prevent ingestion by animals or children,
do not store ethylene glycol based engine coolant in open
containers or allow it to remain in puddles on theground. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine off and cold, the level of the coolant in the bottle
should be between 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
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.
When additional coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.
MAINTAINING YOUR VEHICLE 311
7

Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.
Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.
Fuel System
The Electronic Fuel Injection high-pressure fuel system’s
hoses and quick connect fittings have unique material
characteristics that provide adequate sealing and resist
attack by deteriorated gasoline.
You are urged to use only the manufacture specified
hoses with quick connect fittings, or their equivalent in
material and specification, in any fuel system servicing. It
is mandatory to replace any damaged hoses or quickconnect fittings that have been removed during service.
Care should be taken in installing quick connect fittings
to insure they are properly installed and fully connected.
See your authorized dealer for service.
Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the “Mainte-
nance Schedules” in this manual.
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 wouldn’t have your full
braking capacity in an emergency.
MAINTAINING YOUR VEHICLE 313
7

Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.
Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
NOTE:
•
Often, fluid such as oil, power steering fluid, and
brake fluid are used during assembly plant operations
to facilitate the assembly of hoses to couplings. There-
fore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping
of hot fluid when systems are under pressure (during
vehicle operation), should be noted before a hose is
replaced based on leakage.
•Inspect the brake hoses whenever the brake system is
serviced and at every engine oil change. Inspect hy-
draulic brake hoses for surface cracking, scuffing, or
worn spots. If there is any evidence of cracking,
scuffing, or worn spots, the hose should be replaced
immediately! Eventual deterioration of the hose can
take place resulting in a possibility of a burst failure.
WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
314 MAINTAINING YOUR VEHICLE

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 top of the
“FULL” 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.WARNING!
•Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
•Use of a brake fluid that has a lower initial boiling
point than the recommended MOPARDOT 3
product or a brake fluid that is unidentified as to
FMVSS specification may result in sudden brake
failure during hard prolonged braking. You could
have an accident.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.
CAUTION!
Do not allow petroleum base fluid to contaminate
the brake fluid, all brake seal components could be
damaged causing partial or complete brake failure.
MAINTAINING YOUR VEHICLE 315
7

Fluid Changes
The fluid should be changed as follows:
Normal Usage
Front Differential No Service Required
Transfer Case Refer to Maintenance
Schedule “A”
Severe Usage
Front Differential No Service Required
Transfer Case Refer to Maintenance
Schedule “B”
Severe Usage is defined as:
1. More than 50% of vehicle operation in stop and go
traffic where vehicle is driven regularly for more than 45
minutes of continuous operation, such as in heavy city or
in construction zone traffic.
2. Police, taxi, limousine, commercial type operation, or
trailer towing where the vehicle driven regularly for
more than 45 minutes of continuous operation.
Front And Rear Wheel Bearings
Front and rear wheel bearings are permanently sealed.
No regular maintenance is required for these compo-
nents.
Appearance Care and Protection from Corrosion
Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and chemicals that are sprayed
on trees and road surfaces during other seasons, are
highly corrosive to the metal in your vehicle. Outside
parking, which exposes your vehicle to airborne contami-
nants, road surfaces on which the vehicle is operated,
extreme hot or cold weather and other extreme condi-
tions will have an adverse effect on paint, metal trim, and
underbody protection.
The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.
318 MAINTAINING YOUR VEHICLE

Cavity Car-
tridge
FuseMini
FuseDescription
35 — 5 Amp
OrangeAmplifier - if equipped/
Antenna/Ignition
Delay/Overhead
Console/Passenger Door
Lock & Express Power
Window Switch - if
equipped/Power Mir-
rors - if equipped/Rear
Defrost
36 — 20 Amp
YellowHands Free Phone - if
equipped/Media System
Monitor DVD - if
equipped/Radio/
Satellite Receiver - if
equipped
37 — 15 Amp
BlueTransmission - NAG1
38 — 5 Amp
OrangeCargo Light/Overhead
Console
39 — 10 Amp
RedHeated Mirrors - if
equippedCavity Car-
tridge
FuseMini
FuseDescription
40 — 5 Amp
OrangeHeated Seats - if
equipped/Inside Rear-
view Mirror
41 — 10 Amp
RedAC Heater Control/Tire
Pressure Monitoring - if
equipped
42 30 Amp
Pink— Front Blower Motor
43 30 Amp
Pink— Amplifier - if equipped/
Antenna/Rear Defrost
44 20 Amp
Blue— Amplifier - if equipped/
Front Control Module
(FCM)/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 is fused by the 25 amp circuit
breaker in Cavity 11. The Passenger Seat Switch is fused
by the 25 amp circuit breaker in Cavity 12. The Door
Modules (except base), the Driver Door Lock Switch
328 MAINTAINING YOUR VEHICLE