service DODGE VIPER 2004 ZB / 2.G Owner's Guide

hose routing to be sure hoses do not touch any heat
source or moving component that may cause heat dam-
age 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 degradation that could result in failure.
Brake System
To assure brake system performance, all brake system
components should be inspected periodically. Suggested
service intervals can be found in Section 8 of 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.
Brake, Power Steering, and Fuel System Hoses
When servicing the vehicle for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, checking, tears, cuts, abrasion, and excessive
swelling suggest deterioration of the rubber. Particular
attention should be made to examining those hose sur-
faces nearest to high heat sources, such as the exhaust
manifold.
MAINTAINING YOUR VEHICLE 171
7

Inspect all hose clamps and couplings to make sure they
are secure and no leaks are present.
Insure nylon tubing in these areas has not melted or
collapsed.
NOTE:Often, fluids are used during assembly plant
operations to ease the assembly of hoses to couplings.
Therefore, 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 hose is re-
placed based on leakage.
High pressure fuel system hoses have unique material
characteristics that provide adequate sealing and resist
attack by deteriorated gasoline.Use only manufacturer specified hoses or their equiva-
lent in material and specification, in any fuel system
servicing. It is mandatory to replace all clamps that have
been loosened or removed during service.
NOTE:Inspection of brake hoses should be done when-
ever the brake system is serviced and at every engine oil
change. 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 with
possible burst failure.
172 MAINTAINING YOUR VEHICLE

Master Cylinder
The fluid level in the master cylinder should be checked
when performing underhood services, or immediately if
the brake system warning lamp shows system failure. Be
sure to clean the top of the master cylinder area before
removing the cap. If necessary, add fluid to bring thefluid level up to the requirements 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 the manufacturer's recommended
brake fluid. Refer to the Recommended Fluids, Lubri-
cants and Genuine Parts section for the correct fluid type.
Mopar Brake Fluid is fluid of this quality and is recom-
mended to provide best brake performance. Use of a
brake fluid that may have a lower initial boiling point or
unidentified as to specification, may result in sudden
brake failure during hard prolonged braking.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter.
Brake Fluid Reservoir
174 MAINTAINING YOUR VEHICLE

Hydraulic Clutch
The fluid in the clutch master cylinder should be checked
when performing other under hood services. To check
the fluid level, remove the reservoir cap. If necessary, add
fluid to the reservoir. Use only the manufacturer's rec-
ommended brake fluid. Refer to the Recommended Flu-
ids, Lubricants and Genuine Parts section for the correct
fluid type. Mopar brake fluid is fluid of this quality and
is recommended to provide best brake performance.
Make sure that the fluid has been stored in a tightly
closed container to avoid contamination with dirt or
moisture. Do Not Overfill. Overfilling can cause clutch
release problems as the clutch wears. A low fluid level
may indicate a leak, in which case, hydraulic clutch
linkage replacement may be required. The fluid level in
the reservoir will rise as the clutch wears - Do Not
Remove Fluid.
Do not allow petroleum base fluid to contaminate the
brake fluid Ð seal damage will result.
Transmission
Lubricant Selection
Refer to the Recommended Fluids, Lubricants and Genu-
ine Parts section for correct fluid type.
CAUTION!
Using a transmission fluid other than the manufac-
turer's recommended fluid may cause deterioration
in transmission shift quality. Refer to the Recom-
mended Fluids, Lubricants and Genuine Parts sec-
tion for correct fluid type.
Fluid Level Check
The fluid in the transmission should be checked when-
ever other underhood services are done. Check the fluid
level by removing the fill plug located on the left side of
MAINTAINING YOUR VEHICLE 175
7

²If the vehicle will be subjected to freezing tempera-
tures, remove the battery and store it in a dry, well
ventilated area or place a trickle charger (1.5 Amp)
with automatic shutdown / overcharge protection
connected to the battery. Do not leave the trickle
charger hooked up to the battery without being
plugged into the 110 AC voltage outlet, because this
will result in further drain on the vehicle's battery. If
the vehicle is not going to be driven in the next 3
weeks, follow the battery recharge procedure in the
Service Manual, then disconnect the battery at the
negative terminal or use the save feature described in
Maintaining your Vehicle section under the Mainte-
nance Procedures sub-section, within Maintenance-
Free Battery.CAUTION!
Use care when disconnecting the remote positive
cable. It is connected to the battery and can short out
to any metal on the vehicle. Always tape or wrap the
exposed cable end to prevent electrical shorts.
²Disconnecting the battery causes the engine control
system to lose memory of some ªlearnedº functions,
unless using the Battery Save feature described in
Maintaining your Vehicle section under the Mainte-
nance Procedures sub-section, within Maintenance-
Free Battery. The engine may run rough when first
started after a battery disconnect until the control
module ªrelearnsº these functions.
184 MAINTAINING YOUR VEHICLE

Check the battery every 4 to 6 weeks to ensure that the
voltage is above 12.40. Voltage will drop more rapidly
in hot temperatures. If battery voltage drops below
12.40, follow the battery recharge procedure in the
Service Manual.
²Check that the radiator coolant level of protection is to
at least -20ÉF (-29ÉC).
²Block the wheels. Do not apply the Parking Brake.
²Make sure that all tires are inflated to the optimum
pressure, (29 PSI).
²Cut blocks of plywood about the same size of the tires.
Cover each block with indoor/outdoor carpeting and
place them between the tires and concrete. This will
prevent tire flat spotting.
²For long term storage, remove the tires and put the
vehicle up on blocks. Stack the tires on plywood and
cover with a tarp to prevent flat spotting.
²Move the wiper blades away from the windshield.
NOTE:To help prevent the battery from discharging
during shorter periods of inactivity, perform the follow-
ing:
1. Make sure that the trunk, hood, doors, windows and
convertible top are completely closed.
2. Make sure that remote transmitter is operating and
that the battery is good.
3. Make sure that the hood, trunk and door switches are
in adjustment. Perform the quick system check which
follows.
Use the remote transmitter to set the alarm. If the alarm
SET light comes on and flashes, the system is operating
properly. If not, there is a problem with a switch or the
system. See your dealer for service.
MAINTAINING YOUR VEHICLE 185
7

REPLACEMENT BULBS
Interior Light Bulbs
Message Center Indicators.................. 103
Cluster................................ 103
Gauge Pack............................ 103
Heater Control........................... 37
Interior Light..........................212±2
Courtesy Footwell Lights................... 194
Exterior Light Bulbs
Headlight-Low/High Beam.... Serviced at dealer only
Aux. Headlight-High Beam.........(HB3A) 9005XS
Front Park/Turn......................3157AK
Fog Light.......................(H10 U) 9145
Front Sidemarker.......................2886X
Center Stop Light.......... 16LED(not serviceable)
Rear Tail/Stop..........................3157
Rear Tail Light.......................... 194
Rear Marker Light........................ 194
Back up Light..........................3157
Rear Turn Light.......................3457AK
License................................ 168
NOTE:You will note that upon turning the (HID) High
Intensity Discharge Headlamp Bulbs on, there is a blue
hue to the lamps. This diminishes and becomes more
white after approximately 10 seconds as the system
charges.
186 MAINTAINING YOUR VEHICLE

EXTERIOR LIGHT BULB SERVICE
Headlight, Parking, Front Park, Turn Signal, Front
Sidemarker and Front Fog Light Removal
1. Remove the splash shield.2. Twist off sockets counter-clockwise and pull out bulbs
from the socket, install the new bulbs, and reinstall the
bulb and socket assembly. Replace the splash shield.
MAINTAINING YOUR VEHICLE 187
7

NOTE:On vehicles equipped with High Intensity Dis-
charge Headlights (HID), when the headlights are turned
on there is a blue hue to the lights. This diminishes and
becomes more white after approximately 10 seconds, as
the system charges.
High Intensity Discharge Headlights (HID)
The headlights are a type of high voltage discharge tube.
High voltage can remain in the circuit even with the
headlight switch off and the key removed.Because of
this, you should not attempt to service a headlight bulb
yourself. If a headlight bulb fails, take your vehicle to
an authorized dealer for service.
WARNING!
A transient high tension occurs at the bulb sockets of
High Intensity Discharge (HID) headlights when the
headlight switch is turned ON. It may cause serious
electrical shock or electrocution if not serviced prop-
erly. See your authorized dealer for service.
NOTE:If High Intensity Discharge (HID) lights are not
working, recycle the headlight switch 4 times to see if it
will restrike.
188 MAINTAINING YOUR VEHICLE

EMISSION CONTROL SYSTEM MAINTENANCE
The ªScheduledº maintenance services, listed inbold
typemust be done at the times or mileages specified to
assure the continued proper functioning of the emission
control system. These, and all other maintenance services
included in this manual, should be done to provide best
vehicle performance and reliability. More frequent main-
tenance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the emis-
sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULES
There are two maintenance schedules that show the
requiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.
²Day or night temperatures are below 32É F (0É C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained high
speeds during hot weather, above 90É F ( 32É C).
²Trailer towing.L
200 MAINTENANCE SCHEDULES
8
M
A
I
N
T
E
N
A
N
C
E
S
C
H
E
D
U
L
E
S