Dodge Viper (ZB) - Repair, Service and Maintenance Manual

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DODGE VIPER ZB - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, to vehicles Dodge Viper ZB.
 

CONTENTS:

SERVICE MANUAL

- 2005 ZB SRT-10 Service Manual

-- FOREWORD
-- GROUP TAB LOCATOR
-- in-INTRODUCTION
-- Body Code Plate
-- E-Mark Label
-- Fastener Identification
-- Fastener Usage
-- International Symbols
-- Manufacture Plate
-- Metric System
-- Torque References
-- Veci Label
-- Vehicle Identification Number
-- Vehicle Certification Label
-- 0-LUBRICATION & MAINTENANCE
-- International Symbols
-- Parts & Lubricant Recommendation
-- Fluid Types
-- Fluid Capacities
-- Fluid Fill/Check Locations
-- Lubrication Points
-- Maintenance Schedules
-- Hoisting
-- Jump Starting
-- Towing
-- Vehicle Storage
-- 2-SUSPENSION
-- Suspension
-- Front Suspension
-- Rear Suspension
-- 3-DIFFERENTIAL & DRIVELINE
-- Propeller Shaft
-- Half Shaft
-- Rear Axle - 226ria
-- 5-BRAKES
-- Brakes - Base
-- Brakes - Abs
-- 6-CLUTCH
-- Clutch
-- Clutch Disc
-- Clutch Release Bearing
-- Flywheel
-- Linkage
-- Master Cylinder
-- Clutch Pedal Position Switch
-- 7-COOLING
-- Cooling
-- Accessory Drive
-- 8a-AUDIO/VIDEO
-- Audio
-- Amplifier
-- Antenna
-- Antenna Module
-- Instrument Panel Antenna Cable
-- Radio
-- Radio Noise Suppression Components
-- Speaker
-- 8b-CHIME/BUZZER
-- Chime/Buzzer
-- 8e-ELECTRONIC CONTROL MODULES
-- Body Control Module
-- Controller Antilock Brake
-- Data Link Connector
-- Powertrain Control Module
-- 8f-ENGINE SYSTEMS
-- Battery System
-- Charging
-- Starting
-- 8g-HEATED SYSTEMS
-- Heated Glass
-- Rear Window Defogger Relay
-- Rear Window Defogger Switch
-- Rear Window Defogger Grid
-- 8h-HORN
-- Horn System
-- Horn
-- Horn Switch
-- 8i-IGNITION CONTROL
-- Ignition Control
-- Camshaft Position Sensor
-- Ignition Coil
-- Spark Plug
-- Spark Plug Cable
-- Starter Button
-- 8j-INSTRUMENT CLUSTER
-- Instrument Cluster
-- Airbag Indicator
-- Instrument Cluster Gauge Pack
-- Instrument Cluster Gauge Pack Lens
-- Instrument Cluster Lens
-- Pass Airbag Off Indicator
-- Seat Belt Warning Indicator
-- 8l-LAMPS
-- Lamps/Lighting - Exterior
-- Backup Lamp
-- Back Up Lamp Unit
-- Brake Lamp Switch
-- Center High Mounted Stop Lamp Unit
-- Fog Lamp - Front
-- Fog Lamp Unit - Front
-- Fog Lamp - Rear (Export)
-- Fog Lamp Unit - Rear (Export)
-- Headlamp
-- Headlamp Unit
-- License Plate Lamp
-- License Plate Lamp Unit
-- Multi-Function Switch
-- Multi-Function Switch - Export
-- Front Side Marker Lamp
-- Rear Side Marker Lamp
-- Repeater Lamp - Export
-- Tail Lamp
-- Tail Lamp Unit
-- 8n-POWER SYSTEMS
-- Power Locks
-- Power Mirrors
-- Power Windows
-- 8o-RESTRAINTS
-- Restraints
-- Child Tether
-- Clockspring
-- Driver Airbag
-- Occupant Restraint Controller
-- Passenger Airbag
-- Passenger Airbag On / Off Switch
-- Seat Belt & Retractor
-- Seat Belt Buckle
-- Seat Belt Switch
-- Seat Belt Tensioner
-- 8q-VEHICLE THEFT SECURITY
-- Vehicle Theft Security
-- Hood Ajar Switch
-- Vtss Disarm Switch
-- Vtss Indicator
-- 8r-WIPERS/WASHERS
-- Wipers/Washers
-- Washer Hoses / Tubes
-- Washer Nozzle
-- Washer Pump Motor
-- Washer Reservoir
-- Wiper Arms
-- Wiper Blades
-- Wiper Module
-- Wiper Motor
-- Wiper/Washer Switch
-- Headlamp Washers - Export
-- Headlamp Washer Hoses / Tubes - Export
-- Headlamp Washer Nozzle - Export
-- Headlamp Washer Pump Motor - Export
-- Washer Pump Motor - Export
-- Headlamp Washer Reservoir - Export
-- 8w-WIRING
-- 8w-01 Wiring Diagram Information
-- 8w-02 Component Index
-- 8w-10 Power Distribution
-- 8w-15 Ground Distribution
-- 8w-18 Bus Communications
-- 8w-20 Charging System
-- 8w-21 Starting System
-- 8w-30 Fuel/Ignition System
-- 8w-35 Antilock Brakes
-- 8w-39 Vehicle Theft Security System
-- 8w-40 Instrument Cluster
-- 8w-41 Horn/Cigar Lighter/Power Outlet
-- 8w-42 Air Conditioning/Heater
-- 8w-43 Occupant Restraint System
-- 8w-44 Interior Lighting
-- 8w-45 Body Control Module
-- 8w-47 Audio System
-- 8w-48 Rear Window Defogger
-- 8w-50 Front Lighting
-- 8w-51 Rear Lighting
-- 8w-52 Turn Signals
-- 8w-53 Wipers
-- 8w-56 Convenience Systems
-- 8w-60 Power Windows
-- 8w-61 Power Door Locks
-- 8w-62 Power Mirrors
-- 8w-70 Splice Information
-- 8w-80 Connector Pin-Outs
-- 8w-91 Connector/Ground/Splice Location
-- 8w-97 Power Distribution
-- 9-ENGINE
-- Engine - 8.3l
-- Air Cleaner Element
-- Air Cleaner Housing
-- Engine Mounts
-- Intake Manifold
-- Exhaust Manifold
-- Cylinder Head(S)
-- Cylinder Head Cover(S)
-- Rocker Arms
-- Valve Springs/Seals
-- Intake/Exhaust - Valves/Seats/Guides
-- Timing Chain Cover
-- Timing Chain And Sprockets
-- Lubrication
-- Oil
-- Oil Cooler & Lines
-- Oil Pan
-- Oil Pump
-- Oil Pressure Sensor
-- Sensor-Oil Temperature
-- Engine Block
-- Hydraulic Tappets
-- Camshaft
-- Piston & Connecting Rod
-- Piston Rings
-- Connecting Rod Bearings
-- Crankshaft Damper
-- Crankshaft Oil Seal - Front
-- Crankshaft Oil Seal And Retainer - Rear
-- Crankshaft Main Bearings
-- Crankshaft
-- Crankshaft Pilot Bearing
-- 11-EXHAUST SYSTEM
-- Exhaust System
-- Pipe Clamps
-- Heat Shields
-- Catalytic Converter(S)
-- Resonator(S)
-- Spout Assembly - Left/Right
-- H-Pipe
-- Heat Shields - Export
-- Resonator(S) - Export
-- Spout Assembly - Export
-- H-Pipe - Export
-- Exhaust Pipe - Export
-- Support Bracket And Isolator - Export
-- Exhaust Solenoid - Export
-- 13-FRAME & BUMPERS
-- Frame & Bumpers
-- Front Fascia
-- Front Fascia - Export
-- Front Bumper Reinforcement
-- Front Bumper Reinforcement - Export
-- Rear Fascia
-- Rear Bumper Foam
-- Rear Bumper
-- Front Tow Eye Bracket - Export
-- Bracket - Rear License Plate Export
-- Frame
-- Rear Transmission Crossmember
-- 14-FUEL SYSTEM
-- Fuel Delivery
-- Fuel Injection
-- 19-STEERING
-- Steering
-- Column
-- Gear
-- 21-TRANSMISSION/TRANSAXLE
-- Manual Transmission - T56
-- 22-TIRES/WHEELS
-- Tires/Wheels
-- Tire Pressure Monitoring (Tpm)
-- Module - Tpm
-- Sensor - Tpm
-- Tires
-- Wheels
-- Wheel Mounting Studs - Front
-- Wheel Mounting Studs - Rear
-- 23-BODY
-- Body
-- Convertible Top
-- Decklid
-- Door - Front
-- Exterior
-- Hood
-- Instrument Panel
-- Interior
-- Paint
-- Seats
-- Stationary Glass
-- Weatherstrip/Seals
-- 24-HEATING & AIR CONDITIONING
-- Heating & Air Conditioning
-- Controls
-- Distribution
-- 25-EMISSIONS CONTROL
-- Emissions Control
-- Evaporative Emissions
-- INDEX
-- COMMENTS


POWERTRAIN

- ZB SRT-10 BUX Powertrain

-- TABLE OF CONTENTS
-- 1.0 INTRODUCTION
-- 1.1 System Coverage
-- 1.2 Six-Step Trouble Shooting Procedure
-- 2.0 IDENTIFICATION OF SYSTEM
-- 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
-- 3.1 General Description
-- 3.2 Function Operation
-- 3.3 Diagnostic Trouble Codes
-- 3.4 Using The Drbiii
-- 3.5 Drbiii Error Messages And Blank Screen
-- 4.0 DISCLAIMERS, SAFETY, WARNINGS
-- 4.1 Disclaimers
-- 4.2 Safety
-- 4.3 Warnings And Cautions
-- 5.0 REQUIRED TOOLS AND EQUIPMENT
-- 6.0 ACRONYMS
-- 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES
-- Communication
-- Driveability - Gas
-- Starting
-- Verification Tests
-- 8.0 COMPONENT LOCATIONS
-- 8.1 Control Modules And Pdc
-- 8.2 Data Link Connector
-- 8.3 Sensors And Solenoids
-- 8.4 Fuel System
-- 9.0 CONNECTOR PINOUTS
-- A/C Compressor Clutch - Black 2 Way
-- A/C Low Pressure Switch - Dk. Green 2 Way
-- A/C Pressure Transducer - Black 4 Way
-- Battery Temperature Sensor - 2 Way
-- Brake Lamp Switch - Black 6 Way
-- Camshaft Position Sensor - Gray 3 Way
-- Clockspring - White 8 Way
-- Clutch Interlock Switch - Dk.Green 2 Way
-- Crankshaft Position Sensor - Black 3 Way
-- Data Link Connector - Black 16 Way
-- Engine Coolant Temperature Sensor - Black 2 Way
-- Engine Oil Pressure Sensor - Black 3 Way
-- Engine Oil Temperature Sensor - Black 2 Way
-- Evap/Purge Solenoid - Black 2 Way
-- Fuel Injector No. 1 - Black 2 Way
-- Fuel Injector No. 2 - Black 2 Way
-- Fuel Injector No. 3 - Black 2 Way
-- Fuel Injector No. 4 - Black 2 Way
-- Fuel Injector No. 5 - Black 2 Way
-- Fuel Injector No. 6 - Black 2 Way
-- Fuel Injector No. 7 - Black 2 Way
-- Fuel Injector No. 8 - Black 2 Way
-- Fuel Injector No. 9 - Black 2 Way
-- Fuel Injector No. 10 - Black 2 Way
-- Fuel Tank Module - Gray 4 Way
-- Generator - Gray 2 Way
-- Hydraulic Cooling Module - Black 3 Way
-- Idle Air Control Motor - Black 4 Way
-- Ignition Coil Pack-Left - Black 4 Way
-- Ignition Coil Pack-Right - Black 3 Way
-- Ignition Switch - Black 5 Way
-- Intake Air Temperature Sensor - Black 2 Way
-- Leak Detection Pump - Black 4 Way
-- Manifold Absolute Pressure Sensor - Black 3 Way
-- Multi-Function Switch - Gray 20 Way
-- Oxygen Sensor 1/1 Left Bank Up - Black 4 Way
-- Oxygen Sensor 1/2 Left Bank Down - Black 4 Way
-- Oxygen Sensor 2/1 Right Bank Up - Black 4 Way
-- Oxygen Sensor 2/2 Right Bank Down - Black 4 Way
-- Fuses (Pdc)
-- A/C Compressor Clutch Relay
-- Auto Shut Down Relay
-- Fuel Pump Relay
-- Oxygen Sensor Heater Relay
-- Run/Acc Relay
-- Starter Motor Relay
-- Powertrain Control Module C1 - Black/Black 32 Way
-- Powertrain Control Module C2 - Black/White 32 Way
-- Powertrain Control Module C3 - Black/Gray 32 Way
-- Push-Button Starter Switch - Natural 6 Way
-- Reverse Lock-Out Solenoid - White 2 Way
-- Skip Shift Solenoid - White 2 Way
-- Throttle Position Sensor - Black 3 Way
-- Tire Pressure Monitor Module - Blue 6 Way
-- Vtss Led - Black 2 Way
-- 10.0 SCHEMATIC DIAGRAMS
-- 11.0 CHARTS AND GRAPHS
-- 11.1 O2 Sensor Configuration
-- 11.2 Vacuum Readings
-- 11.3 Cam And Crank Sensors Patterns
-- 11.4 Eeld


CHASSIS

- ZB Chassis

-- TABLE OF CONTENTS
-- 1.0 INTRODUCTION
-- 1.1 System Coverage
-- 1.2 Six-Step Troubleshooting Procedure
-- 2.0 IDENTIFICATION OF SYSTEM
-- 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
-- 3.1 Teves Mark 20e System Description
-- 3.2 Diagnostic Trouble Codes
-- 3.3 Freeze Frame
-- 3.4 Using The Drbiii
-- 3.5 Drbiii Error Messages
-- 4.0 DISCLAIMERS, SAFETY, WARNINGS
-- 4.1 Disclaimers
-- 4.2 Safety
-- 4.3 Warning
-- 4.4 Diagnosis
-- 5.0 REQUIRED TOOLS AND EQUIPMENT
-- 6.0 GLOSSARY OF TERMS
-- 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES
-- Brakes (Cab)
-- Communication
-- Verification Tests
-- 8.0 COMPONENT LOCATIONS
-- 8.1 Controller Antilock Brake (Cab)
-- 8.2 Data Link Connector
-- 8.3 Hydraulic Control Unit (Hcu)
-- 8.4 Power Distribution Center
-- 8.5 Message Centers
-- 8.6 Wheel Speed Sensors
-- 8.7 Wheel Speed Sensor Connectors
-- 8.8 Brake Lamp Switch
-- 8.9 Abs Pump Motor
-- 9.0 CONNECTOR PINOUTS
-- Abs Pump Motor (Connector Side) - 2 Way
-- Brake Lamp Switch - Black 6 Way
-- Controller Antilock Brake - Black 24 Way
-- Data Link Connector - Black 16 Way
-- Fuses (Pdc)
-- Wheel Speed Sensor-Left Front - Lt.Gray 2 Way
-- Wheel Speed Sensor-Left Rear - Gray 2 Way
-- Wheel Speed Sensor-Right Front - Lt.Gray 2 Way
-- Wheel Speed Sensor-Right Rear - Gray 2 Way
-- 10.0 SCHEMATIC DIAGRAMS
-- 10.1 Teves Mark 20e Controller Antilock Brake — Abs


BODY

- ZB BUX Body

-- TABLE OF CONTENTS
-- 1.0 INTRODUCTION
-- 1.1 System Coverage
-- 1.2 Six-Step Troubleshooting Procedure
-- 2.0 IDENTIFICATION OF SYSTEM
-- 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
-- 3.1 Airbag System
-- 3.2 Audio System
-- 3.3 Body Control Module
-- 3.4 Chime Warning System
-- 3.5 Communication
-- 3.6 Door Ajar System
-- 3.7 Exterior Lighting System
-- 3.8 Relays Controlled By The Bcm
-- 3.9 Heating & A/C System
-- 3.10 Instrument Cluster / Gauge Cluster
-- 3.11 Interior Lighting
-- 3.12 Tire Pressure Monitoring System (Tpms)
-- 3.13 Power Door Entry System
-- 3.14 Power Windows
-- 3.15 Electrically Heated Systems
-- 3.16 Vehicle Theft Security System
-- 3.17 Using The Drbiii
-- 3.18 Drbiii Error Messages
-- 3.19 Drbiii Does Not Power Up (Blank Screen)
-- 3.20 Display Is Not Visible
-- 4.0 DISCLAIMERS, SAFETY, WARNINGS
-- 4.1 Disclaimers
-- 4.2 Safety
-- 4.3 Warnings
-- 5.0 REQUIRED TOOLS AND EQUIPMENT
-- 6.0 GLOSSARY OF TERMS
-- 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES
-- Airbag
-- Audio
-- Chime
-- Communication
-- Door Ajar
-- Electrically Heated Systems
-- Exterior Lighting
-- Heating & A/C
-- Ignition, Power, Accessory
-- Instrument Cluster
-- Interior Lighting
-- Power Door Locks/Rke
-- Power Windows
-- Tire Pressure Monitoring
-- Vehicle Theft/Security
-- Windshield Wiper & Washer
-- Verification Tests
-- 8.0 COMPONENT LOCATIONS
-- 8.1 Airbag System
-- 8.2 Body Control Module
-- 8.3 Heating & A/C System
-- 8.4 Instrument Panel
-- 8.5 Power Window Motor
-- 8.6 Power Door Locks
-- 8.7 Tire Pressure Monitor Module (Tpm)
-- 8.8 Vehicle Theft Security System (Vtss)
-- 9.0 CONNECTOR PINOUTS
-- Body Control Module C3 - Black/White 34 Way
-- Body Control Module C4 - Black/Gray 34 Way
-- C108 (Export) - Dk. Gray (Headlamp And Dash Side)
-- C108 (Export) - Lt. Gray (Relay Harness Side)
-- C304 (Export) - Black (Body Side)
-- C304 (Export) - Black (Rear Fog Lamp Side)
-- Exhaust Solenoid (Export) - Black 2 Way
-- Exhaust Solenoid Relay (Export) - 5 Way
-- Export Accessory Fuse
-- Fog Lamp-Left Rear (Export) - 2 Way
-- Fog Lamp-Right Rear (Export) - 2 Way
-- Headlamp Washer Pump Motor (Export) - Black 2 Way
-- Headlamp Washer Pump Relay (Export) - 5 Way
-- Multi-Function Switch - Gray 20 Way
-- Rear Fog Lamp Relay (Export) - 5 Way
-- Side Repeater Lamp-Left (Export) - Black 2 Way
-- Side Repeater Lamp-Right (Export) - Black 2 Way
-- 10.0 SCHEMATIC DIAGRAMS
-- 10.1 Airbag System
-- 10.2 Audio System
-- 10.3 Chime System
-- 10.4 Communication
-- 10.5 Door Ajar System
-- 10.6 Electrically Heated Systems
-- 10.7 Exterior Lighting
-- 10.8 Heating & A/C System
-- 10.9 Ignition, Power, Accessory
-- 10.10 Instrument Cluster/Gauge Cluster
-- 10.11 Interior Lighting
-- 10.12 Power Door Locks/Rke
-- 10.13 Power Window System
-- 10.14 Tire Pressure Monitor Module (Tpm)
-- 10.15 Vehicle Theft Security System
-- 10.16 Wiper System