2005 Dodge-Mercedes Sprinter Service Manual – PDF DOWNLOAD
FILE DETAILS:
2005 Dodge-Mercedes Sprinter Service Manual – PDF DOWNLOAD
Language : English
Pages : 1232
Downloadable : Yes
File Type : PDF
Size: 39.2 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2005 Dodge-Mercedes Sprinter Service Manual – PDF DOWNLOAD
DESCRIPTION:
- The Vehicle Identification Number (VIN) plate is located on the lower windshield fence next to the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN DECODING INFORMATION table to determine the identification of a vehicle.
- To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.
TABLE OF CONTENTS:
2005 Dodge-Mercedes Sprinter Service Manual – PDF DOWNLOAD
VA Service Manual 1
GROUP TAB LOCATOR 1
in-INTRODUCTION 3
VEHICLE IDENTIFICATION NUMBER 3
DESCRIPTION 3
INTERNATIONAL SYMBOLS 4
DESCRIPTION 4
FASTENER IDENTIFICATION 4
DESCRIPTION 4
FASTENER USAGE 7
DESCRIPTION – FASTENER USAGE 7
THREADED HOLE REPAIR 7
DESCRIPTION – THREADED HOLE REPAIR 7
METRIC SYSTEM 7
DESCRIPTION 7
TORQUE REFERENCES 9
DESCRIPTION 9
0-LUBRICATION & MAINTENANCE 11
FLUID TYPES 11
DESCRIPTION 11
DESCRIPTION – FUEL REQUIREMENTS – DIESEL ENGINE 11
DESCRIPTION 11
DESCRIPTION – ENGINE COOLANT 11
ETHYLENE-GLYCOL MIXTURES 11
PROPYLENE-GLYCOL MIXTURES 12
DESCRIPTION – HOAT COOLANT 12
COOLANT PERFORMANCE 12
COOLANT SELECTION AND ADDITIVES 13
DESCRIPTION – AXLE 13
REAR AXLE 13
DESCRIPTION – BRAKE FLUID 13
BRAKE FLUID 13
DESCRIPTION – POWER STEERING FLUID 13
POWER STEERING FLUID 13
DESCRIPTION – ENGINE OIL – DIESEL ENGINES 13
SAE VISCOSITY GRADE 13
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID – NAG1 14
FLUID ADDITIVES 14
OPERATION – AUTOMATIC TRANSMISSION FLUID 14
FLUID CAPACITIES 14
SPECIFICATIONS – FLUID CAPACITIES 14
FLUID FILL/CHECK LOCATIONS 14
INSPECTION – FLUID FILL/CHECK LOCATIONS 14
PARTS & LUBRICANT RECOMMENDATION 15
STANDARD PROCEDURE – PARTS & LUBRICANT RECOMMENDATIONS 15
HOISTING 15
STANDARD PROCEDURE – HOISTING 15
FLOOR JACK 15
HOIST 15
JUMP STARTING 16
STANDARD PROCEDURE – JUMP STARTING 16
TO JUMP START A DISABLED VEHICLE: 16
DISCONNECT CABLE CLAMPS AS FOLLOWS: 16
TOWING 16
STANDARD PROCEDURE – TOWING 16
If the Engine is Damaged 17
If the Transmission is Damaged 17
If the Front Axle is Damaged 17
If the Rear Axle is Damaged 17
SAFETY PRECAUTIONS 17
GROUND CLEARANCE 17
RAMP ANGLE 17
TOWING WHEN KEYS ARE NOT AVAILABLE 17
MAINTENANCE SCHEDULES 17
DESCRIPTION 17
MAINTENANCE – WITHOUT ASSYST MAINTENANCE COMPUTER 17
MAINTENANCE – WITH ASSYST MAINTENANCE COMPUTER 18
REGULAR CHECK-UPS 18
SPECIAL MAINTENANCE REQUIREMENTS 18
ENGINE OIL CHANGE AND FILTER REPLACEMENT 18
SCOPE OF WORK FOR MAINTENANCE SERVICE 18
ADDITIONAL MAINTENANCE WORK 19
ADDITIONAL MAINTENANCE WORK AFTER YEARS 19
INTERNATIONAL SYMBOLS 19
DESCRIPTION 19
2-SUSPENSION 21
FRONT 21
FRONT 22
SPECIFICATIONS – TORQUE CHART 22
SPECIAL TOOLS 22
FRONT SUSPENSION 22
BUSHINGS 23
REMOVAL 23
INSTALLATION 23
HUB / BEARING 24
DIAGNOSIS AND TESTING – 24
REMOVAL 24
INSTALLATION 25
KNUCKLE 25
REMOVAL 25
INSTALLATION 25
LOWER BALL JOINT 26
REMOVAL 26
INSTALLATION 26
LOWER CONTROL ARM 26
REMOVAL 26
INSTALLATION 26
SPRING 27
REMOVAL 27
INSTALLATION 28
SPRING CLAMP PLATES 28
REMOVAL 28
INSTALLATION 28
SPRING STOP PLATES 29
REMOVAL 29
INSTALLATION 29
STABILIZER BAR 29
DESCRIPTION 29
OPERATION 29
REMOVAL 29
INSTALLATION 29
STABILIZER LINK 29
REMOVAL 29
INSTALLATION 29
STRUT 30
REMOVAL 30
INSTALLATION 30
REAR 31
REAR 31
DESCRIPTION 31
DIAGNOSIS AND TESTING – SPRING AND SHOCK 31
SPECIFICATIONS – TORQUE CHART 32
SHOCK 33
DIAGNOSIS AND TESTING – SHOCK 33
REMOVAL 33
INSTALLATION 33
SPRING 34
DESCRIPTION 34
OPERATION 34
REMOVAL 34
REMOVAL – (SRW) 34
REMOVAL – (DRW) 34
INSTALLATION 34
INSTALLATION – (SRW) 34
INSTALLATION – (DRW) 35
SPRING SHACKLE 35
REMOVAL 35
INSTALLATION 35
STABILIZER BAR 35
REMOVAL 35
INSTALLATION 35
STABILIZER LINK 36
REMOVAL 36
INSTALLATION 36
WHEEL ALIGNMENT 37
WHEEL ALIGNMENT 37
DESCRIPTION 37
DIAGNOSIS AND TESTING – PRE-ALIGNMENT INSPECTION 37
STANDARD PROCEDURE – TOE ADJUSTMENT 39
SPECIFICATIONS 39
3-DIFFERENTIAL & DRIVELINE 41
PROPELLER SHAFT 41
PROPELLER SHAFT 41
DIAGNOSIS AND TESTING 41
PROPELLER SHAFT VIBRATION 41
PROPELLER SHAFT BALANCE 42
PROPELLER SHAFT RUNOUT 43
STANDARD PROCEDURE 43
PROPELLER SHAFT ANGLE 43
TWO/THREE-PIECE PROPELLER SHAFT 44
SPECIFICATIONS 45
SPECIAL TOOLS 45
PROPELLER SHAFT 46
REMOVAL 46
INSTALLATION 46
CENTER BEARING 48
REMOVAL 48
INSTALLATION 49
REAR AXLE 50
REAR AXLE 50
DESCRIPTION 50
OPERATION 50
DIAGNOSIS AND TESTING 50
GEAR NOISE 50
BEARING NOISE 50
LOW SPEED KNOCK 51
VIBRATION 51
DRIVELINE SNAP 51
STANDARD PROCEDURE – DRAIN AND FILL 51
REMOVAL 51
INSTALLATION 52
SPECIFICATIONS 53
SPECIAL TOOLS 54
AXLE SHAFTS 55
REMOVAL 55
INSTALLATION 55
AXLE BEARINGS/SEALS 57
REMOVAL 57
INSTALLATION 57
AXLE SHAFTS – DUAL REAR WHEELS 59
REMOVAL 59
INSTALLATION 59
AXLE HUB BEARINGS/SEALS 60
REMOVAL 60
INSTALLATION 60
PINION SEAL 62
REMOVAL 62
INSTALLATION 62
5-BRAKES 65
BRAKES – BASE 65
BRAKES – BASE 66
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 66
PRELIMINARY BRAKE CHECK 66
ROAD TESTING 67
BRAKE NOISES 68
STANDARD PROCEDURE 68
STANDARD PROCEDURE – MANUAL BLEEDING 68
STANDARD PROCEDURE – PRESSURE BLEEDING 69
HYDRAULIC/MECHANICAL 69
SPECIFICATIONS 69
SPECIFICATIONS – TORQUE CHART 69
BASE BRAKE 70
SPECIAL TOOLS 71
BRAKES 71
BRAKE LINES 72
STANDARD PROCEDURE 72
STANDARD PROCEDURE – ISO FLARING 72
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 72
BRAKE PADS/SHOES 73
REMOVAL 73
REMOVAL – FRONT (SRW) 73
REMOVAL – FRONT (DRW) 73
REMOVAL – REAR (16” WHEELS) (SRW) 73
REMOVAL – REAR (15” WHEELS) (SRW) 73
REMOVAL – REAR (DRW) 74
INSTALLATION 74
INSTALLATION – FRONT (SRW) 74
INSTALLATION – FRONT (DRW) 75
INSTALLATION – REAR (16” WHEELS) (SRW) 75
INSTALLATION – REAR (16” WHEELS) (SRW) 75
INSTALLATION – REAR (DRW) 75
DISC BRAKE CALIPERS 75
REMOVAL 75
REMOVAL – FRONT (SRW) 75
REMOVAL – FRONT (DRW) 76
REMOVAL – REAR (SRW) 76
REMOVAL – REAR (DRW) 76
INSTALLATION 76
INSTALLATION – FRONT (SRW) 76
INSTALLATION – FRONT (DRW) 77
INSTALLATION – REAR (SRW) 77
INSTALLATION – REAR (DRW) 77
DISC BRAKE CALIPER ADAPTER 77
REMOVAL 77
REMOVAL – FRONT 77
REMOVAL – REAR 77
INSTALLATION 78
INSTALLATION – FRONT 78
INSTALLATION – REAR 78
FLUID 78
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 78
STANDARD PROCEDURE – BRAKE FLUID LEVEL 78
SPECIFICATIONS 78
BRAKE FLUID 78
FLUID RESERVOIR 79
REMOVAL 79
INSTALLATION 79
ALB LEVER 79
REMOVAL 79
INSTALLATION 79
ALB CONTROLLER 79
REMOVAL 79
INSTALLATION 79
ADJUSTMENTS 80
ADJUSTMENT 80
MASTER CYLINDER 80
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 80
POWER BOOSTER VACUUM TEST 81
POWER BOOSTER CHECK VALVE TEST 81
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 81
REMOVAL 81
INSTALLATION 82
PEDAL 82
REMOVAL 82
INSTALLATION 83
POWER BRAKE BOOSTER 83
DESCRIPTION 83
OPERATION 83
REMOVAL 83
INSTALLATION 83
ROTORS 83
REMOVAL 83
REMOVAL – FRONT (SRW) 83
REMOVAL – REAR (SRW) 84
REMOVAL – FRONT (DRW) 84
REMOVAL – REAR (DRW) 84
INSTALLATION 85
INSTALLATION – FRONT (SRW) 85
INSTALLATION – REAR (SRW) 85
INSTALLATION – FRONT (DRW) 85
INSTALLATION – REAR (DRW) 85
SUPPORT PLATE 86
REMOVAL – REAR 86
INSTALLATION – REAR 86
PARKING BRAKE 86
SPECIFICATIONS 86
TORQUE CHART 86
SPECIAL TOOLS 87
PARK BRAKE 87
CABLE TENSIONER 87
REMOVAL 87
INSTALLATION 87
CABLES 88
REMOVAL 88
REMOVAL – FRONT 88
REMOVAL – REAR 88
INSTALLATION 88
INSTALLATION – FRONT 88
INSTALLATION – REAR 89
ADJUSTMENTS 89
ADJUSTMENT – PARKING BRAKE CABLES 89
LEVER 90
REMOVAL 90
INSTALLATION 90
SHOES 90
REMOVAL 90
REMOVAL – (SRW) 90
REMOVAL – (DRW) 90
CLEANING – REAR DRUM IN HAT BRAKE 91
INSTALLATION 91
INSTALLATION – (SRW) 91
INSTALLATION – (DRW) 91
ADJUSTMENTS 91
ADJUSTMENT 91
BRAKES – ABS 93
BRAKES – ABS 93
SPECIFICATIONS – TORQUE CHART 93
ELECTRICAL 93
DESCRIPTION 93
OPERATION 93
FRONT WHEEL SPEED SENSOR 94
REMOVAL 94
INSTALLATION 94
REAR WHEEL SPEED SENSOR 94
REMOVAL 94
INSTALLATION 95
TONE WHEEL 95
REMOVAL 95
INSTALLATION 95
HCU (HYDRAULIC CONTROL UNIT) 95
DESCRIPTION 95
REMOVAL 95
INSTALLATION 96
7-COOLING 97
COOLING 97
OPERATION—COOLING SYSTEM 97
DIAGNOSIS AND TESTING 97
DIAGNOSIS AND TESTING – PRELIMINARY CHECKS 97
ENGINE COOLING SYSTEM OVERHEATING 97
DIAGNOSIS AND TESTING – COOLING SYSTEM 98
ACCESSORY DRIVE 101
BELT TENSIONERS 101
DESCRIPTION 101
OPERATION 101
DRIVE BELTS 101
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT 101
VISUAL DIAGNOSIS 101
NOISE DIAGNOSIS 102
REMOVAL 104
INSTALLATION 104
ENGINE 105
COOLANT 105
DESCRIPTION 105
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAKS 106
ULTRAVIOLET LIGHT METHOD 106
PRESSURE TESTER METHOD 106
INTERNAL LEAKAGE INSPECTION 107
COMBUSTION LEAKAGE TEST – WITHOUT PRESSURE TESTER 107
STANDARD PROCEDURE 107
STANDARD PROCEDURE – ADDING ADDITIONAL COOLANT 107
STANDARD PROCEDURE – DRAINING COOLING SYSTEM 108
STANDARD PROCEDURE – REFILLING COOLING SYSTEM 108
COOLANT LEVEL SENSOR 109
REMOVAL 109
INSTALLATION 109
RADIATOR FAN 109
REMOVAL 109
INSTALLATION 109
ENGINE BLOCK HEATER 110
REMOVAL 110
INSTALLATION 110
ENGINE COOLANT TEMP SENSOR 110
DESCRIPTION 110
REMOVAL 110
INSTALLATION 111
ENGINE COOLANT THERMOSTAT 111
REMOVAL 111
INSTALLATION 112
FAN DRIVE VISCOUS CLUTCH 112
REMOVAL 112
INSTALLATION 112
RADIATOR 112
REMOVAL 112
INSTALLATION 113
RADIATOR PRESSURE CAP 114
DESCRIPTION 114
OPERATION 114
DIAGNOSIS AND TESTING – RADIATOR PRESSURE CAP 115
WATER PUMP 115
REMOVAL 115
INSTALLATION 116
8a-AUDIO/VIDEO 117
AUDIO 117
SPECIAL TOOLS 117
AUDIO 117
ANTENNA BODY & CABLE 117
REMOVAL 117
INSTALLATION 117
INSTRUMENT PANEL ANTENNA CABLE 117
REMOVAL 117
INSTALLATION 118
RADIO 118
REMOVAL 118
INSTALLATION 118
SPEAKER 118
REMOVAL 118
INSTALLATION 118
8b-CHIME/BUZZER 119
CHIME/BUZZER 119
DESCRIPTION 119
OPERATION 119
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 120
8e-ELECTRONIC CONTROL MODULES 121
CENTRAL TIMER MODULE 121
DESCRIPTION 121
OPERATION 122
DIAGNOSIS AND TESTING – CENTRAL TIMER MODULE 122
REMOVAL 122
INSTALLATION 122
CONTROLLER ANTILOCK BRAKE 123
DESCRIPTION 123
REMOVAL 123
INSTALLATION 123
ENGINE CONTROL MODULE 123
DESCRIPTION 123
REMOVAL 124
INSTALLATION 124
TRANSMISSION CONTROL MODULE 125
DESCRIPTION 125
OPERATION 125
TCM SIGNALS 126
BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI) 126
SHIFT SCHEDULES 126
DOWNSHIFT SAFETY 127
ADAPTATION 127
CONTROLLER MODES OF OPERATION 128
STANDARD PROCEDURE – TCM ADAPTATION 128
8f-ENGINE SYSTEMS 129
BATTERY SYSTEM 129
BATTERY SYSTEM 129
DESCRIPTION 129
OPERATION 130
DIAGNOSIS AND TESTING – BATTERY SYSTEM 130
MICRO 420 BATTERY TESTER 130
ABNORMAL BATTERY DISCHARGING 133
CLEANING 133
INSPECTION 134
SPECIAL TOOLS 134
BATTERY SYSTEM SPECIAL TOOLS 134
BATTERY 134
DESCRIPTION 134
OPERATION 135
DIAGNOSIS AND TESTING – BATTERY 135
MICRO 420 BATTERY TESTER 135
STANDARD PROCEDURE 136
STANDARD PROCEDURE – BATTERY CHARGING 136
CHARGING A COMPLETELY DISCHARGED BATTERY 137
CHARGING TIME REQUIRED 137
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 138
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 138
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 139
BATTERY TESTING 139
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVEL 140
REMOVAL 140
UNDER HOOD BATTERY REMOVAL 140
AUXILIARY BATTERY REMOVAL 141
INSTALLATION 141
UNDER HOOD BATTERY INSTALLATION 141
AUXILIARY BATTERY INSTALLATION 141
BATTERY HOLDDOWN 142
DESCRIPTION 142
REMOVAL 142
INSTALLATION 142
BATTERY CABLES 142
DESCRIPTION 142
OPERATION 142
DIAGNOSIS AND TESTING – BATTERY CABLES 142
REMOVAL 144
INSTALLATION 144
BATTERY TRAY 144
DESCRIPTION 144
OPERATION 144
REMOVAL 144
INSTALLATION 144
CHARGING SYSTEM 145
CHARGING SYSTEM 145
SPECIFICATIONS 145
TORQUE – 2 7L DIESEL 145
SPECIAL TOOLS 145
GENERATOR 146
DESCRIPTION 146
OPERATION 146
REMOVAL 146
INSTALLATION 146
GENERATOR DECOUPLER PULLEY 147
DESCRIPTION 147
OPERATION 147
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER 147
REMOVAL 148
INSTALLATION 149
VOLTAGE REGULATOR 151
DESCRIPTION 151
STARTING SYSTEM 152
STARTING SYSTEM 152
DESCRIPTION 152
OPERATION 152
DIAGNOSIS AND TESTING – STARTING SYSTEM 153
INSPECTION 154
TESTING 154
SPECIFICATIONS 157
TORQUE – STARTER – DIESEL 157
SPECIFICATIONS – STARTER MOTOR – DIESEL 157
STARTER MOTOR 157
DIAGNOSIS AND TESTING – STARTER MOTOR 157
REMOVAL 158
INSTALLATION 159
STARTER MOTOR RELAY 159
DESCRIPTION 159
REMOVAL 159
INSTALLATION 160
8g-HEATED SYSTEMS 161
HEATED SEATS 161
DESCRIPTION 161
OPERATION 162
DIAGNOSIS AND TESTING – HEATED SEATS 162
DRIVER HEATED SEAT SWITCH 162
DESCRIPTION 162
OPERATION 162
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCH 162
REMOVAL 163
INSTALLATION 163
HEATED SEAT ELEMENT 163
DESCRIPTION 163
OPERATION 163
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENT 163
HEATED SEAT RELAY 164
DESCRIPTION 164
OPERATION 164
DIAGNOSIS AND TESTING – HEATED SEAT RELAY 164
REMOVAL 164
INSTALLATION 164
HEATED SEAT SENSOR 164
DESCRIPTION 164
DIAGNOSIS AND TESTING – HEATED SEAT SENSOR 164
PASSENGER HEATED SEAT SWITCH 165
DESCRIPTION 165
OPERATION 165
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCH 165
REMOVAL 165
INSTALLATION 165
8h-HORN 167
HORN 167
REMOVAL 167
INSTALLATION 167
HORN SWITCH 167
REMOVAL 167
INSTALLATION 167
8i-IGNITION CONTROL 169
IGNITION CONTROL 169
SPECIAL TOOLS 169
GLOW PLUG 169
REMOVAL 169
INSTALLATION 169
GLOW PLUG RELAY 170
DESCRIPTION 170
OPERATION 170
DIAGNOSIS AND TESTING – GLOW PLUG RELAYS 170
8j-INSTRUMENT CLUSTER 171
INSTRUMENT CLUSTER 172
DESCRIPTION 172
OPERATION 175
INPUT AND OUTPUT CIRCUITS 176
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER 177
REMOVAL 177
INSTALLATION 179
ABS INDICATOR 179
DESCRIPTION 179
OPERATION 179
AIRBAG INDICATOR 180
DESCRIPTION 180
OPERATION 180
AMBIENT TEMPERATURE INDICATOR 181
DESCRIPTION 181
OPERATION 181
BRAKE/PARK BRAKE INDICATOR 181
DESCRIPTION 181
OPERATION 182
BRAKE WEAR INDICATOR 182
DESCRIPTION 182
OPERATION 182
CHARGING INDICATOR 183
DESCRIPTION 183
OPERATION 183
CLOCK 183
DESCRIPTION 183
OPERATION 184
COOLANT LOW INDICATOR 184
DESCRIPTION 184
OPERATION 184
ENGINE TEMPERATURE GAUGE 185
DESCRIPTION 185
OPERATION 185
FUEL FILTER CLOGGED INDICATOR 185
DESCRIPTION 185
OPERATION 185
FUEL GAUGE 186
DESCRIPTION 186
OPERATION 186
GEAR SELECTOR INDICATOR 187
DESCRIPTION 187
OPERATION 187
HIGH BEAM INDICATOR 187
DESCRIPTION 187
OPERATION 187
LOW FUEL INDICATOR 188
DESCRIPTION 188
OPERATION 188
LOW OIL LEVEL INDICATOR 188
DESCRIPTION 188
OPERATION 188
MAINTENANCE INDICATOR 189
DESCRIPTION 189
OPERATION 189
MALFUNCTION INDICATOR LAMP (MIL) 190
DESCRIPTION 190
OPERATION 190
MULTI-FUNCTION INDICATOR 190
DESCRIPTION 190
OPERATION 191
ODOMETER 191
DESCRIPTION 191
OPERATION 192
SEATBELT INDICATOR 192
DESCRIPTION 192
OPERATION 192
SPEEDOMETER 193
DESCRIPTION 193
OPERATION 193
TACHOMETER 193
DESCRIPTION 193
OPERATION 194
TRACTION CONTROL INDICATOR 194
DESCRIPTION 194
OPERATION 194
TRACTION CONTROL MALFUNCTION INDICATOR 195
DESCRIPTION 195
OPERATION 195
TURN SIGNAL INDICATOR 195
DESCRIPTION 195
OPERATION 195
WAIT-TO-START INDICATOR 196
DESCRIPTION 196
OPERATION 196
WASHER FLUID INDICATOR 197
DESCRIPTION 197
OPERATION 197
WATER-IN-FUEL INDICATOR 197
DESCRIPTION 197
OPERATION 198
8l-LAMPS 199
LAMPS/LIGHTING – EXTERIOR 199
LAMPS/LIGHTING – EXTERIOR 200
DESCRIPTION 200
OPERATION 201
SPECIFICATIONS – LAMPS/LIGHTING – EXTERIOR 203
BACKUP LAMP BULB 203
REMOVAL 203
INSTALLATION 204
BRAKE LAMP SWITCH 204
REMOVAL0 – 2 VA (Continued) 204
INSTALLATION 204
BRAKE/PARK LAMP BULB 205
REMOVAL 205
INSTALLATION 205
CENTER HIGH MOUNTED STOP LAMP BULB 205
REMOVAL 205
INSTALLATION 205
CENTER HIGH MOUNTED STOP LAMP UN 206
REMOVAL 206
INSTALLATION 206
CLEARANCE LAMP BULB 206
REMOVAL 206
INSTALLATION 206
CLEARANCE LAMP UNIT 206
REMOVAL 206
INSTALLATION 207
DAYTIME RUNNING LAMP RELAY 207
REMOVAL 207
INSTALLATION 207
FOG LAMP BULB 208
REMOVAL 208
INSTALLATION 208
FOG LAMP RELAY 208
REMOVAL 208
INSTALLATION 209
FOG LAMP SWITCH 209
REMOVAL 209
INSTALLATION 210
FRONT LAMP UNIT 210
REMOVAL 210
INSTALLATION 210
ADJUSTMENTS 210
ADJUSTMENT – FRONT LAMP UNIT 210
VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT 210
FRONT LAMP UNIT ALIGNMENT 211
FRONT POSITION LAMP BULB 212
REMOVAL 212
INSTALLATION 212
FRONT TURN/PARK/SIDE MARKER LAMP BULB 212
REMOVAL 212
INSTALLATION 213
HEADLAMP LEVELING MOTOR 213
REMOVAL 213
INSTALLATION 214
HEADLAMP LEVELING SWITCH 214
REMOVAL 214
INSTALLATION 215
HIGH BEAM HEADLAMP BULB 215
REMOVAL 215
INSTALLATION 215
LICENSE PLATE LAMP BULB 215
REMOVAL 215
INSTALLATION 216
LICENSE PLATE LAMP UNIT 216
REMOVAL 216
INSTALLATION 216
LOW BEAM HEADLAMP BULB 216
REMOVAL 216
INSTALLATION 217
MULTI-FUNCTION SWITCH 217
REMOVAL 217
INSTALLATION 218
PARK BRAKE SWITCH 218
REMOVAL 218
INSTALLATION 218
REAR SIDE MARKER LAMP BULB 219
REMOVAL 219
INSTALLATION 219
REAR TURN LAMP BULB 219
REMOVAL 219
INSTALLATION 220
REPEATER LAMP BULB 220
REMOVAL 220
INSTALLATION 220
REPEATER LAMP UNIT 220
REMOVAL 220
INSTALLATION 221
TAIL LAMP UNIT 221
REMOVAL 221
INSTALLATION 221
TURN SIGNAL RELAY 222
REMOVAL 222
INSTALLATION 222
LAMPS/LIGHTING – INTERIOR 223
LAMPS/LIGHTING – INTERIOR 223
DESCRIPTION 223
OPERATION 224
INTERIOR LIGHTING CIRCUIT 224
EXTERIOR LIGHTING CIRCUIT 224
SPECIFICATIONS – INTERIOR LIGHTING 224
ASH RECEIVER/CIGAR LIGHTER LAMP UNIT 225
REMOVAL 225
INSTALLATION 225
CARGO/DOME LAMP BULB 225
REMOVAL 225
INSTALLATION 225
CARGO/DOME LAMP UNIT 226
REMOVAL 226
INSTALLATION 226
CARGO LAMP SWITCH 226
REMOVAL 226
REMOVAL – INSTRUMENT PANEL 226
REMOVAL – BULKHEAD 226
REMOVAL – REAR PILLAR 226
INSTALLATION 227
INSTALLATION – INSTRUMENT PANEL 227
INSTALLATION – BULKHEAD 227
INSTALLATION – REAR PILLAR 227
DOME/READING LAMP BULB 227
REMOVAL 227
INSTALLATION 227
DOME/READING LAMP UNIT 228
REMOVAL 228
INSTALLATION 228
DOME LAMP/INTRUSION SENSOR BULB 228
REMOVAL 228
INSTALLATION 228
DOME LAMP/INTRUSION SENSOR 229
REMOVAL 229
INSTALLATION 229
DOOR JAMB SWITCH 229
REMOVAL 229
INSTALLATION 229
ENTRY/EXIT LAMP BULB 229
REMOVAL 229
INSTALLATION 230
ENTRY/EXIT LAMP UNIT 230
REMOVAL 230
INSTALLATION 230
TIME DELAY RELAY 230
REMOVAL 230
INSTALLATION 231
8n-POWER SYSTEMS 233
POWER LOCKS 233
POWER LOCKS 233
DESCRIPTION 233
CENTRAL LOCKING 233
REMOTE KEYLESS ENTRY 233
AUTO DOOR LOCKS 233
ACCIDENT RESPONSE 233
DOOR LOCK MOTOR 233
REMOVAL 233
INSTALLATION 233
REMOTE KEYLESS ENTRY TRANSMITTER 234
DESCRIPTION 234
MASTER LOCK SWITCH 234
DESCRIPTION 234
DIAGNOSIS AND TESTING – MASTER LOCK SWITCH 234
REMOVAL 234
INSTALLATION 234
POWER MIRRORS 235
POWER MIRRORS 235
DESCRIPTION 235
POWER MIRROR SWITCH 235
DIAGNOSIS AND TESTING – POWER MIRROR SWITCH 235
REMOVAL 235
INSTALLATION 236
POWER WINDOWS 237
POWER WINDOWS 237
DESCRIPTION 237
OPERATION 237
WINDOW SWITCH 237
WINDOW MOTOR 237
WINDOW MOTOR 237
REMOVAL 237
POWER WINDOW SWITCH 237
DIAGNOSIS AND TESTING – POWER WINDOW SWITCH 237
REMOVAL 238
INSTALLATION 238
8o-RESTRAINTS 239
RESTRAINTS 240
DESCRIPTION 240
ACTIVE RESTRAINTS 241
PASSIVE RESTRAINTS 241
OPERATION 242
ACTIVE RESTRAINTS 242
PASSIVE RESTRAINTS 242
WARNING 243
WARNINGS – RESTRAINT SYSTEM 243
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEM 243
STANDARD PROCEDURE 244
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 244
SUPPLEMENTAL RESTRAINT STORAGE 244
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT 244
CLEANUP PROCEDURE 244
STANDARD PROCEDURE – VERIFICATION TEST 245
AIRBAG CONTROL MODULE 246
DESCRIPTION 246
OPERATION 247
REMOVAL 248
INSTALLATION 249
CLOCKSPRING 250
DESCRIPTION 250
OPERATION 251
STANDARD PROCEDURE – CLOCKSPRING CENTERING 251
REMOVAL 252
INSTALLATION 253
DRIVER AIRBAG 254
DESCRIPTION 254
OPERATION 255
REMOVAL 255
INSTALLATION 256
FRONT SEAT BELT & RETRACTOR 257
REMOVAL 257
INSTALLATION 259
FRONT SEAT BELT BUCKLE 260
REMOVAL 260
INSTALLATION 261
PASSENGER AIRBAG 261
DESCRIPTION 261
OPERATION 262
REMOVAL 262
INSTALLATION 264
PASSENGER AIRBAG BRACKET 265
REMOVAL 265
INSTALLATION 265
REAR SEAT BELT & RETRACTOR 265
REMOVAL 265
INSTALLATION 267
REAR SEAT BELT BUCKLE 267
REMOVAL 267
REMOVAL – INBOARD 267
REMOVAL – OUTBOARD 268
INSTALLATION 268
INSTALLATION – INBOARD 268
INSTALLATION – OUTBOARD 269
SEAT BELT SWITCH 269
DESCRIPTION 269
OPERATION 269
SEAT BELT TENSIONER 269
DESCRIPTION 269
OPERATION 270
SEAT BELT TURNING LOOP ADJUSTER 271
REMOVAL 271
INSTALLATION 272
8p-SPEED CONTROL 273
SPEED CONTROL 273
DESCRIPTION 273
OPERATION 273
SPECIFICATIONS 274
TORQUE 274
CABLE 275
DESCRIPTION 275
SERVO 275
DESCRIPTION 275
SWITCH 275
REMOVAL 275
INSTALLATION 275
8q-VEHICLE THEFT SECURITY 277
VEHICLE THEFT SECURITY 277
DESCRIPTION 277
OPERATION 277
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY 277
INTRUSION SENSOR 278
REMOVAL 278
INSTALLATION 278
SECURITY SYSTEM MODULE 278
REMOVAL 278
INSTALLATION 278
SENTRY KEY REMOTE ENTRY MODULE 278
DESCRIPTION 278
SENTRY KEY IMMOBILIZER 279
REMOTE KEYLESS ENTRY (RKE) 279
OPERATION 279
SENTRY KEY IMMOBILIZER 279
REMOTE KEYLESS ENTRY 279
REMOVAL 279
SENTRY KEY REMOTE ENTRY MODULE 279
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING 280
INSTALLATION 280
SENTRY KEY REMOTE ENTRY MODULE 280
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING 280
SIREN 280
REMOVAL 280
INSTALLATION 280
TRANSPONDER KEY 281
DESCRIPTION 281
OPERATION 281
8r-WIPERS/WASHERS 283
WIPERS/WASHERS 283
DESCRIPTION 283
OPERATING MODES 285
OPERATION 285
DIAGNOSIS AND TESTING – WIPER & WASHER SYSTEM 287
CLEANING – WIPER & WASHER SYSTEM 287
WIPER SYSTEM 287
WASHER SYSTEM 287
INSPECTION – WIPER & WASHER SYSTEM 288
WIPER SYSTEM 288
WASHER SYSTEM 288
CHECK VALVE 289
DESCRIPTION 289
OPERATION 289
REMOVAL 289
INSTALLATION 289
WASHER FLUID LEVEL SWITCH 289
DESCRIPTION 289
OPERATION 290
WASHER HOSES/TUBES 290
DESCRIPTION 290
OPERATION 291
WASHER NOZZLE 291
DESCRIPTION 291
OPERATION 291
REMOVAL 291
INSTALLATION 291
WASHER PUMP/MOTOR 291
DESCRIPTION 291
OPERATION 292
REMOVAL 292
INSTALLATION 292
WASHER RESERVOIR 293
DESCRIPTION 293
OPERATION 293
REMOVAL 293
INSTALLATION 294
WIPER ARM 295
DESCRIPTION 295
OPERATION 296
REMOVAL 296
INSTALLATION 296
WIPER BLADE 297
DESCRIPTION 297
OPERATION 297
REMOVAL 298
INSTALLATION 298
WIPER LINKAGE 299
DESCRIPTION 299
OPERATION 299
REMOVAL 299
INSTALLATION 300
WIPER MOTOR 301
DESCRIPTION 301
OPERATION 301
REMOVAL 301
INSTALLATION 301
WIPER RELAY 302
DESCRIPTION 302
OPERATION 303
REMOVAL 304
INSTALLATION 304
8w-WIRING 305
8W-01 WIRING DIAGRAM INFORMATION 307
WIRING DIAGRAM INFORMATION 307
DESCRIPTION 307
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 307
SYMBOLS 307
TERMINOLOGY 311
DESCRIPTION – CIRCUIT INFORMATION 311
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 311
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 311
IDENTIFICATION 311
LOCATIONS 312
WARNING 312
WARNINGS – GENERAL 312
DIAGNOSIS AND TESTING – WIRING HARNESS 312
TROUBLESHOOTING TOOLS 312
INTERMITTENT AND POOR CONNECTIONS 313
TROUBLESHOOTING WIRING PROBLEMS 313
STANDARD PROCEDURE 313
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 313
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 313
STANDARD PROCEDURE – TESTING FOR CONTINUITY 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 314
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 314
CONNECTOR 314
REMOVAL 314
INSTALLATION 315
DIODE 315
REMOVAL 315
INSTALLATION 315
TERMINAL 315
REMOVAL 315
INSTALLATION 316
WIRE 316
STANDARD PROCEDURE – WIRE SPLICING 316
8W-02 COMPONENT INDEX 317
8W-10 POWER DISTRIBUTION 319
8W-11 FUSE BLOCK 353
8W-15 GROUND DISTRIBUTION 393
8W-18 BUS COMMUNICATIONS 421
8W-20 CHARGING SYSTEM 427
8W-21 STARTING SYSTEM 433
8W-30 FUEL/IGNITION SYSTEM 435
8W-31 TRANSMISSION CONTROL SYSTEM 453
8W-33 VEHICLE SPEED CONTROL 463
8W-35 ANTILOCK BRAKES 467
8W-39 VEHICLE THEFT SECURITY SYSTEM 475
8W-40 INSTRUMENT CLUSTER 489
8W-41 HORN/CIGAR LIGHTER 497
8W-42 AIR CONDITIONER/HEATER 501
8W-43 AIRBAG SYSTEM 525
8W-44 INTERIOR LIGHTING 529
8W-45 CENTRAL TIMER MODULE 541
8W-47 AUDIO SYSTEM 549
8W-48 REAR WINDOW DEFOGGER 555
8W-50 FRONT LIGHTING 561
8W-51 REAR LIGHTING 577
8W-52 TURN SIGNALS 587
8W-53 WIPERS 593
8W-54 TRAILER TOW 597
8W-55 NAVIGATION/TELECOMMUNICATIONS 601
8W-60 POWER WINDOWS 605
8W-61 POWER DOOR LOCKS 609
8W-62 POWER MIRRORS 617
8W-63 POWER SEATS 621
8W-70 SPLICE INFORMATION 625
8W-80 CONNECTOR PIN-OUTS 627
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 695
CONNECTOR/GROUND/SPLICE LOCATION 695
DESCRIPTION 695
8W-97 POWER DISTRIBUTION 733
POWER DISTRIBUTION 733
DESCRIPTION 733
OPERATION 733
CIGAR LIGHTER OUTLET 733
DESCRIPTION 733
OPERATION 734
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLET 734
REMOVAL 734
CIRCUIT BREAKER 734
DESCRIPTION 734
OPERATION 734
DIAGNOSIS AND TESTING – CIRCUIT BREAKER 734
FUSE BLOCK #1 734
DESCRIPTION 734
OPERATION 734
REMOVAL 735
INSTALLATION 735
FUSE BLOCK #2 735
DESCRIPTION 735
OPERATION 735
POWER DISTRIBUTION CENTER 735
DESCRIPTION 735
OPERATION 735
POWER OUTLET 735
DESCRIPTION 735
OPERATION 736
DIAGNOSIS AND TESTING – POWER OUTLET 736
REMOVAL 736
INSTALLATION 736
RELAY 736
DESCRIPTION 736
OPERATION 737
DIAGNOSIS AND TESTING – RELAY 737
DIAGNOSIS AND TESTING – RELAY CIRCUIT TEST 737
REMOVAL 737
INSTALLATION 737
9-ENGINE 739
ENGINE 740
DESCRIPTION 740
STANDARD PROCEDURE 741
STANDARD PROCEDURE – COMPRESSION TESTING ENGINE 741
STANDARD PROCEDURE – CYLINDER LEAK DOWN TEST 741
INSPECTING 741
STANDARD PROCEDURE – DETERMINING CYLINDER PRESSURE LOSS 742
REMOVAL 742
REMOVAL – ENGINE COVER 742
REMOVAL 742
INSTALLATION 745
INSTALLATION – ENGINE COVER 745
INSTALLATION 745
SPECIFICATIONS – TORQUE SPECIFICATIONS 746
SPECIAL TOOLS 752
AIR CLEANER ELEMENT 758
REMOVAL 758
INSTALLATION 758
AIR CLEANER HOUSING 758
REMOVAL 758
INSTALLATION 758
CYLINDER HEAD 759
STANDARD PROCEDURE 759
STANDARD PROCEDURE – CYLINDER HEAD BOLT INSPECTION 759
STANDARD PROCEDURE – MEASURE CYLINDER HEAD SURFACE 759
REMOVAL 760
REMOVAL – CYLINDER HEAD 760
REMOVAL – CYLINDER HEAD FRONT COVER 761
REMOVAL – CYLINDER HEAD GUIDE RAIL 762
INSTALLATION 763
INSTALLATION – CYLINDER HEAD 763
CYLINDER HEAD BOLT TORQUE SEQUENCE 763
INSTALLATION – CYLINDER HEAD FRONT COVER 764
INSTALLATION – CYLINDER HEAD GUIDE RAIL 764
CAMSHAFT(S) 765
STANDARD PROCEDURE – CHECKING CAMSHAFT POSITION 765
REMOVAL 766
INSTALLATION 767
CYLINDER HEAD COVER(S) 768
REMOVAL 768
INSTALLATION 768
VALVE SPRINGS 769
REMOVAL 769
REMOVAL – VALVE SPRINGS 769
REMOVAL – VALVES 769
INSTALLATION 770
INSTALLATION – VALVE SPRINGS 770
INSTALLATION – VALVES 771
ENGINE BLOCK 772
STANDARD PROCEDURE 772
STANDARD PROCEDURE – REPLACING ENGINE CORE AND OIL GALLERY PLUGS 772
STANDARD PROCEDURE – MEASURING CYLINDER BORES 772
CRANKSHAFT 773
STANDARD PROCEDURE – MEASURE CRANKSHAFT AND BLOCK JOURNALS 773
ASSIGN CRANKSHAFT BEARING SHELLS 773
REMOVAL 773
INSTALLATION 774
CRANKSHAFT OIL SEAL – REAR 775
REMOVAL 775
INSTALLATION 775
CRANKSHAFT OIL SEAL – FRONT 776
REMOVAL 776
INSTALLATION 776
FLYWHEEL 777
REMOVAL 777
INSTALLATION 777
INSTALLATION 777
INSTALLATION 777
PISTON & CONNECTING ROD 778
DESCRIPTION 778
STANDARD PROCEDURE 778
STANDARD PROCEDURE – CHECKING AND REPAIRING CONNECTING RODS 778
CONNECTING ROD SPECIFICATIONS 780
STANDARD PROCEDURE – MEASURING PISTON PROTRUSION 780
REMOVAL 780
INSTALLATION 781
PISTON RINGS 784
STANDARD PROCEDURE – PISTON RING FITTING 784
VIBRATION DAMPER 785
REMOVAL 785
INSTALLATION 786
VACUUM PUMP 786
DESCRIPTION 786
OPERATION 786
REMOVAL 786
INSTALLATION 787
LEFT MOUNT 787
REMOVAL 787
INSTALLATION 787
RIGHT MOUNT 787
REMOVAL 787
INSTALLATION 787
OIL 788
REMOVAL – OIL SEPARATOR 788
INSTALLATION – OIL SEPARATOR 788
OIL COOLER & LINES 788
REMOVAL 788
INSTALLATION 788
OIL FILTER 789
REMOVAL 789
INSTALLATION 789
OIL JET 789
DESCRIPTION 789
REMOVAL 789
INSTALLATION 789
OIL PAN 790
REMOVAL 790
INSTALLATION 790
OIL PUMP 791
REMOVAL 791
REMOVAL 791
REMOVAL- OIL PUMP CHAIN 791
INSTALLATION 792
INSTALLATION 792
INSTALLATION – OIL PUMP CHAIN 792
OIL TEMPERATURE SENSOR 794
DESCRIPTION 794
OPERATION 794
REMOVAL 795
INSTALLATION 795
INTAKE MANIFOLD 795
REMOVAL 795
INSTALLATION 796
EXHAUST MANIFOLD 797
REMOVAL 797
INSTALLATION 797
TIMING CHAIN COVER 797
REMOVAL 797
INSTALLATION 798
TIMING BELT/CHAIN AND SPROCKETS 799
REMOVAL 799
REMOVAL – TENSIONING AND SLIDE RAILS 799
REMOVAL – INTERMEDIATE GEAR 799
REMOVAL – TIMING CHAIN TENSIONING RAIL 801
REMOVAL – TIMING CHAIN 801
INSTALLATION 804
INSTALLATION – TENSIONING AND SLIDE RAIL 804
INSTALLATION – INTERMEDIATE GEAR 804
INSTALLATION – TIMING CHAIN TENSIONING RAIL 804
ADJUSTMENTS 805
INSTALLATION – TIMING CHAIN 805
TIMING CHAIN TENSIONER 808
REMOVAL 808
INSTALLATION 809
11-EXHAUST SYSTEM 811
EXHAUST SYSTEM 811
DESCRIPTION – 2 7L DIESEL 811
DIAGNOSIS AND TESTING – DIESEL ENGINE 812
CATALYTIC CONVERTER 813
REMOVAL 813
INSTALLATION 813
EXHAUST PIPE 813
REMOVAL 813
INSTALLATION 813
TAILPIPE 813
REMOVAL 813
INSTALLATION 813
TURBOCHARGER SYSTEM 813
DESCRIPTION 813
OPERATION 814
CHARGE AIR COOLER AND PLUMBING 814
DESCRIPTION 814
OPERATION 814
DIAGNOSIS AND TESTING – CHARGE AIR COOLER SYSTEM – LEAKS 814
REMOVAL 815
CLEANING 815
INSPECTION 815
INSTALLATION 815
TURBOCHARGER 816
DESCRIPTION 816
OPERATION 816
REMOVAL 817
REMOVAL 817
REMOVAL – VACUUM TRANSDUCER 817
INSTALLATION 818
INSTALLATION 818
INSTALLATION – VACUUM TRANSDUCER 818
13-FRAME & BUMPERS 819
BUMPERS 819
SPECIFICATIONS – TORQUE 819
FRONT BUMPER – STEPS 820
REMOVAL 820
INSTALLATION 820
FRONT FASCIA 820
REMOVAL 820
INSTALLATION 820
REAR BUMPER – STEP 821
REMOVAL 821
INSTALLATION 821
REAR FASCIA 821
REMOVAL 821
INSTALLATION 821
FRAME 822
SPECIFICATIONS 822
SPECIFICATIONS – FRAME DIMENSIONS 822
VEHICLE PREPARATION 822
SPECIFICATIONS – TORQUE 824
ENGINE CRADLE CROSSMEMBER 824
REMOVAL 824
INSTALLATION 826
REAR CROSSMEMBER – TRANSMISSION 827
REMOVAL 827
INSTALLATION 827
TRAILER HITCH 827
REMOVAL 827
INSTALLATION 828
14-FUEL SYSTEM 829
FUEL SYSTEM 829
WARNING 829
WARNING – HIGH FUEL SYSTEM PRESSURE 829
WARNING 829
DIAGNOSIS AND TESTING 829
DIAGNOSIS AND TESTING – HIGH PRESSURE FUEL LINES 829
DIAGNOSIS AND TESTING – AIR IN FUEL SYSTEM 830
STANDARD PROCEDURE 830
STANDARD PROCEDURES – CLEANING FUEL SYSTEM COMPONENTS 830
STANDARD PROCEDURE – DISCONNECTING AND CONNECTING FUEL LINES 830
STANDARD PROCEDURES – DRAINING WATER FROM FUEL FILTER 830
STANDARD PROCEDURE – LOW PRESSURE FUEL PUMP TEST 831
FUEL DELIVERY 832
FUEL DELIVERY 832
SPECIFICATIONS 832
TORQUE 832
SPECIAL TOOLS 833
FUEL SYSTEM 833
FUEL DRAIN TUBES 833
DIAGNOSIS AND TESTING – FUEL SUPPLY RESTRICTIONS 833
LOW-PRESSURE LINES0 – 4 VA (Continued) 833
HIGH-PRESSURE LINES 833
FUEL FILTER 833
DESCRIPTION 833
OPERATION 833
REMOVAL 833
INSTALLATION 834
FUEL LINES 834
REMOVAL – HIGH PRESSURE LINES 834
INSTALLATION – HIGH PRESSURE LINES 835
FUEL PUMP 835
DESCRIPTION 835
DESCRIPTION – HIGH PRESSURE PUMP 835
DESCRIPTION – LOW PRESSURE PUMP 835
OPERATION 835
OPERATION 835
LOW PRESSURE SIDE 835
HIGH PRESSURE SIDE 836
OPERATION – LOW PRESSURE PUMP 836
REMOVAL 836
REMOVAL – HIGH PRESSURE PUMP 836
REMOVAL – LOW PRESSURE PUMP 837
INSTALLATION 838
INSTALLATION – HIGH PRESSURE PUMP 838
INSTALLATION – LOW PRESSURE PUMP 839
FUEL RAIL 839
DESCRIPTION 839
OPERATION 839
REMOVAL 839
INSTALLATION 839
FUEL TANK 840
DESCRIPTION 840
REMOVAL 840
INSTALLATION 841
FUEL TANK MODULE 841
DESCRIPTION 841
REMOVAL 841
INSTALLATION 842
FUEL LEVEL SENDING UNIT / SENSOR 843
DESCRIPTION 843
REMOVAL 843
INSTALLATION 843
HI PRESSURE FUEL SHUTOFF SOL 844
DESCRIPTION 844
OPERATION 844
WATER IN FUEL SENSOR 844
DESCRIPTION 844
OPERATION 844
FUEL INJECTION 845
ACCELERATOR PEDAL POSITION SENSOR 845
DESCRIPTION 845
BOOST PRESSURE SENSOR 845
DESCRIPTION 845
OPERATION 846
DIAGNOSIS AND TESTING – BOOST PRESSURE SENSOR 846
REMOVAL 846
INSTALLATION 846
CAMSHAFT POSITION SENSOR 847
DESCRIPTION 847
OPERATION 847
REMOVAL 847
INSTALLATION 847
CRANKSHAFT POSITION SENSOR 848
DESCRIPTION 848
OPERATION 848
REMOVAL 848
INSTALLATION 848
FUEL INJECTOR 848
DESCRIPTION 848
FUEL INJECTOR 848
OPERATION 848
Injector closed (with high pressure applied) 849
Injector opens (start of injection) 849
Injector opens fully 850
Injector closes (end of injection) 850
STANDARD PROCEDURE 850
STANDARD PROCEDURE – INJECTOR CLASSIFICATION 850
INJECTOR CLASSIFICATION PROCEDURE 850
STANDARD PROCEDURE – CLEANING FUEL INJECTORS 850
REMOVAL 851
INSTALLATION 851
FUEL PRESSURE SENSOR 853
DESCRIPTION 853
DESCRIPTION 853
DESCRIPTION 853
OPERATION 853
OPERATION 853
OPERATION 853
REMOVAL 854
REMOVAL 854
REMOVAL 854
INSTALLATION 854
INSTALLATION 854
INSTALLATION 855
FUEL PRESSURE SOLENOID 855
DESCRIPTION 855
OPERATION 855
REMOVAL 856
INSTALLATION 856
FUEL TEMPERATURE SENSOR 857
DESCRIPTION 857
OPERATION 857
REMOVAL 857
INSTALLATION 857
INLET AIR TEMPERATURE SENSOR 857
DESCRIPTION 857
OPERATION 857
REMOVAL 858
INSTALLATION 858
MANIFOLD AIR FLOW (MAF) SENSOR 858
DESCRIPTION 858
OPERATION 858
REMOVAL 859
INSTALLATION 859
19-STEERING 861
STEERING 861
DESCRIPTION 861
OPERATION 861
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM 862
COLUMN 865
COLUMN 865
SPECIFICATIONS – TORQUE CHART 865
INTERMEDIATE SHAFT 865
REMOVAL 865
INSTALLATION 865
KEY/LOCK CYLINDER 866
REMOVAL 866
INSTALLATION 867
STEERING WHEEL 867
REMOVAL 867
INSTALLATION 867
GEAR 868
GEAR 868
DESCRIPTION 868
REMOVAL 868
INSTALLATION 868
SPECIFICATIONS – TORQUE CHART 869
LINKAGE 870
LINKAGE 870
DIAGNOSIS AND TESTING – OUTER TIE ROD END 870
SPECIFICATIONS – TORQUE CHART 870
SPECIAL TOOLS 871
FRONT SUSPENSION 871
TIE ROD END 871
REMOVAL 871
INSTALLATION 871
PUMP 872
PUMP 872
DESCRIPTION 872
OPERATION 872
DIAGNOSIS AND TESTING – PUMP LEAKAGE 872
STANDARD PROCEDURE 872
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATION 872
STANDARD PROCEDURE – FLUSHING POWER STEERING SYSTEM 873
REMOVAL 873
INSTALLATION 873
SPECIFICATIONS – TORQUE CHART 874
FLUID 874
STANDARD PROCEDURE 874
POWER STEERING PUMP FILL AND BLEED PROCEDURE 874
FLUID COOLER TUBE 874
REMOVAL 874
INSTALLATION 874
HOSES 875
REMOVAL 875
REMOVAL – PRESSURE HOSE 875
REMOVAL – RETURN LINE FROM PUMP TO COOLER TUBE 875
REMOVAL – RETURN HOSE FROM GEAR TO COOLER TUBE 875
INSTALLATION 875
INSTALLATION – PRESSURE HOSE 875
INSTALLATION – RETURN LINE FROM PUMP TO COOLER TUBE 875
INSTALLATION – RETURN HOSE FROM GEAR TO COOLER TUBE 875
21-TRANSMISSION 877
AUTOMATIC TRANSMISSION – NAG1 877
AUTOMATIC TRANSMISSION – NAG1 878
DESCRIPTION 878
TRANSMISSION IDENTIFICATION 878
TRANSMISSION GEAR RATIOS 878
TRANSMISSION HOUSING 878
MECHANICAL SECTION 879
ELECTROHYDRAULIC CONTROL UNIT 879
SHIFT GROUPS 880
OPERATION 880
EMERGENCY RUNNING FUNCTION 880
CLUTCH APPLICATION 880
FIRST GEAR POWERFLOW 881
SECOND GEAR POWERFLOW 883
THIRD GEAR POWERFLOW 885
FOURTH GEAR POWERFLOW 887
FIFTH GEAR POWERFLOW 889
REVERSE GEAR POWERFLOW 891
SHIFT GROUPS/ SHIFT SEQUENCE 893
DIAGNOSIS AND TESTING 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 899
DIAGNOSIS AND TESTING – PRELIMINARY 899
VEHICLE IS DRIVABLE 899
VEHICLE IS DISABLED 899
DIAGNOSIS AND TESTING – ROAD TESTING 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 900
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 903
REMOVAL 903
DISASSEMBLY 906
ASSEMBLY 910
INSTALLATION 917
SCHEMATICS AND DIAGRAMS 923
SPECIFICATIONS – NAG1 AUTOMATIC TRANSMISSION 944
SPECIAL TOOLS – NAG1 AUTOMATIC TRANSMISSION 945
DRIVING CLUTCHES 948
DESCRIPTION 948
OPERATION 948
DRIVING CLUTCH K1 950
DISASSEMBLY 950
ASSEMBLY 951
DRIVING CLUTCH K2 952
DISASSEMBLY 952
ASSEMBLY 954
DRIVING CLUTCH K3 956
DISASSEMBLY 956
ASSEMBLY 956
ELECTROHYDRAULIC UNIT 958
DESCRIPTION 958
ELECTRICAL CONTROL UNIT 958
HYDRAULIC CONTROL UNIT 958
OPERATION 963
ELECTRICAL CONTROL UNIT 963
HYDRAULIC CONTROL UNIT 964
REMOVAL 968
DISASSEMBLY 968
ASSEMBLY 971
INSTALLATION 976
FLUID AND FILTER 977
DESCRIPTION 977
OPERATION 977
DIAGNOSIS AND TESTING 978
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 978
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 978
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 978
STANDARD PROCEDURE 978
STANDARD PROCEDURE – CHECK OIL LEVEL 978
STANDARD PROCEDURE – TRANSMISSION FILL 979
STANDARD PROCEDURE – FLUID/FILTER SERVICE 980
FREEWHEELING CLUTCH 981
DESCRIPTION 981
OPERATION 981
DISASSEMBLY 982
ASSEMBLY 983
GEARSHIFT CABLE 985
DIAGNOSIS AND TESTING – GEARSHIFT CABLE 985
REMOVAL 985
INSTALLATION 985
HOLDING CLUTCHES 987
DESCRIPTION 987
OPERATION 988
HOLDING CLUTCH B1 988
DISASSEMBLY 988
ASSEMBLY 989
HOLDING CLUTCH B2 991
DISASSEMBLY 991
ASSEMBLY 992
INPUT SPEED SENSORS 995
DESCRIPTION 995
OPERATION 995
OIL PUMP 996
DESCRIPTION 996
OPERATION 996
DISASSEMBLY 996
ASSEMBLY 997
OUTPUT SHAFT BEARING 998
REMOVAL 998
INSTALLATION 998
OUTPUT SHAFT SEAL 1001
REMOVAL 1001
INSTALLATION 1001
PARK LOCK CABLE 1001
REMOVAL 1001
INSTALLATION 1002
PISTONS 1004
DESCRIPTION 1004
OPERATION 1004
PRESSURE 1005
PRESSURE ON A CONFINED FLUID 1005
FORCE MULTIPLICATION 1005
PISTON TRAVEL 1005
PLANETARY GEARTRAIN 1006
DESCRIPTION 1006
OPERATION 1006
DISASSEMBLY 1007
ASSEMBLY 1007
SHIFT MECHANISM 1009
DESCRIPTION 1009
OPERATION 1009
REMOVAL 1010
INSTALLATION 1011
SOLENOID 1012
DESCRIPTION 1012
UPSHIFT/DOWNSHIFT SOLENOID VALVES 1013
MODULATING PRESSURE CONTROL SOLENOID VALVE 1013
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE 1013
SHIFT PRESSURE CONTROL SOLENOID VALVE 1014
OPERATION 1014
UPSHIFT/DOWNSHIFT SOLENOID VALVES 1015
MODULATING PRESSURE CONTROL SOLENOID VALVE 1015
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE 1015
SHIFT PRESSURE CONTROL SOLENOID VALVE 1015
TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT 1015
DESCRIPTION 1015
DESCRIPTION – PARK/NEUTRAL CONTACT 1015
DESCRIPTION – TRANSMISSION TEMPERATURE SENSOR 1016
OPERATION 1016
OPERATION – PARK/NEUTRAL CONTACT 1016
OPERATION – TRANSMISSION TEMPERATURE SENSOR 1017
TORQUE CONVERTER 1017
DESCRIPTION 1017
IMPELLER 1018
TURBINE 1018
STATOR 1018
TORQUE CONVERTER CLUTCH (TCC) 1019
OPERATION 1019
TURBINE 1020
STATOR 1021
TORQUE CONVERTER CLUTCH (TCC) 1022
REMOVAL 1022
INSTALLATION 1022
TORQUE CONVERTER HUB SEAL 1023
REMOVAL 1023
INSTALLATION 1023
22-TIRES/WHEELS 1025
TIRES/WHEELS 1025
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 1025
METHOD 1 (RELOCATE WHEEL ON HUB) 1026
METHOD 2 (RELOCATE TIRE ON WHEEL) 1026
STANDARD PROCEDURE 1026
STANDARD PROCEDURE – MATCH MOUNTING 1026
STANDARD PROCEDURE – TIRE AND WHEEL BALANCE 1027
STANDARD PROCEDURE – TIRE ROTATION 1029
SPECIFICATIONS 1029
TORQUE CHART 1029
TIRES 1030
DESCRIPTION 1030
DESCRIPTION – TIRES 1030
TIRE IDENTIFICATION 1030
TIRE CHAINS 1030
DESCRIPTION – RADIAL – PLY TIRES 1030
DESCRIPTION – TIRE PRESSURE FOR HIGH SPEEDS 1030
DESCRIPTION – REPLACEMENT TIRES 1031
DESCRIPTION – TIRE INFLATION PRESSURES 1031
DIAGNOSIS AND TESTING 1032
DIAGNOSIS AND TESTING – PRESSURE GAUGES 1032
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION 1032
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 1032
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 1032
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD 1032
STANDARD PROCEDURE – REPAIRING LEAKS 1034
CLEANING 1034
SPECIFICATIONS 1034
TIRES 1034
SPARE TIRE CARRIER 1034
REMOVAL 1034
INSTALLATION 1034
WHEELS 1035
DESCRIPTION 1035
OPERATION 1035
DIAGNOSIS AND TESTING 1035
WHEEL INSPECTION 1035
STANDARD PROCEDURE 1035
STANDARD PROCEDURE – WHEEL REPLACEMENT 1035
STANDARD PROCEDURE – DUAL REAR WHEEL INSTALLATION 1036
REMOVAL 1037
INSTALLATION 1037
23-BODY 1039
BODY 1039
WARNING 1039
SAFETY PRECAUTIONS AND WARNINGS 1039
DIAGNOSIS AND TESTING 1039
DIAGNOSIS AND TESTING – WATER LEAKS 1039
VISUAL INSPECTION BEFORE WATER LEAK TESTS 1040
WATER LEAK TESTS 1040
WATER LEAK DETECTION 1040
DIAGNOSIS AND TESTING – WIND NOISE 1040
VISUAL INSPECTION BEFORE TESTS 1040
STANDARD PROCEDURE 1041
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 1041
Rigid Plastics: 1041
Semi-Rigid Plastics: 1041
Flexible Plastics: 1041
Repair Procedure: 1041
Adhesion Promoter/Surface Modifier: 1041
SAFETY PRECAUTION AND WARNINGS 1041
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 1042
PANEL SECTIONING 1044
PANEL REINFORCEMENT 1044
VISUAL INSPECTION 1045
PANEL SURFACE PREPARATION 1045
PATCHING PANELS 1045
PANEL PATCH FABRICATIONS 1045
PANEL PATCH INSTALLATION 1046
PATCHED PANEL SURFACING 1048
STANDARD PROCEDURE – BUZZ, SQUEAK & RATTLE 1048
SPECIFICATIONS 1050
DOOR – FRONT 1051
CHECK 1051
REMOVAL 1051
INSTALLATION 1051
DOOR 1052
REMOVAL 1052
INSTALLATION 1052
ADJUSTMENTS 1053
ADJUSTMENT 1053
DOOR GLASS 1053
REMOVAL 1053
INSTALLATION 1053
EXTERIOR HANDLE 1054
REMOVAL 1054
INSTALLATION 1054
HINGE 1055
REMOVAL 1055
INSTALLATION 1055
LATCH 1056
REMOVAL 1056
INSTALLATION 1056
LATCH STRIKER 1056
REMOVAL 1056
INSTALLATION 1056
LOCK CYLINDER 1056
REMOVAL 1056
INSTALLATION 1056
TRIM PANEL 1057
REMOVAL 1057
INSTALLATION 1058
WINDOW REGULATOR – POWER 1058
REMOVAL 1058
INSTALLATION 1059
WINDOW REGULATOR – MANUAL 1060
REMOVAL 1060
INSTALLATION 1061
DOORS – REAR 1062
CHECK 1062
REMOVAL 1062
INSTALLATION 1062
DOOR 1063
REMOVAL 1063
DISASSEMBLY 1064
RIGHT DOOR 1064
LEFT DOOR 1065
ASSEMBLY 1066
RIGHT DOOR 1066
LEFT DOOR 1067
INSTALLATION 1068
ADJUSTMENTS 1068
ADJUSTMENT 1068
DOOR GLASS 1069
REMOVAL 1069
INSTALLATION 1069
EXTERIOR HANDLE 1070
REMOVAL 1070
INSTALLATION 1071
HINGE 1072
REMOVAL 1072
INSTALLATION 1072
INSIDE HANDLE ACTUATOR 1072
REMOVAL 1072
INSTALLATION 1072
LATCH 1072
REMOVAL 1072
INSTALLATION 1073
TRIM PANEL 1073
REMOVAL 1073
INSTALLATION 1073
DOORS – SLIDING 1074
EXTERIOR HANDLE 1074
REMOVAL 1074
INSTALLATION 1074
INSIDE HANDLE ACTUATOR 1075
REMOVAL 1075
INSTALLATION 1075
UPPER ROLLER ARM 1075
REMOVAL 1075
INSTALLATION 1075
CENTER ROLLER ARM 1075
REMOVAL 1075
INSTALLATION 1076
LOWER ROLLER ARM 1076
REMOVAL 1076
INSTALLATION 1076
CENTER TRACK 1076
REMOVAL 1076
INSTALLATION 1077
LATCH / LOCK CONTROL 1077
REMOVAL 1077
INSTALLATION 1078
REAR LATCH 1078
REMOVAL 1078
INSTALLATION 1078
REAR LATCH STRIKER 1079
REMOVAL 1079
INSTALLATION 1079
SLIDING DOOR 1079
REMOVAL 1079
DISASSEMBLY 1080
ASSEMBLY 1081
INSTALLATION 1082
ADJUSTMENTS 1082
ADJUSTMENT 1082
Gaps and Ridge Adjustment 1082
Flush Adjustment 1083
Door Stop Bumper Adjust 1083
STABILIZER 1083
REMOVAL 1083
INSTALLATION 1083
TRIM PANEL 1084
REMOVAL 1084
Upper 1084
Lower 1084
INSTALLATION 1084
Upper 1084
Lower 1084
DOOR GLASS 1084
REMOVAL 1084
INSTALLATION 1084
EXTERIOR 1085
FUEL FILL DOOR 1085
REMOVAL 1085
INSTALLATION 1085
GRILLE 1085
REMOVAL 1085
INSTALLATION 1085
LICENSE PLATE BRACKET 1085
REMOVAL 1085
INSTALLATION 1085
RADIATOR CROSSMEMBER 1085
REMOVAL 1085
INSTALLATION 1086
SIDE VIEW MIRROR 1086
REMOVAL 1086
Driver’s Side 1086
Passenger Side 1086
INSTALLATION 1086
Driver’s Side 1086
Passenger Side 1087
SIDE VIEW MIRROR – GLASS 1087
REMOVAL 1087
INSTALLATION 1087
HOOD 1088
HINGE 1088
REMOVAL 1088
INSTALLATION 1088
HOOD 1088
REMOVAL 1088
INSTALLATION 1088
ADJUSTMENTS 1089
ADJUSTMENT 1089
LATCH 1089
REMOVAL 1089
INSTALLATION 1089
LATCH RELEASE CABLE 1089
REMOVAL 1089
INSTALLATION 1089
LATCH RELEASE HANDLE 1090
REMOVAL 1090
INSTALLATION 1090
PROP ROD 1090
REMOVAL 1090
INSTALLATION 1090
SAFETY LATCH 1090
REMOVAL 1090
INSTALLATION 1090
INSTRUMENT PANEL 1091
CLUSTER BEZEL 1091
REMOVAL 1091
INSTALLATION 1092
ACCESSORY SWITCH BEZEL 1092
REMOVAL 1092
INSTALLATION 1092
INSTRUMENT PANEL CENTER BEZEL 1093
REMOVAL 1093
INSTALLATION 1093
ASH RECEIVER 1093
REMOVAL 1093
INSTALLATION 1093
CUP HOLDER 1093
REMOVAL 1093
INSTALLATION 1094
GLOVE BOX 1094
REMOVAL 1094
INSTALLATION 1094
INSTRUMENT PANEL ASSEMBLY 1095
REMOVAL 1095
INSTALLATION 1099
TOP COVER – CLUSTER 1100
REMOVAL 1100
INSTALLATION 1100
TOP COVER – TRAY 1101
REMOVAL 1101
INSTALLATION 1102
TOP COVER 1102
REMOVAL 1102
INSTALLATION 1103
STEERING COLUMN OPENING COVER 1104
REMOVAL 1104
INSTALLATION 1104
INTERIOR 1105
INTERIOR 1105
CAUTION 1105
A-PILLAR TRIM 1105
REMOVAL 1105
INSTALLATION 1106
ASSIST HANDLE 1106
REMOVAL 1106
INSTALLATION 1106
B-PILLAR TRIM 1106
REMOVAL 1106
INSTALLATION 1107
BULKHEAD TRIM PANEL 1107
REMOVAL 1107
INSTALLATION 1107
CARPETS AND FLOOR MATS 1107
REMOVAL 1107
Cargo/Passenger Van – Front 1107
Passenger Van – Rear 1107
Cargo Van – Rear 1108
INSTALLATION 1108
Cargo/Passenger Van – Front 1108
Passenger Van – Rear 1108
Cargo Van – Rear 1108
COWL TRIM 1108
REMOVAL 1108
INSTALLATION 1108
D-PILLAR TRIM 1108
REMOVAL 1108
INSTALLATION 1108
HEADLINER 1108
REMOVAL 1108
Cab Section 1108
Number 2 Section 1108
Number 3 Section 1108
Number 4 Section 1109
INSTALLATION 1109
Cab Section 1109
Number 2 Section 1109
Number 3 Section 1109
Number 4 Section 1109
QUARTER TRIM PANEL 1109
REMOVAL 1109
Passenger Van 1109
Cargo Van 1110
INSTALLATION 1110
Passenger Van 1110
Cargo Van 1110
REAR VIEW MIRROR 1110
REMOVAL 1110
INSTALLATION 1110
INSTALLATION 1110
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKET 1110
STEPWELL SCUFF PADS 1110
REMOVAL 1110
INSTALLATION 1111
SUN VISOR 1111
REMOVAL 1111
INSTALLATION 1111
PAINT 1112
PAINT 1112
SPECIFICATIONS – PAINT CODES 1112
BASECOAT/CLEARCOAT FINISH 1112
DESCRIPTION 1112
PAINT TOUCH-UP 1112
DESCRIPTION 1112
STANDARD PROCEDURE – PAINT TOUCH-UP 1113
FINESSE SANDING/BUFFING & POLISH 1113
DESCRIPTION 1113
SEATS 1114
ARMREST 1114
REMOVAL 1114
INSTALLATION 1114
HEADREST 1114
REMOVAL 1114
INSTALLATION 1114
SEAT – FRONT 1115
REMOVAL 1115
INSTALLATION0 – 6 VA (Continued) 1115
SEAT BACK – FRONT 1115
REMOVAL 1115
INSTALLATION 1115
SEAT CUSHION – FRONT 1116
REMOVAL 1116
INSTALLATION 1116
SEAT ADJUSTERS – FRONT 1116
REMOVAL 1116
INSTALLATION 1116
SEAT – REAR 1117
REMOVAL 1117
INSTALLATION 1117
REAR SEAT BACK SHIELD 1117
REMOVAL 1117
INSTALLATION 1117
SEAT BACK CUSHION/COVER – REAR 1118
REMOVAL 1118
INSTALLATION 1118
SEAT CUSHION/COVER – REAR 1118
REMOVAL 1118
INSTALLATION 1118
STATIONARY GLASS 1119
BACKLITE – BULKHEAD TRIM PANEL 1119
REMOVAL 1119
INSTALLATION 1119
QUARTER WINDOW 1119
REMOVAL 1119
INSTALLATION 1119
WINDSHIELD 1120
WARNING 1120
WINDSHIELD SAFETY PRECAUTIONS 1120
REMOVAL 1120
INSTALLATION 1121
Windshield Preparation – Installing A Previously Installed Windshield 1122
Windshield Preparation – Installing A New Windshield 1123
Windshield Opening Preparation 1123
Windshield Installation 1123
WEATHERSTRIP/SEALS 1125
FRONT DOOR INNER BELT WEATHERSTRIP 1125
REMOVAL 1125
INSTALLATION 1125
FRONT DOOR OUTER BELT WEATHERSTRIP 1125
REMOVAL 1125
INSTALLATION 1125
DOOR OPENING SEALS 1125
REMOVAL 1125
INSTALLATION 1125
BODY STRUCTURE 1126
GAP AND FLUSH 1126
SPECIFICATIONS 1126
OPENING DIMENSIONS 1128
SPECIFICATIONS 1128
24-HEATING & AIR CONDITIONING 1129
HEATING & AIR CONDITIONING 1129
DESCRIPTION 1129
DESCRIPTION – COOLING SYSTEM REQUIREMENTS 1129
DESCRIPTION – HEATER AND AIR CONDITIONER 1129
OPERATION – HEATER AND AIR CONDITIONER 1130
DIAGNOSIS AND TESTING 1131
DIAGNOSIS AND TESTING – FUNCTION TEST 1131
DIAGNOSIS AND TESTING – A/C PERFORMANCE TEST 1131
DIAGNOSIS AND TESTING – HEATER PERFORMANCE 1132
MAXIMUM HEATER OUTPUT 1132
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW 1132
POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT 1132
TEMPERATURE CONTROL 1132
SPECIFICATIONS 1133
A/C SYSTEM 1133
CONTROLS – FRONT 1136
A/C COMPRESSOR CLUTCH 1136
DESCRIPTION 1136
OPERATION 1136
STANDARD PROCEDURE 1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH AIR GAP 1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH BREAK-IN 1137
REMOVAL 1137
INSPECTION – COMPRESSOR CLUTCH/COIL 1138
INSTALLATION 1139
A/C COMPRESSOR CLUTCH COIL 1140
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH COIL 1140
A/C HEATER CONTROL 1140
DESCRIPTION 1140
OPERATION 1140
REMOVAL 1140
INSTALLATION 1141
A/C PRESSURE TRANSDUCER 1141
DESCRIPTION 1141
OPERATION 1141
DIAGNOSIS AND TESTING – A/C PRESSURE TRANSDUCER 1141
REMOVAL 1142
INSTALLATION 1142
AIR OUTLET TEMPERATURE SENSOR 1142
DESCRIPTION 1142
OPERATION 1143
REMOVAL 1143
INSTALLATION 1143
AMBIENT TEMPERATURE SENSOR 1143
DESCRIPTION 1143
OPERATION 1143
REMOVAL 1143
INSTALLATION 1144
BLOWER MOTOR RESISTOR BLOCK 1144
DESCRIPTION 1144
OPERATION 1144
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR BLOCK 1144
REMOVAL 1144
INSTALLATION 1145
BLOWER MOTOR SWITCH 1145
DESCRIPTION 1145
OPERATION 1145
DIAGNOSIS AND TESTING – BLOWER MOTOR SWITCH 1145
REMOVAL 1145
EVAPORATOR TEMPERATURE SENSOR 1145
DESCRIPTION 1145
OPERATION 1146
REMOVAL 1146
INSTALLATION 1146
IN-CAR TEMPERATURE SENSOR 1147
DESCRIPTION 1147
OPERATION 1147
DIAGNOSIS AND TESTING 1147
REMOVAL 1147
MODE DOOR CABLES 1147
REMOVAL 1147
INSTALLATION 1147
RECIRCULATION DOOR ACTUATOR 1148
DESCRIPTION 1148
OPERATION 1148
REMOVAL 1149
INSTALLATION 1149
CONTROLS – REAR 1150
BLOWER MOTOR SWITCH 1150
DESCRIPTION 1150
OPERATION 1150
DIAGNOSIS AND TESTING 1151
REMOVAL 1151
INSTALLATION 1151
BLOWER MOTOR RELAY 1151
DESCRIPTION 1151
OPERATION 1151
DIAGNOSIS AND TESTING 1152
REMOVAL 1152
INSTALLATION 1152
CONTROL MODULE 1152
DESCRIPTION 1152
OPERATION 1152
DIAGNOSIS AND TESTING 1152
REMOVAL 1152
INSTALLATION 1153
EVAPORATOR TEMPERATURE SENSOR 1153
DESCRIPTION 1153
OPERATION 1154
DIAGNOSIS AND TESTING 1154
REMOVAL 1154
INSTALLATION 1154
SOLENOID VALVE 1155
DESCRIPTION 1155
OPERATION 1155
DIAGNOSIS AND TESTING 1155
REMOVAL 1155
INSTALLATION 1156
TEMPERATURE CONTROL 1157
DESCRIPTION 1157
OPERATION 1157
DIAGNOSIS AND TESTING 1157
REMOVAL 1157
INSTALLATION 1157
TEMPERATURE SENSOR 1158
DESCRIPTION 1158
OPERATION 1158
DIAGNOSIS AND TESTING 1158
REMOVAL 1158
INSTALLATION 1158
DISTRIBUTION – FRONT 1159
AIR FILTER 1159
REMOVAL 1159
INSTALLATION 1159
AIR OUTLETS 1159
REMOVAL 1159
INSTALLATION 1160
BLOWER MOTOR 1160
REMOVAL 1160
INSTALLATION 1161
DEFROSTER DUCTS 1161
REMOVAL 1161
INSTALLATION 1161
FLOOR DISTRIBUTION DUCTS 1161
REMOVAL 1161
INSTALLATION 1162
HVAC HOUSING 1162
REMOVAL 1162
DISASSEMBLY 1164
ASSEMBLY 1164
INSTALLATION 1164
INSTRUMENT PANEL DUCTS 1165
REMOVAL 1165
INSTALLATION 1166
DISTRIBUTION – REAR 1167
AIR FILTER 1167
REMOVAL 1167
INSTALLATION 1167
BLOWER MOTOR 1167
REMOVAL 1167
INSTALLATION 1168
REAR A/C HOUSING 1168
REMOVAL 1168
INSTALLATION 1169
PLUMBING 1171
PLUMBING 1172
DESCRIPTION – REFRIGERANT LINE 1172
OPERATION – REFRIGERANT LINE 1172
WARNING 1172
CAUTION 1173
CAUTION 1173
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS 1173
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKS 1174
SYSTEM EMPTY 1174
SYSTEM LOW 1174
STANDARD PROCEDURE 1174
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENT 1174
MANIFOLD GAUGE SET CONNECTIONS 1175
STANDARD PROCEDURE – REFRIGERANT RECOVERY 1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE 1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE 1176
PARTIAL CHARGE METHOD 1176
SPECIFICATIONS 1177
CHARGE CAPACITY 1177
A/C COMPRESSOR 1177
DESCRIPTION 1177
OPERATION 1177
DIAGNOSIS AND TESTING – COMPRESSOR NOISE 1177
REMOVAL 1178
INSTALLATION 1179
A/C CONDENSER 1180
DESCRIPTION 1180
OPERATION 1180
REMOVAL 1180
INSTALLATION 1180
A/C DISCHARGE LINE 1181
REMOVAL 1181
INSTALLATION 1182
A/C EVAPORATOR 1182
DESCRIPTION 1182
OPERATION 1182
REMOVAL 1183
INSTALLATION 1183
A/C EXPANSION VALVE 1183
DESCRIPTION 1183
OPERATION 1183
DIAGNOSIS AND TESTING – A/C EXPANSION VALVE 1184
REMOVAL 1184
INSTALLATION 1184
ELECTRIC COOLANT PUMP 1185
DESCRIPTION 1185
OPERATION 1185
REMOVAL 1185
INSTALLATION 1185
HEATER CORE 1185
DESCRIPTION 1185
OPERATION 1185
REMOVAL 1186
INSTALLATION 1186
LIQUID LINE 1186
REMOVAL 1186
INSTALLATION 1187
REAR EVAPORATOR 1188
REMOVAL 1188
INSTALLATION 1189
REAR EXPANSION VALVE 1190
REMOVAL 1190
INSTALLATION 1191
RECEIVER/DRIER 1192
DESCRIPTION 1192
OPERATION 1192
REMOVAL 1192
INSTALLATION 1192
REFRIGERANT 1193
DESCRIPTION 1193
OPERATION 1193
REFRIGERANT OIL 1193
DESCRIPTION 1193
OPERATION 1193
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL 1193
SUCTION LINE 1194
REMOVAL 1194
INSTALLATION 1194
WATER VALVE 1195
REMOVAL 1195
INSTALLATION 1195
UNDERBODY LINES 1196
REMOVAL 1196
INSTALLATION 1197
CABIN HEATER 1200
CABIN HEATER 1200
DESCRIPTION 1200
OPERATION 1200
DIAGNOSIS AND TESTING – DIESEL SUPPLEMENTAL HEATER – DCHA 1200
EXHAUST TUBE 1201
REMOVAL 1201
INSTALLATION 1201
FUEL DOSING PUMP 1202
DESCRIPTION 1202
OPERATION 1202
REMOVAL 1202
INSTALLATION 1202
FUEL LINE 1203
STANDARD PROCEDURE – CLEANING 1203
REMOVAL 1203
INSTALLATION 1204
HEATER UNIT 1205
REMOVAL 1205
REMOVAL 1205
REMOVAL 1205
INSTALLATION 1206
INSTALLATION 1206
INSTALLATION 1206
INLET HOSE 1206
REMOVAL 1206
INSTALLATION 1206
25-EMISSIONS CONTROL 1209
EXHAUST GAS RECIRCULATION 1209
VALVE 1209
DESCRIPTION 1209
OPERATION 1209
REMOVAL 1210
INSTALLATION 1210
INDEX 1211
COMMENTS 1231
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V