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Sprinter 2004 VA Service Manual – PDF DOWNLOAD
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Description
Sprinter 2004 VA Service Manual – PDF DOWNLOAD
FILE DETAILS:
Sprinter 2004 VA Service Manual – PDF DOWNLOAD
Language : English
Pages : 1276
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Sprinter 2004 VA Service Manual – PDF DOWNLOAD
MAIN WELCOME PAGE................................................................................ 0 INSTRUCTIONS..................................................................................... 0 VA Powertrain.................................................................................... 0 VA Body.......................................................................................... 0 VA Chassis....................................................................................... 0 VA Transmission.................................................................................. 0 VA Service Manual................................................................................ 1 FOREWORD..................................................................................... 0 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 SPECIFICATIONS - TORQUE CHART........................................................ 22 SPECIAL TOOLS........................................................................ 23 FRONT SUSPENSION................................................................. 23 BUSHINGS............................................................................. 24 REMOVAL.......................................................................... 24 INSTALLATION..................................................................... 24 HUB / BEARING........................................................................ 24 DIAGNOSIS AND TESTING -.......................................................... 24 REMOVAL.......................................................................... 25 INSTALLATION..................................................................... 25 KNUCKLE.............................................................................. 26 REMOVAL.......................................................................... 26 INSTALLATION..................................................................... 26 LOWER BALL JOINT..................................................................... 26 REMOVAL.......................................................................... 26 INSTALLATION..................................................................... 26 LOWER CONTROL ARM.................................................................... 27 REMOVAL.......................................................................... 27 INSTALLATION..................................................................... 27 SPRING............................................................................... 28 REMOVAL.......................................................................... 28 INSTALLATION..................................................................... 28 SPRING CLAMP PLATES.................................................................. 29 REMOVAL.......................................................................... 29 INSTALLATION..................................................................... 29 SPRING STOP PLATES................................................................... 29 REMOVAL.......................................................................... 29 INSTALLATION..................................................................... 29 STABILIZER BAR....................................................................... 29 DESCRIPTION...................................................................... 29 OPERATION........................................................................ 29 REMOVAL.......................................................................... 29 INSTALLATION..................................................................... 30 STABILIZER LINK...................................................................... 30 REMOVAL.......................................................................... 30 INSTALLATION..................................................................... 30 STRUT................................................................................ 30 REMOVAL.......................................................................... 30 INSTALLATION..................................................................... 30 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............................................................................... 33 DESCRIPTION...................................................................... 33 OPERATION........................................................................ 33 REMOVAL.......................................................................... 34 REMOVAL - (SRW).............................................................. 34 REMOVAL - (DRW).............................................................. 34 INSTALLATION..................................................................... 34 INSTALLATION - (SRW)......................................................... 34 INSTALLATION - (DRW)......................................................... 34 SPRING SHACKLE....................................................................... 35 REMOVAL.......................................................................... 35 INSTALLATION..................................................................... 35 STABILIZER BAR....................................................................... 35 REMOVAL.......................................................................... 35 INSTALLATION..................................................................... 35 STABILIZER LINK...................................................................... 35 REMOVAL.......................................................................... 35 INSTALLATION..................................................................... 35 WHEEL ALIGNMENT.......................................................................... 36 DESCRIPTION.......................................................................... 36 DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION..................................... 36 STANDARD PROCEDURE - TOE ADJUSTMENT.................................................. 37 SPECIFICATIONS....................................................................... 38 3-DIFFERENTIAL & DRIVELINE................................................................... 39 PROPELLER SHAFT.......................................................................... 39 DIAGNOSIS AND TESTING................................................................ 39 PROPELLER SHAFT VIBRATION........................................................ 39 PROPELLER SHAFT BALANCE.......................................................... 40 PROPELLER SHAFT RUNOUT........................................................... 41 STANDARD PROCEDURE................................................................... 41 PROPELLER SHAFT ANGLE............................................................ 41 TWO/THREE-PIECE PROPELLER SHAFT.................................................. 42 SPECIFICATIONS....................................................................... 43 SPECIAL TOOLS........................................................................ 43 REMOVAL.............................................................................. 44 INSTALLATION......................................................................... 44 CENTER BEARING....................................................................... 46 REMOVAL.......................................................................... 46 INSTALLATION..................................................................... 47 REAR AXLE................................................................................ 48 DESCRIPTION.......................................................................... 48 OPERATION............................................................................ 48 DIAGNOSIS AND TESTING................................................................ 48 GEAR NOISE....................................................................... 48 BEARING NOISE.................................................................... 48 LOW SPEED KNOCK.................................................................. 49 VIBRATION........................................................................ 49 DRIVELINE SNAP................................................................... 49 STANDARD PROCEDURE - DRAIN AND FILL.................................................. 49 REMOVAL.............................................................................. 49 INSTALLATION......................................................................... 50 SPECIFICATIONS....................................................................... 51 SPECIAL TOOLS........................................................................ 52 AXLE SHAFTS.......................................................................... 53 REMOVAL.......................................................................... 53 INSTALLATION..................................................................... 53 AXLE BEARINGS/SEALS.................................................................. 55 REMOVAL.......................................................................... 55 INSTALLATION..................................................................... 55 AXLE SHAFTS - DUAL REAR WHEELS....................................................... 57 REMOVAL.......................................................................... 57 INSTALLATION..................................................................... 57 AXLE HUB BEARINGS/SEALS.............................................................. 58 REMOVAL.......................................................................... 58 INSTALLATION..................................................................... 58 PINION SEAL.......................................................................... 60 REMOVAL.......................................................................... 60 INSTALLATION..................................................................... 60 5-BRAKES..................................................................................... 63 BRAKES - BASE............................................................................ 63 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM............................................ 64 PRELIMINARY BRAKE CHECK.......................................................... 64 ROAD TESTING..................................................................... 65 BRAKE NOISES..................................................................... 66 STANDARD PROCEDURE................................................................... 66 STANDARD PROCEDURE - MANUAL BLEEDING............................................. 66 STANDARD PROCEDURE - PRESSURE BLEEDING........................................... 67 HYDRAULIC/MECHANICAL................................................................. 67 SPECIFICATIONS................................................................... 67 SPECIFICATIONS - TORQUE CHART................................................ 67 BASE BRAKE................................................................... 68 SPECIAL TOOLS.................................................................... 69 BRAKES....................................................................... 69 BRAKE LINES.......................................................................... 70 STANDARD PROCEDURE............................................................... 70 STANDARD PROCEDURE - ISO FLARING............................................. 70 STANDARD PROCEDURE - DOUBLE INVERTED FLARING................................. 70 BRAKE PADS/SHOES..................................................................... 71 REMOVAL.......................................................................... 71 REMOVAL - FRONT (SRW)........................................................ 71 REMOVAL - FRONT (DRW)........................................................ 71 REMOVAL - REAR (16” WHEELS) (SRW)............................................ 71 REMOVAL - REAR (15” WHEELS) (SRW)............................................ 71 REMOVAL - REAR (DRW)......................................................... 72 INSTALLATION..................................................................... 72 INSTALLATION - FRONT (SRW)................................................... 72 INSTALLATION - FRONT (DRW)................................................... 73 INSTALLATION - REAR (16” WHEELS) (SRW)....................................... 73 INSTALLATION - REAR (16” WHEELS) (SRW)....................................... 73 INSTALLATION - REAR (DRW).................................................... 73 DISC BRAKE CALIPERS.................................................................. 73 REMOVAL.......................................................................... 73 REMOVAL - FRONT (SRW)........................................................ 73 REMOVAL - FRONT (DRW)........................................................ 74 REMOVAL - REAR (SRW)......................................................... 74 REMOVAL - REAR (DRW)......................................................... 74 INSTALLATION..................................................................... 74 INSTALLATION - FRONT (SRW)................................................... 74 INSTALLATION - FRONT (DRW)................................................... 75 INSTALLATION - REAR (SRW).................................................... 75 INSTALLATION - REAR (DRW).................................................... 75 DISC BRAKE CALIPER ADAPTER........................................................... 75 REMOVAL.......................................................................... 75 REMOVAL - FRONT.............................................................. 75 REMOVAL - REAR............................................................... 75 INSTALLATION..................................................................... 76 INSTALLATION - FRONT......................................................... 76 INSTALLATION - REAR.......................................................... 76 FLUID................................................................................ 76 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION................................ 76 STANDARD PROCEDURE - BRAKE FLUID LEVEL........................................... 76 SPECIFICATIONS................................................................... 76 BRAKE FLUID.................................................................. 76 FLUID RESERVOIR...................................................................... 77 REMOVAL.......................................................................... 77 INSTALLATION..................................................................... 77 ALB LEVER............................................................................ 77 REMOVAL.......................................................................... 77 INSTALLATION..................................................................... 77 ALB CONTROLLER....................................................................... 77 REMOVAL.......................................................................... 77 INSTALLATION..................................................................... 77 ADJUSTMENTS...................................................................... 78 ADJUSTMENT................................................................... 78 MASTER CYLINDER...................................................................... 78 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER............................ 78 POWER BOOSTER VACUUM TEST.................................................... 79 POWER BOOSTER CHECK VALVE TEST............................................... 79 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING.................................... 79 REMOVAL.......................................................................... 79 INSTALLATION..................................................................... 80 PEDAL................................................................................ 80 REMOVAL.......................................................................... 80 INSTALLATION..................................................................... 81 POWER BRAKE BOOSTER.................................................................. 81 DESCRIPTION...................................................................... 81 OPERATION........................................................................ 81 REMOVAL.......................................................................... 81 INSTALLATION..................................................................... 81 ROTORS............................................................................... 81 REMOVAL.......................................................................... 81 REMOVAL - FRONT (SRW)........................................................ 81 REMOVAL - REAR (SRW)......................................................... 82 REMOVAL - FRONT (DRW)........................................................ 82 REMOVAL - REAR (DRW)......................................................... 82 INSTALLATION..................................................................... 83 INSTALLATION - FRONT (SRW)................................................... 83 INSTALLATION - REAR (SRW).................................................... 83 INSTALLATION - FRONT (DRW)................................................... 83 INSTALLATION - REAR (DRW).................................................... 83 SUPPORT PLATE........................................................................ 84 REMOVAL - REAR................................................................... 84 INSTALLATION - REAR.............................................................. 84 PARKING BRAKE........................................................................ 84 SPECIFICATIONS................................................................... 84 TORQUE CHART................................................................. 84 SPECIAL TOOLS.................................................................... 85 PARK BRAKE................................................................... 85 CABLE TENSIONER...................................................................... 85 REMOVAL.......................................................................... 85 INSTALLATION..................................................................... 85 CABLES............................................................................... 86 REMOVAL.......................................................................... 86 REMOVAL - FRONT.............................................................. 86 REMOVAL - REAR............................................................... 86 INSTALLATION..................................................................... 86 INSTALLATION - FRONT......................................................... 86 INSTALLATION - REAR.......................................................... 87 ADJUSTMENTS...................................................................... 87 ADJUSTMENT - PARKING BRAKE CABLES............................................ 87 LEVER................................................................................ 88 REMOVAL.......................................................................... 88 INSTALLATION..................................................................... 88 SHOES................................................................................ 88 REMOVAL.......................................................................... 88 REMOVAL - (SRW).............................................................. 88 REMOVAL - (DRW).............................................................. 88 CLEANING - REAR DRUM IN HAT BRAKE................................................ 89 INSTALLATION..................................................................... 89 INSTALLATION - (SRW)......................................................... 89 INSTALLATION - (DRW)......................................................... 89 ADJUSTMENTS...................................................................... 89 ADJUSTMENT................................................................... 89 BRAKES - ABS............................................................................. 91 SPECIFICATIONS - TORQUE CHART........................................................ 91 ELECTRICAL........................................................................... 91 DESCRIPTION...................................................................... 91 OPERATION........................................................................ 91 FRONT WHEEL SPEED SENSOR............................................................. 92 REMOVAL.......................................................................... 92 INSTALLATION..................................................................... 92 REAR WHEEL SPEED SENSOR.............................................................. 92 REMOVAL.......................................................................... 92 INSTALLATION..................................................................... 93 TONE WHEEL........................................................................... 93 REMOVAL.......................................................................... 93 INSTALLATION..................................................................... 93 HCU (HYDRAULIC CONTROL UNIT)......................................................... 93 DESCRIPTION...................................................................... 93 REMOVAL.......................................................................... 93 INSTALLATION..................................................................... 94 7-COOLING.................................................................................... 95 COOLING.................................................................................. 95 OPERATION - COOLING SYSTEM........................................................... 95 DIAGNOSIS AND TESTING................................................................ 95 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS....................................... 95 ENGINE COOLING SYSTEM OVERHEATING............................................ 95 COOLING SYSTEM................................................................... 96 ACCESSORY DRIVE.......................................................................... 99 BELT TENSIONERS...................................................................... 99 DESCRIPTION...................................................................... 99 OPERATION........................................................................ 99 DRIVE BELTS.......................................................................... 100 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT..................................... 100 VISUAL DIAGNOSIS............................................................. 100 NOISE DIAGNOSIS.............................................................. 100 REMOVAL.......................................................................... 102 INSTALLATION..................................................................... 102 8a-AUDIO/VIDEO............................................................................... 115 AUDIO.................................................................................... 115 SPECIAL TOOLS........................................................................ 115 AUDIO............................................................................ 115 ANTENNA BODY & CABLE..................................................................... 115 REMOVAL.............................................................................. 115 INSTALLATION......................................................................... 115 INSTRUMENT PANEL ANTENNA CABLE........................................................... 115 REMOVAL.............................................................................. 115 INSTALLATION......................................................................... 116 RADIO.................................................................................... 116 REMOVAL.............................................................................. 116 INSTALLATION......................................................................... 116 SPEAKER.................................................................................. 116 REMOVAL.............................................................................. 116 INSTALLATION......................................................................... 116 8b-CHIME/BUZZER.............................................................................. 117 CHIME/BUZZER............................................................................. 117 DESCRIPTION.......................................................................... 117 OPERATION............................................................................ 117 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM......................................... 118 8e-ELECTRONIC CONTROL MODULES................................................................ 121 CENTRAL TIMER MODULE..................................................................... 121 DESCRIPTION.......................................................................... 121 OPERATION............................................................................ 121 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.............................................................................. 126 INSTALLATION......................................................................... 126 TRANSMISSION CONTROL MODULE.............................................................. 126 DESCRIPTION.......................................................................... 126 OPERATION............................................................................ 126 TCM SIGNALS...................................................................... 127 BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)........................................ 128 SHIFT SCHEDULES.................................................................. 128 DOWNSHIFT SAFETY................................................................. 128 ADAPTATION....................................................................... 128 CONTROLLER MODES OF OPERATION.................................................... 129 STANDARD PROCEDURE - TCM ADAPTATION.................................................. 129 8f-ENGINE SYSTEMS............................................................................ 131 BATTERY SYSTEM........................................................................... 131 DESCRIPTION.......................................................................... 131 OPERATION............................................................................ 132 DIAGNOSIS AND TESTING - BATTERY SYSTEM............................................... 132 MICRO 420 BATTERY TESTER......................................................... 132 ABNORMAL BATTERY DISCHARGING..................................................... 134 CLEANING............................................................................. 134 INSPECTION........................................................................... 136 SPECIAL TOOLS........................................................................ 136 BATTERY SYSTEM SPECIAL TOOLS..................................................... 136 BATTERY.............................................................................. 136 DESCRIPTION...................................................................... 136 OPERATION........................................................................ 137 DIAGNOSIS AND TESTING - BATTERY.................................................. 137 MICRO 420 BATTERY TESTER..................................................... 137 STANDARD PROCEDURE............................................................... 138 STANDARD PROCEDURE - BATTERY CHARGING........................................ 138 CHARGING A COMPLETELY DISCHARGED BATTERY................................. 138 CHARGING TIME REQUIRED................................................... 139 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST............................... 139 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST.................................. 140 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER.......................... 141 BATTERY TESTING.......................................................... 141 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL...................... 142 REMOVAL.......................................................................... 142 UNDER HOOD BATTERY REMOVAL................................................... 142 AUXILIARY BATTERY REMOVAL.................................................... 143 INSTALLATION..................................................................... 143 UNDER HOOD BATTERY INSTALLATION.............................................. 143 AUXILIARY BATTERY INSTALLATION............................................... 143 BATTERY HOLDDOWN..................................................................... 143 DESCRIPTION...................................................................... 143 REMOVAL.......................................................................... 143 INSTALLATION..................................................................... 144 BATTERY CABLES....................................................................... 144 DESCRIPTION...................................................................... 144 OPERATION........................................................................ 144 DIAGNOSIS AND TESTING - BATTERY CABLES........................................... 144 REMOVAL.......................................................................... 146 INSTALLATION..................................................................... 146 BATTERY TRAY......................................................................... 146 DESCRIPTION...................................................................... 146 OPERATION........................................................................ 146 REMOVAL.......................................................................... 146 INSTALLATION..................................................................... 146 CHARGING SYSTEM.......................................................................... 147 SPECIFICATIONS....................................................................... 147 TORQUE – 2.7L DIESEL............................................................. 147 SPECIAL TOOLS........................................................................ 148 GENERATOR............................................................................ 148 DESCRIPTION...................................................................... 148 OPERATION........................................................................ 148 REMOVAL.......................................................................... 148 INSTALLATION..................................................................... 149 GENERATOR DECOUPLER PULLEY........................................................... 149 DESCRIPTION...................................................................... 149 OPERATION........................................................................ 149 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER...................................... 150 REMOVAL.......................................................................... 150 INSTALLATION..................................................................... 152 VOLTAGE REGULATOR.................................................................... 153 DESCRIPTION...................................................................... 153 STARTING SYSTEM.......................................................................... 154 DESCRIPTION.......................................................................... 154 OPERATION............................................................................ 154 DIAGNOSIS AND TESTING - STARTING SYSTEM.............................................. 155 INSPECTION....................................................................... 156 TESTING.......................................................................... 156 SPECIFICATIONS....................................................................... 159 TORQUE - STARTER - DIESEL........................................................ 159 SPECIFICATIONS - STARTER MOTOR - DIESEL.......................................... 159 STARTER MOTOR........................................................................ 159 DIAGNOSIS AND TESTING - STARTER MOTOR............................................ 159 REMOVAL.......................................................................... 160 INSTALLATION..................................................................... 160 STARTER MOTOR RELAY.................................................................. 160 DESCRIPTION...................................................................... 160 REMOVAL.......................................................................... 161 INSTALLATION..................................................................... 162 8g-HEATED SYSTEMS............................................................................ 163 HEATED GLASS............................................................................. 163 DESCRIPTION.......................................................................... 163 OPERATION............................................................................ 164 DIAGNOSIS AND TESTING................................................................ 164 ELECTRIC BACKLIGHT (EBL) SYSTEM.................................................. 164 REAR WINDOW DEFOGGER RELAY........................................................... 165 DESCRIPTION...................................................................... 165 OPERATION........................................................................ 165 REMOVAL.......................................................................... 166 INSTALLATION..................................................................... 166 REAR WINDOW DEFOGGER SWITCH.......................................................... 166 DESCRIPTION...................................................................... 166 OPERATION........................................................................ 166 DIAGNOSIS AND TESTING............................................................ 167 REAR WINDOW DEFOGGER SWITCH.................................................. 167 REMOVAL.......................................................................... 168 INSTALLATION..................................................................... 168 REAR WINDOW DEFOGGER GRID............................................................ 168 STANDARD PROCEDURE............................................................... 168 GRID LINE AND TERMINAL REPAIR................................................ 168 HEATED MIRRORS........................................................................... 170 DESCRIPTION.......................................................................... 170 OPERATION............................................................................ 170 HEATED SEATS............................................................................. 171 DESCRIPTION.......................................................................... 171 OPERATION............................................................................ 171 DIAGNOSIS AND TESTING - HEATED SEATS................................................. 172 DRIVER HEATED SEAT SWITCH............................................................ 172 DESCRIPTION...................................................................... 172 OPERATION........................................................................ 172 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH................................ 172 REMOVAL.......................................................................... 172 INSTALLATION..................................................................... 173 HEATED SEAT ELEMENT.................................................................. 173 DESCRIPTION...................................................................... 173 OPERATION........................................................................ 173 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT...................................... 173 HEATED SEAT RELAY.................................................................... 173 DESCRIPTION...................................................................... 173 OPERATION........................................................................ 174 DIAGNOSIS AND TESTING - HEATED SEAT RELAY........................................ 174 REMOVAL.......................................................................... 174 INSTALLATION..................................................................... 174 HEATED SEAT SENSOR................................................................... 174 DESCRIPTION...................................................................... 174 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR....................................... 174 PASSENGER HEATED SEAT SWITCH......................................................... 174 DESCRIPTION...................................................................... 174 OPERATION........................................................................ 174 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH............................. 175 REMOVAL.......................................................................... 175 INSTALLATION..................................................................... 175 8h-HORN...................................................................................... 177 HORN..................................................................................... 177 REMOVAL.............................................................................. 177 INSTALLATION......................................................................... 177 HORN SWITCH.............................................................................. 177 REMOVAL.............................................................................. 177 INSTALLATION0 - 2 VA (Continued)................................................. 177 8i-IGNITION CONTROL.......................................................................... 179 IGNITION CONTROL......................................................................... 179 OPERATION - GLOW PLUG................................................................ 179 Pre-Glowing...................................................................... 179 Glow Output Stage................................................................ 179 After Glow....................................................................... 179 SPECIAL TOOLS........................................................................ 179 GLOW PLUG................................................................................ 180 REMOVAL.............................................................................. 180 INSTALLATION......................................................................... 180 GLOW PLUG RELAY.......................................................................... 180 DESCRIPTION.......................................................................... 180 OPERATION............................................................................ 180 DIAGNOSIS AND TESTING - GLOW PLUG RELAYS............................................. 181 8j-INSTRUMENT CLUSTER........................................................................ 183 INSTRUMENT CLUSTER....................................................................... 184 DESCRIPTION.......................................................................... 184 OPERATION............................................................................ 187 INPUT AND OUTPUT CIRCUITS........................................................ 188 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER........................................... 189 REMOVAL.............................................................................. 189 INSTALLATION......................................................................... 190 ABS INDICATOR............................................................................ 191 DESCRIPTION.......................................................................... 191 OPERATION............................................................................ 191 ADR INDICATOR............................................................................ 191 DESCRIPTION.......................................................................... 191 OPERATION............................................................................ 192 AIRBAG INDICATOR......................................................................... 192 DESCRIPTION.......................................................................... 192 OPERATION............................................................................ 192 AMBIENT TEMPERATURE INDICATOR............................................................ 193 DESCRIPTION.......................................................................... 193 OPERATION............................................................................ 193 BRAKE INDICATOR.......................................................................... 194 DESCRIPTION.......................................................................... 194 OPERATION............................................................................ 194 BRAKE WEAR INDICATOR..................................................................... 195 DESCRIPTION.......................................................................... 195 OPERATION............................................................................ 195 CHARGING INDICATOR....................................................................... 195 DESCRIPTION.......................................................................... 195 OPERATION............................................................................ 195 CLOCK.................................................................................... 196 DESCRIPTION.......................................................................... 196 OPERATION............................................................................ 196 COOLANT LOW INDICATOR.................................................................... 196 DESCRIPTION.......................................................................... 196 OPERATION............................................................................ 196 ENGINE TEMPERATURE GAUGE................................................................. 197 DESCRIPTION.......................................................................... 197 OPERATION............................................................................ 197 ESP INDICATOR............................................................................ 198 DESCRIPTION.......................................................................... 198 OPERATION............................................................................ 198 FUEL FILTER CLOGGED INDICATOR............................................................ 198 DESCRIPTION.......................................................................... 198 OPERATION............................................................................ 198 FUEL GAUGE............................................................................... 199 DESCRIPTION.......................................................................... 199 OPERATION............................................................................ 199 GEAR SELECTOR INDICATOR.................................................................. 200 DESCRIPTION.......................................................................... 200 OPERATION............................................................................ 200 HIGH BEAM INDICATOR...................................................................... 200 DESCRIPTION.......................................................................... 200 OPERATION............................................................................ 200 LOW FUEL INDICATOR....................................................................... 201 DESCRIPTION.......................................................................... 201 OPERATION............................................................................ 201 LOW OIL LEVEL INDICATOR.................................................................. 201 DESCRIPTION.......................................................................... 201 OPERATION............................................................................ 202 MAINTENANCE INDICATOR.................................................................... 202 DESCRIPTION.......................................................................... 202 OPERATION............................................................................ 202 MALFUNCTION INDICATOR LAMP (MIL)......................................................... 203 DESCRIPTION.......................................................................... 203 OPERATION............................................................................ 203 MULTI-FUNCTION INDICATOR................................................................. 203 DESCRIPTION.......................................................................... 203 OPERATION............................................................................ 204 ODOMETER................................................................................. 204 DESCRIPTION.......................................................................... 204 OPERATION............................................................................ 205 PARK BRAKE INDICATOR..................................................................... 205 DESCRIPTION.......................................................................... 205 OPERATION............................................................................ 205 SEATBELT INDICATOR....................................................................... 206 DESCRIPTION.......................................................................... 206 OPERATION............................................................................ 206 SPEEDOMETER.............................................................................. 206 DESCRIPTION.......................................................................... 206 OPERATION............................................................................ 207 TACHOMETER............................................................................... 207 DESCRIPTION.......................................................................... 207 OPERATION............................................................................ 207 TRACTION CONTROL INDICATOR............................................................... 208 DESCRIPTION.......................................................................... 208 OPERATION............................................................................ 208 TRACTION CONTROL MALFUNCTION INDICATOR................................................... 208 DESCRIPTION.......................................................................... 208 OPERATION............................................................................ 209 TURN SIGNAL INDICATOR.................................................................... 209 DESCRIPTION.......................................................................... 209 OPERATION............................................................................ 209 WAIT-TO-START INDICATOR.................................................................. 210 DESCRIPTION.......................................................................... 210 OPERATION............................................................................ 210 WASHER FLUID INDICATOR................................................................... 211 DESCRIPTION.......................................................................... 211 OPERATION............................................................................ 211 WATER-IN-FUEL INDICATOR.................................................................. 211 DESCRIPTION.......................................................................... 211 OPERATION............................................................................ 211 8l-LAMPS..................................................................................... 213 LAMPS/LIGHTING - EXTERIOR................................................................ 213 DESCRIPTION.......................................................................... 214 OPERATION............................................................................ 215 SPECIFICATIONS - LAMPS/LIGHTING - EXTERIOR........................................... 217 BACKUP LAMP BULB..................................................................... 217 REMOVAL.......................................................................... 217 INSTALLATION..................................................................... 217 BRAKE LAMP SWITCH.................................................................... 218 REMOVAL.......................................................................... 218 INSTALLATION..................................................................... 218 ADJUSTMENTS...................................................................... 219 ADJUSTMENT................................................................... 219 BRAKE/PARK LAMP BULB................................................................. 219 REMOVAL.......................................................................... 219 INSTALLATION..................................................................... 219 CENTER HIGH MOUNTED STOP LAMP BULB................................................... 220 REMOVAL.......................................................................... 220 INSTALLATION..................................................................... 220 CENTER HIGH MOUNTED STOP LAMP UN..................................................... 220 REMOVAL.......................................................................... 220 INSTALLATION..................................................................... 220 CLEARANCE LAMP BULB.................................................................. 221 REMOVAL.......................................................................... 221 INSTALLATION..................................................................... 221 CLEARANCE LAMP UNIT.................................................................. 221 REMOVAL.......................................................................... 221 INSTALLATION..................................................................... 221 DAYTIME RUNNING LAMP RELAY........................................................... 221 REMOVAL.......................................................................... 221 INSTALLATION..................................................................... 222 FOG LAMP BULB........................................................................ 222 REMOVAL.......................................................................... 222 INSTALLATION..................................................................... 223 FOG LAMP RELAY....................................................................... 223 REMOVAL.......................................................................... 223 INSTALLATION..................................................................... 223 FOG LAMP SWITCH...................................................................... 224 REMOVAL.......................................................................... 224 INSTALLATION..................................................................... 225 FRONT LAMP UNIT...................................................................... 225 REMOVAL.......................................................................... 225 INSTALLATION..................................................................... 225 ADJUSTMENTS...................................................................... 225 ADJUSTMENT - FRONT LAMP UNIT................................................. 225 VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT........................ 225 FRONT LAMP UNIT ALIGNMENT................................................ 226 FRONT POSITION LAMP BULB............................................................. 226 REMOVAL.......................................................................... 226 INSTALLATION..................................................................... 227 FRONT TURN/PARK/SIDE MARKER LAMP BULB................................................ 227 REMOVAL.......................................................................... 227 INSTALLATION..................................................................... 227 HEADLAMP LEVELING MOTOR.............................................................. 228 REMOVAL.......................................................................... 228 INSTALLATION..................................................................... 228 HEADLAMP LEVELING SWITCH............................................................. 229 REMOVAL.......................................................................... 229 INSTALLATION..................................................................... 229 HIGH BEAM HEADLAMP BULB.............................................................. 229 REMOVAL.......................................................................... 229 INSTALLATION..................................................................... 230 LICENSE PLATE LAMP BULB.............................................................. 230 REMOVAL.......................................................................... 230 INSTALLATION..................................................................... 231 LICENSE PLATE LAMP UNIT.............................................................. 231 REMOVAL.......................................................................... 231 INSTALLATION..................................................................... 231 LOW BEAM HEADLAMP BULB............................................................... 231 REMOVAL.......................................................................... 231 INSTALLATION..................................................................... 231 MULTI-FUNCTION SWITCH................................................................ 232 REMOVAL.......................................................................... 232 INSTALLATION..................................................................... 233 PARK BRAKE SWITCH.................................................................... 233 REMOVAL.......................................................................... 233 INSTALLATION..................................................................... 233 REAR SIDE MARKER LAMP BULB........................................................... 233 REMOVAL.......................................................................... 233 INSTALLATION..................................................................... 234 REAR TURN LAMP BULB.................................................................. 234 REMOVAL.......................................................................... 234 INSTALLATION..................................................................... 234 REPEATER LAMP BULB................................................................... 235 REMOVAL.......................................................................... 235 INSTALLATION..................................................................... 235 REPEATER LAMP UNIT................................................................... 235 REMOVAL.......................................................................... 235 SMALL........................................................................ 235 LARGE........................................................................ 236 INSTALLATION..................................................................... 236 SMALL........................................................................ 236 LARGE........................................................................ 236 TAIL LAMP UNIT....................................................................... 236 REMOVAL.......................................................................... 236 INSTALLATION..................................................................... 237 TURN SIGNAL RELAY.................................................................... 237 REMOVAL.......................................................................... 237 INSTALLATION..................................................................... 237 LAMPS/LIGHTING - INTERIOR................................................................ 239 DESCRIPTION.......................................................................... 239 OPERATION............................................................................ 240 INTERIOR LIGHTING CIRCUIT........................................................ 240 EXTERIOR LIGHTING CIRCUIT........................................................ 240 SPECIFICATIONS - INTERIOR LIGHTING................................................... 240 ASH RECEIVER/CIGAR LIGHTER LAMP UNIT................................................. 241 REMOVAL.......................................................................... 241 INSTALLATION..................................................................... 241 CARGO/DOME LAMP BULB................................................................. 241 REMOVAL.......................................................................... 241 INSTALLATION..................................................................... 241 CARGO/DOME LAMP UNIT................................................................. 241 REMOVAL.......................................................................... 241 INSTALLATION..................................................................... 242 CARGO LAMP SWITCH.................................................................... 242 REMOVAL.......................................................................... 242 REMOVAL - INSTRUMENT PANEL................................................... 242 REMOVAL - BULKHEAD........................................................... 242 REMOVAL - REAR PILLAR........................................................ 242 INSTALLATION..................................................................... 243 INSTALLATION - INSTRUMENT PANEL.............................................. 243 INSTALLATION - BULKHEAD...................................................... 243 INSTALLATION - REAR PILLAR................................................... 243 DOME/READING LAMP BULB............................................................... 243 REMOVAL.......................................................................... 243 INSTALLATION..................................................................... 243 DOME/READING LAMP UNIT............................................................... 243 REMOVAL.......................................................................... 243 INSTALLATION..................................................................... 244 DOME LAMP/INTRUSION SENSOR BULB...................................................... 244 REMOVAL.......................................................................... 244 INSTALLATION..................................................................... 244 DOME LAMP/INTRUSION SENSOR........................................................... 244 REMOVAL.......................................................................... 244 INSTALLATION..................................................................... 244 DOOR JAMB SWITCH..................................................................... 245 REMOVAL.......................................................................... 245 INSTALLATION..................................................................... 245 ENTRY/EXIT LAMP BULB................................................................. 245 REMOVAL.......................................................................... 245 INSTALLATION..................................................................... 245 ENTRY/EXIT LAMP UNIT................................................................. 246 REMOVAL.......................................................................... 246 INSTALLATION..................................................................... 246 TIME DELAY RELAY..................................................................... 246 REMOVAL.......................................................................... 246 INSTALLATION..................................................................... 247 8n-POWER SYSTEMS............................................................................. 249 POWER LOCKS.............................................................................. 249 DOOR LOCK MOTOR...................................................................... 249 REMOVAL.......................................................................... 249 INSTALLATION..................................................................... 249 REMOTE KEYLESS ENTRY TRANSMITTER..................................................... 249 DESCRIPTION...................................................................... 249 MASTER LOCK SWITCH................................................................... 249 DESCRIPTION...................................................................... 249 DIAGNOSIS AND TESTING - MASTER LOCK SWITCH....................................... 249 REMOVAL.......................................................................... 250 INSTALLATION..................................................................... 250 POWER MIRRORS............................................................................ 251 DESCRIPTION.......................................................................... 251 POWER MIRROR SWITCH.................................................................. 251 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH...................................... 251 REMOVAL.......................................................................... 251 INSTALLATION..................................................................... 252 POWER WINDOWS............................................................................ 253 DESCRIPTION.......................................................................... 253 OPERATION............................................................................ 253 WINDOW SWITCH.................................................................... 253 WINDOW MOTOR..................................................................... 253 WINDOW MOTOR......................................................................... 253 REMOVAL.......................................................................... 253 POWER WINDOW SWITCH.................................................................. 253 DIAGNOSIS AND TESTING - POWER WINDOW SWITCH...................................... 253 REMOVAL.......................................................................... 254 INSTALLATION..................................................................... 254 8o-RESTRAINTS................................................................................ 255 RESTRAINTS............................................................................... 255 DESCRIPTION.......................................................................... 255 ACTIVE RESTRAINTS................................................................ 256 PASSIVE RESTRAINTS............................................................... 257 OPERATION............................................................................ 258 ACTIVE RESTRAINTS................................................................ 258 PASSIVE RESTRAINTS............................................................... 258 WARNING.............................................................................. 259 WARNINGS - RESTRAINT SYSTEM...................................................... 259 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM................................ 259 STANDARD PROCEDURE................................................................... 260 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS............... 260 SUPPLEMENTAL RESTRAINT STORAGE............................................... 260 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT........... 260 CLEANUP PROCEDURE............................................................ 260 STANDARD PROCEDURE - VERIFICATION TEST........................................... 261 AIRBAG CONTROL MODULE.................................................................... 262 DESCRIPTION.......................................................................... 262 OPERATION............................................................................ 263 REMOVAL.............................................................................. 264 INSTALLATION......................................................................... 265 CLOCKSPRING.............................................................................. 266 DESCRIPTION.......................................................................... 266 OPERATION............................................................................ 267 STANDARD PROCEDURE - CLOCKSPRING CENTERING........................................... 267 REMOVAL.............................................................................. 268 INSTALLATION......................................................................... 269 DRIVER AIRBAG............................................................................ 270 DESCRIPTION.......................................................................... 270 OPERATION............................................................................ 270 REMOVAL.............................................................................. 271 INSTALLATION......................................................................... 272 FRONT SEAT BELT & RETRACTOR.............................................................. 273 REMOVAL.............................................................................. 273 INSTALLATION......................................................................... 275 FRONT SEAT BELT BUCKLE................................................................... 276 REMOVAL.............................................................................. 276 INSTALLATION......................................................................... 276 PASSENGER AIRBAG......................................................................... 276 DESCRIPTION.......................................................................... 276 OPERATION............................................................................ 277 REMOVAL.............................................................................. 278 INSTALLATION......................................................................... 278 PASSENGER AIRBAG BRACKET................................................................. 280 REMOVAL.............................................................................. 280 INSTALLATION......................................................................... 280 REAR SEAT BELT & RETRACTOR............................................................... 280 REMOVAL.............................................................................. 280 INSTALLATION......................................................................... 282 REAR SEAT BELT BUCKLE.................................................................... 282 REMOVAL.............................................................................. 282 REMOVAL - INBOARD................................................................ 282 REMOVAL - OUTBOARD............................................................... 283 INSTALLATION......................................................................... 283 INSTALLATION - INBOARD........................................................... 283 INSTALLATION - OUTBOARD.......................................................... 284 SEAT BELT SWITCH......................................................................... 284 DESCRIPTION.......................................................................... 284 OPERATION............................................................................ 284 SEAT BELT TENSIONER...................................................................... 284 DESCRIPTION.......................................................................... 284 OPERATION............................................................................ 285 SEAT BELT TURNING LOOP ADJUSTER.......................................................... 286 REMOVAL.............................................................................. 286 INSTALLATION......................................................................... 287 SIDE CURTAIN AIRBAG...................................................................... 287 DESCRIPTION.......................................................................... 287 OPERATION............................................................................ 288 REMOVAL.............................................................................. 288 INSTALLATION......................................................................... 290 SIDE IMPACT SENSOR....................................................................... 291 DESCRIPTION.......................................................................... 291 OPERATION............................................................................ 292 REMOVAL.............................................................................. 292 INSTALLATION......................................................................... 292 8p-SPEED CONTROL............................................................................. 295 SPEED CONTROL............................................................................ 295 DESCRIPTION.......................................................................... 295 OPERATION............................................................................ 295 SPECIFICATIONS....................................................................... 296 TORQUE........................................................................... 296 CABLE.................................................................................... 296 DESCRIPTION.......................................................................... 296 SERVO.................................................................................... 296 DESCRIPTION.......................................................................... 296 SWITCH................................................................................... 297 REMOVAL.............................................................................. 297 INSTALLATION......................................................................... 297 8q-VEHICLE THEFT SECURITY.................................................................... 299 VEHICLE THEFT SECURITY................................................................... 299 DESCRIPTION.......................................................................... 299 OPERATION............................................................................ 299 DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY....................................... 299 INTRUSION SENSOR......................................................................... 300 REMOVAL.............................................................................. 300 INSTALLATION......................................................................... 300 SECURITY SYSTEM MODULE................................................................... 300 REMOVAL.............................................................................. 300 INSTALLATION......................................................................... 300 SENTRY KEY REMOTE ENTRY MODULE........................................................... 300 DESCRIPTION.......................................................................... 300 SENTRY KEY IMMOBILIZER........................................................... 300 REMOTE KEYLESS ENTRY (RKE)....................................................... 300 OPERATION............................................................................ 301 SENTRY KEY IMMOBILIZER........................................................... 301 REMOTE KEYLESS ENTRY............................................................. 301 REMOVAL.............................................................................. 301 SENTRY KEY REMOTE ENTRY MODULE................................................... 301 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING.................................. 302 INSTALLATION......................................................................... 302 SENTRY KEY REMOTE ENTRY MODULE................................................... 302 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING.................................. 302 SIREN.................................................................................... 302 REMOVAL.............................................................................. 302 INSTALLATION......................................................................... 302 TRANSPONDER KEY.......................................................................... 302 DESCRIPTION.......................................................................... 302 OPERATION............................................................................ 302 8r-WIPERS/WASHERS............................................................................ 305 WIPERS/WASHERS........................................................................... 305 DESCRIPTION.......................................................................... 305 OPERATION............................................................................ 307 INTERMITTENT WIPE SYSTEM......................................................... 308 AUTOMATIC WIPE SYSTEM............................................................ 308 OPERATING MODES.................................................................. 309 DIAGNOSIS AND TESTING - WIPER & WASHER SYSTEM........................................ 309 INTERMITTENT WIPER SYSTEM........................................................ 310 AUTOMATIC WIPER SYSTEM........................................................... 311 CLEANING - WIPER & WASHER SYSTEM..................................................... 313 WIPER SYSTEM..................................................................... 313 WASHER SYSTEM.................................................................... 313 INSPECTION - WIPER & WASHER SYSTEM................................................... 314 WIPER SYSTEM..................................................................... 314 WASHER SYSTEM.................................................................... 314 CHECK VALVE.............................................................................. 315 DESCRIPTION.......................................................................... 315 OPERATION............................................................................ 315 REMOVAL.............................................................................. 315 INSTALLATION......................................................................... 315 RAIN SENSOR.............................................................................. 315 DESCRIPTION.......................................................................... 315 OPERATION............................................................................ 316 STANDARD PROCEDURE................................................................... 316 RAIN SENSOR BRACKET REPLACEMENT.................................................. 316 REMOVAL.............................................................................. 317 INSTALLATION......................................................................... 318 RAIN SENSOR CONTROL MODULE............................................................... 318 DESCRIPTION.......................................................................... 318 OPERATION............................................................................ 319 REMOVAL.............................................................................. 319 INSTALLATION......................................................................... 320 WASHER FLUID LEVEL SWITCH................................................................ 320 DESCRIPTION.......................................................................... 320 OPERATION............................................................................ 320 WASHER HOSES/TUBES....................................................................... 321 DESCRIPTION.......................................................................... 321 OPERATION............................................................................ 321 WASHER NOZZLE............................................................................ 322 DESCRIPTION.......................................................................... 322 OPERATION............................................................................ 322 REMOVAL.............................................................................. 322 INSTALLATION......................................................................... 322 WASHER PUMP/MOTOR........................................................................ 322 DESCRIPTION.......................................................................... 322 OPERATION............................................................................ 323 REMOVAL.............................................................................. 323 INSTALLATION......................................................................... 323 WASHER RESERVOIR......................................................................... 324 DESCRIPTION.......................................................................... 324 OPERATION............................................................................ 324 REMOVAL.............................................................................. 324 INSTALLATION......................................................................... 325 WIPER ARM................................................................................ 326 DESCRIPTION.......................................................................... 326 OPERATION............................................................................ 327 REMOVAL.............................................................................. 327 INSTALLATION......................................................................... 327 WIPER BLADE.............................................................................. 328 DESCRIPTION.......................................................................... 328 OPERATION............................................................................ 328 REMOVAL.............................................................................. 329 INSTALLATION......................................................................... 329 WIPER LINKAGE............................................................................ 329 DESCRIPTION.......................................................................... 329 OPERATION............................................................................ 330 REMOVAL.............................................................................. 330 INSTALLATION......................................................................... 331 WIPER MOTOR.............................................................................. 332 DESCRIPTION.......................................................................... 332 OPERATION............................................................................ 332 REMOVAL.............................................................................. 332 INSTALLATION......................................................................... 332 WIPER RELAY.............................................................................. 333 DESCRIPTION.......................................................................... 333 OPERATION............................................................................ 334 REMOVAL.............................................................................. 334 INSTALLATION......................................................................... 335 8w-WIRING.................................................................................... 337 8W-01 WIRING DIAGRAM INFORMATION......................................................... 339 WIRING DIAGRAM INFORMATION........................................................... 339 DESCRIPTION...................................................................... 339 HOW TO USE WIRING DIAGRAMS................................................... 339 CIRCUIT INFORMATION.......................................................... 343 SECTION IDENTIFICATION AND INFORMATION....................................... 343 CONNECTOR, GROUND, AND SPLICE INFORMATION.................................... 343 WARNINGS - GENERAL............................................................... 344 DIAGNOSIS AND TESTING............................................................ 344 WIRING HARNESS............................................................... 344 STANDARD PROCEDURE............................................................... 345 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.............................. 345 TESTING FOR VOLTAGE POTENTIAL................................................ 346 TESTING FOR CONTINUITY....................................................... 346 TESTING FOR A SHORT TO GROUND................................................ 346 TESTING COMPONENTS FOR A SHORT TO GROUND ON A FUSE POWERING SEVERAL LOADS.... 346 TESTING FOR A VOLTAGE DROP................................................... 347 CONNECTOR........................................................................ 347 REMOVAL...................................................................... 347 INSTALLATION................................................................. 347 DIODE............................................................................ 348 REMOVAL...................................................................... 348 INSTALLATION................................................................. 348 TERMINAL......................................................................... 348 REMOVAL...................................................................... 348 INSTALLATION................................................................. 348 WIRE............................................................................. 349 STANDARD PROCEDURE........................................................... 349 WIRE SPLICING............................................................ 349 8W-02 COMPONENT INDEX.................................................................... 351 8W-10 POWER DISTRIBUTION................................................................. 353 8W-11 FUSE BLOCK......................................................................... 387 8W-15 GROUND DISTRIBUTION................................................................ 427 8W-18 BUS COMMUNICATIONS................................................................. 455 8W-20 CHARGING SYSTEM.................................................................... 461 8W-21 STARTING SYSTEM.................................................................... 467 8W-30 FUEL/IGNITION SYSTEM............................................................... 469 8W-31 TRANSMISSION CONTROL SYSTEM........................................................ 495 8W-33 VEHICLE SPEED CONTROL.............................................................. 505 8W-35 ANTILOCK BRAKES.................................................................... 509 8W-39 VEHICLE THEFT SECURITY SYSTEM...................................................... 517 8W-40 INSTRUMENT CLUSTER................................................................. 531 8W-41 HORN/CIGAR LIGHTER................................................................. 539 8W-42 AIR CONDITIONING-HEATER............................................................ 543 8W-43 AIRBAG SYSTEM...................................................................... 565 8W-44 INTERIOR LIGHTING.................................................................. 569 8W-45 CENTRAL TIMER MODULE............................................................... 581 8W-47 AUDIO SYSTEM....................................................................... 589 8W-48 REAR WINDOW DEFOGGER............................................................... 595 8W-50 FRONT LIGHTING..................................................................... 601 8W-51 REAR LIGHTING...................................................................... 617 8W-52 TURN SIGNALS....................................................................... 627 8W-53 WIPERS............................................................................. 633 8W-54 TRAILER TOW........................................................................ 637 8W-55 NAVIGATION/TELECOMMUNICATIONS...................................................... 641 8W-60 POWER WINDOWS...................................................................... 645 8W-61 POWER DOOR LOCKS................................................................... 649 8W-62 POWER MIRRORS...................................................................... 657 8W-63 POWER SEATS........................................................................ 661 8W-70 SPLICE INFORMATION................................................................. 665 8W-80 CONNECTOR PIN-OUTS................................................................. 667 8W-91 CONNECTOR/GROUND/SPLICE LOCATION................................................... 741 CONNECTOR/GROUND/SPLICE LOCATION..................................................... 741 DESCRIPTION...................................................................... 741 8W-97 POWER DISTRIBUTION................................................................. 785 POWER DISTRIBUTION................................................................... 785 DESCRIPTION...................................................................... 785 OPERATION........................................................................ 785 CIGAR LIGHTER OUTLET................................................................. 785 DESCRIPTION...................................................................... 785 OPERATION........................................................................ 786 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..................................... 786 REMOVAL.......................................................................... 786 FUSE BLOCK #1........................................................................ 786 DESCRIPTION...................................................................... 786 OPERATION........................................................................ 786 REMOVAL.......................................................................... 787 INSTALLATION..................................................................... 787 FUSE BLOCK #2........................................................................ 787 DESCRIPTION...................................................................... 787 OPERATION........................................................................ 787 POWER DISTRIBUTION CENTER............................................................ 787 DESCRIPTION...................................................................... 787 OPERATION........................................................................ 787 POWER OUTLET......................................................................... 787 DESCRIPTION...................................................................... 787 OPERATION........................................................................ 788 DIAGNOSIS AND TESTING - POWER OUTLET............................................. 788 REMOVAL.......................................................................... 788 INSTALLATION..................................................................... 788 RELAY................................................................................ 788 DESCRIPTION...................................................................... 788 OPERATION........................................................................ 789 DIAGNOSIS AND TESTING - RELAY.................................................... 789 REMOVAL.......................................................................... 789 INSTALLATION..................................................................... 789 9-ENGINE..................................................................................... 791 ENGINE................................................................................... 793 DESCRIPTION.......................................................................... 793 STANDARD PROCEDURE................................................................... 793 STANDARD PROCEDURE - COMPRESSION TESTING ENGINE.................................. 793 STANDARD PROCEDURE - CYLINDER LEAK DOWN TEST..................................... 794 INSPECTING................................................................... 794 STANDARD PROCEDURE - DETERMINING CYLINDER PRESSURE LOSS.......................... 795 REMOVAL.............................................................................. 795 REMOVAL - ENGINE COVER........................................................... 795 INSTALLATION......................................................................... 799 INSTALLATION - ENGINE COVER...................................................... 799 SPECIFICATIONS - TORQUE SPECIFICATIONS............................................... 801 SPECIAL TOOLS........................................................................ 805 AIR CLEANER ELEMENT...................................................................... 809 REMOVAL.............................................................................. 809 INSTALLATION......................................................................... 809 AIR CLEANER HOUSING...................................................................... 809 REMOVAL.............................................................................. 809 INSTALLATION......................................................................... 809 CYLINDER HEAD............................................................................ 810 DESCRIPTION.......................................................................... 810 STANDARD PROCEDURE................................................................... 810 STANDARD PROCEDURE - CYLINDER HEAD BOLT INSPECTION............................... 810 STANDARD PROCEDURE - MEASURE CYLINDER HEAD SURFACE............................... 810 REMOVAL.............................................................................. 811 REMOVAL - CYLINDER HEAD.......................................................... 811 REMOVAL - CYLINDER HEAD FRONT COVER.............................................. 813 REMOVAL - CYLINDER HEAD GUIDE RAIL............................................... 813 INSTALLATION......................................................................... 814 INSTALLATION - CYLINDER HEAD..................................................... 814 INSTALLATION - CYLINDER HEAD FRONT COVER......................................... 815 INSTALLATION - CYLINDER HEAD GUIDE RAIL.......................................... 816 CAMSHAFT(S).............................................................................. 816 STANDARD PROCEDURE - CHECKING CAMSHAFT POSITION...................................... 816 REMOVAL.............................................................................. 817 INSTALLATION......................................................................... 818 CYLINDER HEAD COVER(S)................................................................... 820 REMOVAL.............................................................................. 820 INSTALLATION......................................................................... 820 VALVE STEM SEALS......................................................................... 821 DESCRIPTION.......................................................................... 821 VALVE SPRINGS............................................................................ 821 REMOVAL.............................................................................. 821 REMOVAL - VALVE SPRINGS.......................................................... 821 REMOVAL - VALVES................................................................. 821 INSTALLATION......................................................................... 822 INSTALLATION - VALVE SPRINGS..................................................... 822 INSTALLATION - VALVES............................................................ 823 ENGINE BLOCK............................................................................. 824 STANDARD PROCEDURE................................................................... 824 STANDARD PROCEDURE - REPLACING ENGINE CORE AND OIL GALLERY PLUGS................. 824 STANDARD PROCEDURE - MEASURING CYLINDER BORES.................................... 824 CRANKSHAFT............................................................................... 824 DESCRIPTION.......................................................................... 824 STANDARD PROCEDURE - MEASURE CRANKSHAFT AND BLOCK JOURNALS........................... 824 ASSIGN CRANKSHAFT BEARING SHELLS................................................. 825 REMOVAL.............................................................................. 826 INSTALLATION......................................................................... 826 CRANKSHAFT OIL SEAL - REAR............................................................... 827 REMOVAL.............................................................................. 827 INSTALLATION......................................................................... 827 CRANKSHAFT OIL SEAL - FRONT.............................................................. 828 REMOVAL.............................................................................. 828 INSTALLATION......................................................................... 828 FLYWHEEL................................................................................. 829 REMOVAL.............................................................................. 829 INSTALLATION......................................................................... 829 PISTON & CONNECTING ROD.................................................................. 831 DESCRIPTION.......................................................................... 831 STANDARD PROCEDURE................................................................... 831 STANDARD PROCEDURE - CHECKING AND REPAIRING CONNECTING RODS...................... 831 CONNECTING ROD SPECIFICATIONS................................................ 832 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION................................. 832 REMOVAL.............................................................................. 832 INSTALLATION......................................................................... 834 PISTON RINGS............................................................................. 836 STANDARD PROCEDURE - PISTON RING FITTING............................................. 836 VIBRATION DAMPER......................................................................... 837 REMOVAL.............................................................................. 837 INSTALLATION......................................................................... 837 VACUUM PUMP.............................................................................. 838 DESCRIPTION.......................................................................... 838 OPERATION............................................................................ 838 REMOVAL.............................................................................. 838 INSTALLATION......................................................................... 838 LEFT MOUNT............................................................................... 839 REMOVAL.............................................................................. 839 INSTALLATION......................................................................... 839 RIGHT MOUNT.............................................................................. 840 REMOVAL.............................................................................. 840 INSTALLATION......................................................................... 840 OIL...................................................................................... 840 REMOVAL - OIL SEPARATOR.............................................................. 840 INSTALLATION - OIL SEPARATOR......................................................... 840 OIL COOLER & LINES....................................................................... 840 REMOVAL.............................................................................. 840 INSTALLATION......................................................................... 841 OIL FILTER............................................................................... 841 REMOVAL.............................................................................. 841 INSTALLATION......................................................................... 841 OIL JET.................................................................................. 842 DESCRIPTION.......................................................................... 842 REMOVAL.............................................................................. 842 INSTALLATION......................................................................... 842 OIL PAN.................................................................................. 843 REMOVAL.............................................................................. 843 INSTALLATION......................................................................... 844 OIL PUMP................................................................................. 845 REMOVAL.............................................................................. 845 REMOVAL- OIL PUMP CHAIN.......................................................... 845 INSTALLATION......................................................................... 845 INSTALLATION - OIL PUMP CHAIN.................................................... 846 OIL SENSOR............................................................................... 848 DESCRIPTION.......................................................................... 848 OPERATION............................................................................ 848 REMOVAL.............................................................................. 848 INSTALLATION......................................................................... 848 INTAKE MANIFOLD.......................................................................... 848 REMOVAL.............................................................................. 848 INSTALLATION......................................................................... 850 EXHAUST MANIFOLD......................................................................... 851 REMOVAL.............................................................................. 851 INSTALLATION......................................................................... 851 TIMING CHAIN COVER....................................................................... 852 REMOVAL.............................................................................. 852 INSTALLATION......................................................................... 853 TIMING CHAIN AND SPROCKETS............................................................... 854 REMOVAL.............................................................................. 854 REMOVAL - TENSIONING AND SLIDE RAILS............................................. 854 REMOVAL - INTERMEDIATE GEAR...................................................... 854 REMOVAL - TIMING CHAIN TENSIONING RAIL........................................... 856 REMOVAL - TIMING CHAIN........................................................... 856 INSTALLATION......................................................................... 858 INSTALLATION - TENSIONING AND SLIDE RAIL......................................... 858 INSTALLATION - INTERMEDIATE GEAR................................................. 858 INSTALLATION - TIMING CHAIN TENSIONING RAIL...................................... 859 ADJUSTMENTS.......................................................................... 859 INSTALLATION - TIMING CHAIN...................................................... 859 TIMING CHAIN TENSIONER................................................................... 863 REMOVAL.............................................................................. 863 INSTALLATION......................................................................... 863 11-EXHAUST SYSTEM............................................................................ 865 EXHAUST SYSTEM........................................................................... 865 DESCRIPTION - 2.7L DIESEL............................................................ 865 DIAGNOSIS AND TESTING - DIESEL ENGINE................................................ 866 CATALYTIC CONVERTER...................................................................... 867 REMOVAL.............................................................................. 867 INSTALLATION......................................................................... 867 EXHAUST PIPE............................................................................. 867 REMOVAL.............................................................................. 867 INSTALLATION......................................................................... 867 TAILPIPE................................................................................. 867 REMOVAL.............................................................................. 867 INSTALLATION......................................................................... 867 TURBOCHARGER SYSTEM...................................................................... 867 DESCRIPTION.......................................................................... 867 OPERATION............................................................................ 868 CHARGE AIR COOLER AND PLUMBING........................................................... 868 DESCRIPTION.......................................................................... 868 OPERATION............................................................................ 868 DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS............................. 868 REMOVAL.............................................................................. 869 CLEANING............................................................................. 869 INSPECTION........................................................................... 869 INSTALLATION......................................................................... 869 TURBOCHARGER............................................................................. 870 DESCRIPTION.......................................................................... 870 OPERATION............................................................................ 870 REMOVAL.............................................................................. 871 REMOVAL - VACUUM TRANSDUCER...................................................... 871 INSTALLATION......................................................................... 872 INSTALLATION - VACUUM TRANSDUCER................................................. 872 13-FRAME & BUMPERS........................................................................... 873 BUMPERS.................................................................................. 873 SPECIFICATIONS - TORQUE.............................................................. 873 FRONT BUMPER - STEPS..................................................................... 874 REMOVAL.............................................................................. 874 INSTALLATION......................................................................... 874 FRONT FASCIA............................................................................. 874 REMOVAL.............................................................................. 874 INSTALLATION......................................................................... 874 REAR BUMPER - STEP....................................................................... 875 REMOVAL.............................................................................. 875 INSTALLATION......................................................................... 875 REAR FASCIA.............................................................................. 875 REMOVAL.............................................................................. 875 INSTALLATION......................................................................... 875 FRAME.................................................................................... 876 SPECIFICATIONS....................................................................... 876 SPECIFICATIONS - FRAME DIMENSIONS................................................ 876 VEHICLE PREPARATION.......................................................... 876 SPECIFICATIONS - TORQUE.......................................................... 878 ENGINE CRADLE CROSSMEMBER................................................................ 878 REMOVAL.............................................................................. 878 INSTALLATION......................................................................... 880 REAR CROSSMEMBER - TRANSMISSION.......................................................... 881 REMOVAL.............................................................................. 881 INSTALLATION......................................................................... 881 TRAILER HITCH............................................................................ 881 REMOVAL.............................................................................. 881 INSTALLATION......................................................................... 882 14-FUEL SYSTEM............................................................................... 883 FUEL SYSTEM.............................................................................. 883 WARNING.............................................................................. 883 WARNING - HIGH FUEL SYSTEM PRESSURE.............................................. 883 DIAGNOSIS AND TESTING................................................................ 883 DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES................................. 883 DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM....................................... 884 DIAGNOSIS AND TESTING - INJECTOR LEAK QUANTITY................................... 884 STANDARD PROCEDURE................................................................... 885 STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS............................ 885 STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER............................ 885 STANDARD PROCEDURE - LOW PRESSURE FUEL PUMP TEST................................. 885 FUEL DELIVERY............................................................................ 887 DESCRIPTION.......................................................................... 887 OPERATION............................................................................ 887 Start of Actuation............................................................... 888 Switching Off Main Injection..................................................... 888 Calculating Main Injection....................................................... 888 Period of Actuation.............................................................. 889 Deceleration Mode................................................................ 889 Full Load Injected Quantity...................................................... 889 Limiting Maximum Engine Speed.................................................... 889 Fuel Quantity Control............................................................ 889 Boiling Protection............................................................... 889 Fuel Tank Protection............................................................. 889 SPECIFICATIONS....................................................................... 889 TORQUE........................................................................... 889 SPECIAL TOOLS........................................................................ 890 FUEL SYSTEM...................................................................... 890 FUEL DRAIN TUBES..................................................................... 890 DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS................................. 890 LOW-PRESSURE LINES........................................................... 890 HIGH-PRESSURE LINES.......................................................... 890 FUEL FILTER.......................................................................... 890 DESCRIPTION...................................................................... 890 REMOVAL.......................................................................... 890 INSTALLATION..................................................................... 891 FUEL LINES........................................................................... 891 REMOVAL - HIGH PRESSURE LINES.................................................... 891 INSTALLATION - HIGH PRESSURE LINES............................................... 891 FUEL RAIL PRESSURE SENSOR............................................................ 892 DESCRIPTION...................................................................... 892 OPERATION........................................................................ 892 REMOVAL.......................................................................... 892 INSTALLATION..................................................................... 893 FUEL PUMP............................................................................ 893 DESCRIPTION...................................................................... 893 DESCRIPTION - HIGH PRESSURE PUMP............................................. 893 DESCRIPTION - LOW PRESSURE PUMP.............................................. 893 OPERATION........................................................................ 893 LOW PRESSURE SIDE............................................................ 893 HIGH PRESSURE SIDE........................................................... 895 OPERATION - LOW PRESSURE PUMP................................................ 895 REMOVAL - HIGH PRESSURE PUMP..................................................... 896 INSTALLATION - HIGH PRESSURE PUMP................................................ 896 FUEL PUMP MODULE..................................................................... 897 DESCRIPTION...................................................................... 897 REMOVAL.......................................................................... 897 INSTALLATION..................................................................... 898 FUEL QUANTITY CONTROL VALVE.......................................................... 899 DESCRIPTION...................................................................... 899 OPERATION........................................................................ 899 REMOVAL.......................................................................... 900 INSTALLATION..................................................................... 900 FUEL RAIL............................................................................ 900 DESCRIPTION...................................................................... 900 OPERATION........................................................................ 900 REMOVAL.......................................................................... 900 INSTALLATION..................................................................... 901 FUEL TANK............................................................................ 902 DESCRIPTION...................................................................... 902 REMOVAL.......................................................................... 902 INSTALLATION..................................................................... 904 FUEL LEVEL SENDING UNIT / SENSOR..................................................... 906 DESCRIPTION...................................................................... 906 REMOVAL.......................................................................... 906 INSTALLATION..................................................................... 906 WATER IN FUEL SENSOR................................................................. 907 DESCRIPTION...................................................................... 907 OPERATION........................................................................ 907 19-STEERING.................................................................................. 925 STEERING................................................................................. 925 DESCRIPTION.......................................................................... 925 OPERATION............................................................................ 925 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM........................................ 926 COLUMN................................................................................... 929 SPECIFICATIONS - TORQUE CHART........................................................ 929 INTERMEDIATE SHAFT................................................................... 929 REMOVAL.......................................................................... 929 INSTALLATION..................................................................... 929 KEY/LOCK CYLINDER.................................................................... 930 REMOVAL.......................................................................... 930 INSTALLATION..................................................................... 931 STEERING WHEEL....................................................................... 931 REMOVAL.......................................................................... 931 INSTALLATION..................................................................... 931 GEAR..................................................................................... 932 DESCRIPTION.......................................................................... 932 REMOVAL.............................................................................. 932 INSTALLATION......................................................................... 932 SPECIFICATIONS - TORQUE CHART........................................................ 933 LINKAGE.................................................................................. 934 DIAGNOSIS AND TESTING - OUTER TIE ROD END............................................ 934 SPECIFICATIONS - TORQUE CHART........................................................ 934 SPECIAL TOOLS........................................................................ 935 FRONT SUSPENSION................................................................. 935 TIE ROD END.......................................................................... 935 REMOVAL.......................................................................... 935 INSTALLATION..................................................................... 935 21-TRANSMISSION.............................................................................. 941 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION........................................ 941 DESCRIPTION.......................................................................... 942 TRANSMISSION IDENTIFICATION...................................................... 942 TRANSMISSION GEAR RATIOS......................................................... 942 TRANSMISSION HOUSING............................................................. 944 MECHANICAL SECTION............................................................... 944 ELECTROHYDRAULIC CONTROL UNIT.................................................... 944 SHIFT GROUPS..................................................................... 944 OPERATION............................................................................ 944 EMERGENCY RUNNING FUNCTION....................................................... 944 CLUTCH APPLICATION............................................................... 945 FIRST GEAR POWERFLOW ............................................................ 946 SECOND GEAR POWERFLOW ........................................................... 948 THIRD GEAR POWERFLOW ............................................................ 950 FOURTH GEAR POWERFLOW ........................................................... 952 FIFTH GEAR POWERFLOW ............................................................ 954 REVERSE GEAR POWERFLOW .......................................................... 956 SHIFT GROUPS/ SHIFT SEQUENCE0 - 4 VA (Continued)............................. 958 DIAGNOSIS AND TESTING................................................................ 970 AUTOMATIC TRANSMISSION........................................................... 970 PRELIMINARY...................................................................... 970 VEHICLE IS DRIVABLE.......................................................... 970 VEHICLE IS DISABLED.......................................................... 970 ROAD TESTING..................................................................... 970 AUTOMATIC TRANSMISSION........................................................... 971 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR.......................................... 974 REMOVAL.............................................................................. 974 DISASSEMBLY.......................................................................... 977 ASSEMBLY............................................................................. 983 INSTALLATION......................................................................... 989 SCHEMATICS AND DIAGRAMS.............................................................. 994 SPECIFICATIONS - NAG1 AUTOMATIC TRANSMISSION.........................................1015 SPECIAL TOOLS - AUTOMATIC TRANSMISSION - NAG1........................................1017 INPUT CLUTCHES.......................................................................1019 DESCRIPTION......................................................................1019 OPERATION........................................................................1020 INPUT CLUTCH K1......................................................................1021 DISASSEMBLY......................................................................1021 ASSEMBLY.........................................................................1021 INPUT CLUTCH K2......................................................................1024 DISASSEMBLY......................................................................1024 ASSEMBLY.........................................................................1026 INPUT CLUTCH K3......................................................................1028 DISASSEMBLY......................................................................1028 ASSEMBLY.........................................................................1030 ELECTROHYDRAULIC UNIT................................................................1032 DESCRIPTION......................................................................1032 ELECTRICAL CONTROL UNIT .....................................................1032 HYDRAULIC CONTROL UNIT.......................................................1032 OPERATION........................................................................1037 ELECTRICAL CONTROL UNIT .....................................................1037 HYDRAULIC CONTROL UNIT.......................................................1038 REMOVAL..........................................................................1043 DISASSEMBLY......................................................................1044 ASSEMBLY.........................................................................1047 INSTALLATION.....................................................................1050 FLUID AND FILTER.....................................................................1052 DESCRIPTION......................................................................1052 OPERATION........................................................................1052 DIAGNOSIS AND TESTING............................................................1052 EFFECTS OF INCORRECT FLUID LEVEL.............................................1052 CAUSES OF BURNT FLUID........................................................1052 FLUID CONTAMINATION..........................................................1053 STANDARD PROCEDURE...............................................................1053 CHECK OIL LEVEL..............................................................1053 TRANSMISSION FILL............................................................1054 FLUID/FILTER SERVICE.........................................................1055 FREEWHEELING CLUTCH..................................................................1056 DESCRIPTION......................................................................1056 OPERATION........................................................................1056 DISASSEMBLY......................................................................1057 ASSEMBLY.........................................................................1058 GEARSHIFT CABLE......................................................................1059 DIAGNOSIS AND TESTING............................................................1059 GEARSHIFT CABLE..............................................................1059 REMOVAL..........................................................................1060 INSTALLATION.....................................................................1060 HOLDING CLUTCHES.....................................................................1061 DESCRIPTION......................................................................1061 OPERATION........................................................................1062 HOLDING CLUTCH B1....................................................................1063 DISASSEMBLY......................................................................1063 ASSEMBLY.........................................................................1064 HOLDING CLUTCH B2....................................................................1067 DISASSEMBLY......................................................................1067 ASSEMBLY.........................................................................1069 INPUT SPEED SENSORS..................................................................1072 DESCRIPTION......................................................................1072 OPERATION........................................................................1073 OIL PUMP.............................................................................1073 DESCRIPTION......................................................................1073 OPERATION........................................................................1073 DISASSEMBLY......................................................................1074 ASSEMBLY.........................................................................1074 OUTPUT SHAFT BEARING.................................................................1074 REMOVAL..........................................................................1074 INSTALLATION.....................................................................1076 OUTPUT SHAFT SEAL....................................................................1077 REMOVAL..........................................................................1077 INSTALLATION.....................................................................1077 PARK LOCK CABLE......................................................................1078 REMOVAL..........................................................................1078 INSTALLATION.....................................................................1079 PISTONS..............................................................................1081 DESCRIPTION......................................................................1081 OPERATION........................................................................1081 PRESSURE.....................................................................1081 PRESSURE ON A CONFINED FLUID.................................................1081 FORCE MULTIPLICATION.........................................................1082 PISTON TRAVEL................................................................1082 PLANETARY GEARTRAIN..................................................................1083 DESCRIPTION......................................................................1083 OPERATION........................................................................1083 DISASSEMBLY......................................................................1083 ASSEMBLY.........................................................................1084 SHIFT MECHANISM......................................................................1085 DESCRIPTION......................................................................1085 OPERATION........................................................................1085 REMOVAL..........................................................................1086 INSTALLATION.....................................................................1088 SOLENOID.............................................................................1089 DESCRIPTION......................................................................1089 UPSHIFT/DOWNSHIFT SOLENOID VALVES ...........................................1089 MODULATING PRESSURE CONTROL SOLENOID VALVE ..................................1089 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE ...........................1090 SHIFT PRESSURE CONTROL SOLENOID VALVE .......................................1090 OPERATION........................................................................1091 UPSHIFT/DOWNSHIFT SOLENOID VALVES ...........................................1091 MODULATING PRESSURE CONTROL SOLENOID VALVE ..................................1092 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE ...........................1092 SHIFT PRESSURE CONTROL SOLENOID VALVE .......................................1093 TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT..............................................1093 DESCRIPTION......................................................................1093 PARK/NEUTRAL CONTACT.........................................................1093 TRANSMISSION TEMPERATURE SENSOR..............................................1093 OPERATION........................................................................1094 PARK/NEUTRAL CONTACT.........................................................1094 TRANSMISSION TEMPERATURE SENSOR..............................................1094 TORQUE CONVERTER.....................................................................1095 DESCRIPTION......................................................................1095 IMPELLER ....................................................................1096 TURBINE .....................................................................1097 STATOR ......................................................................1098 TORQUE CONVERTER CLUTCH (TCC) ...............................................1098 OPERATION........................................................................1099 TURBINE......................................................................1099 STATOR ......................................................................1099 TORQUE CONVERTER CLUTCH (TCC) ...............................................1100 REMOVAL..........................................................................1100 INSTALLATION.....................................................................1100 TORQUE CONVERTER HUB SEAL............................................................1101 REMOVAL..........................................................................1101 INSTALLATION.....................................................................1101 22-TIRES/WHEELS..............................................................................1103 TIRES/WHEELS.............................................................................1103 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT........................................1103 METHOD 1 (RELOCATE WHEEL ON HUB).................................................1104 METHOD 2 (RELOCATE TIRE ON WHEEL)................................................1104 STANDARD PROCEDURE...................................................................1104 STANDARD PROCEDURE - MATCH MOUNTING..............................................1104 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE......................................1105 STANDARD PROCEDURE - TIRE ROTATION...............................................1107 SPECIFICATIONS.......................................................................1107 TORQUE CHART.....................................................................1107 TIRES....................................................................................1108 DESCRIPTION..........................................................................1108 DESCRIPTION - TIRES..............................................................1108 TIRE IDENTIFICATION..........................................................1108 TIRE CHAINS..................................................................1108 DESCRIPTION - RADIAL – PLY TIRES.................................................1108 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEEDS......................................1108 DESCRIPTION - REPLACEMENT TIRES..................................................1109 DESCRIPTION - TIRE INFLATION PRESSURES...........................................1109 DIAGNOSIS AND TESTING................................................................1110 DIAGNOSIS AND TESTING - PRESSURE GAUGES..........................................1110 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION..................................1110 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS....................................1110 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS.......................................1110 DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD........................................1110 STANDARD PROCEDURE - REPAIRING LEAKS.................................................1112 CLEANING.............................................................................1112 SPECIFICATIONS.......................................................................1112 TIRES............................................................................1112 SPARE TIRE CARRIER.......................................................................1112 REMOVAL..............................................................................1112 INSTALLATION.........................................................................1112 WHEELS...................................................................................1113 DESCRIPTION..........................................................................1113 OPERATION............................................................................1113 DIAGNOSIS AND TESTING................................................................1113 WHEEL INSPECTION.................................................................1113 STANDARD PROCEDURE...................................................................1113 STANDARD PROCEDURE - WHEEL REPLACEMENT...........................................1113 STANDARD PROCEDURE - DUAL REAR WHEEL INSTALLATION................................1114 REMOVAL..............................................................................1115 INSTALLATION.........................................................................1115 23-BODY......................................................................................1117 BODY.....................................................................................1117 WARNING..............................................................................1117 SAFETY PRECAUTIONS AND WARNINGS..................................................1117 DIAGNOSIS AND TESTING................................................................1117 DIAGNOSIS AND TESTING - WATER LEAKS..............................................1117 VISUAL INSPECTION BEFORE WATER LEAK TESTS....................................1118 WATER LEAK TESTS.............................................................1118 WATER LEAK DETECTION.........................................................1118 DIAGNOSIS AND TESTING - WIND NOISE...............................................1118 VISUAL INSPECTION BEFORE TESTS...............................................1118 STANDARD PROCEDURE...................................................................1119 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR...................................1119 Rigid Plastics:..............................................................1119 Semi-Rigid Plastics:.........................................................1119 Flexible Plastics:...........................................................1119 Repair Procedure:............................................................1119 Adhesion Promoter/Surface Modifier:..........................................1119 SAFETY PRECAUTION AND WARNINGS...............................................1119 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES..........................1120 PANEL SECTIONING.............................................................1122 PANEL REINFORCEMENT..........................................................1122 VISUAL INSPECTION............................................................1123 PANEL SURFACE PREPARATION....................................................1123 PATCHING PANELS..............................................................1123 PANEL PATCH FABRICATIONS.....................................................1123 PANEL PATCH INSTALLATION.....................................................1124 PATCHED PANEL SURFACING......................................................1126 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE.......................................1126 SPECIFICATIONS.......................................................................1128 DOOR - FRONT.............................................................................1129 CHECK................................................................................1129 REMOVAL..........................................................................1129 INSTALLATION.....................................................................1129 DOOR.................................................................................1130 REMOVAL..........................................................................1130 INSTALLATION.....................................................................1130 ADJUSTMENTS......................................................................1131 ADJUSTMENT...................................................................1131 DOOR GLASS...........................................................................1131 REMOVAL..........................................................................1131 INSTALLATION.....................................................................1131 EXTERIOR HANDLE......................................................................1132 REMOVAL..........................................................................1132 INSTALLATION.....................................................................1132 HINGE................................................................................1133 REMOVAL..........................................................................1133 INSTALLATION.....................................................................1133 LATCH................................................................................1134 REMOVAL..........................................................................1134 INSTALLATION.....................................................................1134 LATCH STRIKER........................................................................1134 REMOVAL..........................................................................1134 INSTALLATION.....................................................................1134 LOCK CYLINDER........................................................................1134 REMOVAL..........................................................................1134 INSTALLATION.....................................................................1134 TRIM PANEL...........................................................................1135 REMOVAL..........................................................................1135 INSTALLATION.....................................................................1136 WINDOW REGULATOR - POWER.............................................................1136 REMOVAL..........................................................................1136 INSTALLATION.....................................................................1137 WINDOW REGULATOR - MANUAL............................................................1138 REMOVAL..........................................................................1138 INSTALLATION.....................................................................1139 DOORS - REAR.............................................................................1140 CHECK................................................................................1140 REMOVAL..........................................................................1140 INSTALLATION.....................................................................1140 DOOR.................................................................................1141 REMOVAL..........................................................................1141 DISASSEMBLY......................................................................1142 RIGHT DOOR ..................................................................1142 LEFT DOOR ...................................................................1143 ASSEMBLY.........................................................................1144 RIGHT DOOR ..................................................................1144 LEFT DOOR ...................................................................1145 INSTALLATION.....................................................................1146 ADJUSTMENTS......................................................................1146 ADJUSTMENT...................................................................1146 DOOR GLASS...........................................................................1147 REMOVAL..........................................................................1147 INSTALLATION.....................................................................1147 EXTERIOR HANDLE......................................................................1148 REMOVAL..........................................................................1148 INSTALLATION.....................................................................1149 HINGE................................................................................1150 REMOVAL..........................................................................1150 INSTALLATION.....................................................................1150 INSIDE HANDLE ACTUATOR...............................................................1150 REMOVAL..........................................................................1150 INSTALLATION.....................................................................1150 LATCH................................................................................1150 REMOVAL..........................................................................1150 INSTALLATION.....................................................................1151 TRIM PANEL...........................................................................1151 REMOVAL..........................................................................1151 INSTALLATION.....................................................................1151 DOORS - SLIDING..........................................................................1152 EXTERIOR HANDLE......................................................................1152 REMOVAL..........................................................................1152 INSTALLATION.....................................................................1152 INSIDE HANDLE ACTUATOR...............................................................1153 REMOVAL..........................................................................1153 INSTALLATION.....................................................................1153 UPPER ROLLER ARM.....................................................................1153 REMOVAL..........................................................................1153 INSTALLATION.....................................................................1153 CENTER ROLLER ARM....................................................................1153 REMOVAL..........................................................................1153 INSTALLATION.....................................................................1154 LOWER ROLLER ARM.....................................................................1154 REMOVAL..........................................................................1154 INSTALLATION.....................................................................1154 CENTER TRACK.........................................................................1154 REMOVAL..........................................................................1154 INSTALLATION.....................................................................1155 LATCH / LOCK CONTROL.................................................................1155 REMOVAL..........................................................................1155 INSTALLATION.....................................................................1156 REAR LATCH...........................................................................1156 REMOVAL..........................................................................1156 INSTALLATION.....................................................................1156 REAR LATCH STRIKER...................................................................1157 REMOVAL..........................................................................1157 INSTALLATION.....................................................................1157 SLIDING DOOR.........................................................................1157 REMOVAL..........................................................................1157 DISASSEMBLY......................................................................1158 ASSEMBLY.........................................................................1159 INSTALLATION.....................................................................1160 ADJUSTMENTS......................................................................1160 ADJUSTMENT...................................................................1160 Gaps and Ridge Adjustment................................................1160 Flush Adjustment.........................................................1161 Door Stop Bumper Adjust..................................................1161 STABILIZER...........................................................................1161 REMOVAL..........................................................................1161 INSTALLATION.....................................................................1161 TRIM PANEL...........................................................................1162 REMOVAL..........................................................................1162 Upper........................................................................1162 Lower........................................................................1162 INSTALLATION.....................................................................1162 Upper........................................................................1162 Lower........................................................................1162 DOOR GLASS...........................................................................1162 REMOVAL..........................................................................1162 INSTALLATION.....................................................................1162 EXTERIOR.................................................................................1163 FUEL FILL DOOR.......................................................................1163 REMOVAL..........................................................................1163 INSTALLATION.....................................................................1163 GRILLE...............................................................................1163 REMOVAL..........................................................................1163 INSTALLATION.....................................................................1163 LICENSE PLATE BRACKET................................................................1163 REMOVAL..........................................................................1163 INSTALLATION.....................................................................1163 RADIATOR CROSSMEMBER.................................................................1163 REMOVAL..........................................................................1163 INSTALLATION.....................................................................1164 SIDE VIEW MIRROR.....................................................................1164 REMOVAL..........................................................................1164 Driver's Side................................................................1164 Passenger Side...............................................................1164 INSTALLATION.....................................................................1164 Driver's Side................................................................1164 Passenger Side...............................................................1165 SIDE VIEW MIRROR - GLASS.............................................................1165 REMOVAL..........................................................................1165 INSTALLATION.....................................................................1165 HOOD.....................................................................................1166 HINGE................................................................................1166 REMOVAL..........................................................................1166 INSTALLATION.....................................................................1166 REMOVAL..............................................................................1166 INSTALLATION.........................................................................1166 ADJUSTMENTS..........................................................................1167 ADJUSTMENT.......................................................................1167 LATCH................................................................................1167 REMOVAL..........................................................................1167 INSTALLATION.....................................................................1167 LATCH RELEASE CABLE..................................................................1167 REMOVAL..........................................................................1167 INSTALLATION.....................................................................1167 LATCH RELEASE HANDLE.................................................................1168 REMOVAL..........................................................................1168 INSTALLATION.....................................................................1168 PROP ROD.............................................................................1168 REMOVAL..........................................................................1168 INSTALLATION.....................................................................1168 SAFETY LATCH.........................................................................1168 REMOVAL..........................................................................1168 INSTALLATION.....................................................................1168 INSTRUMENT PANEL.........................................................................1169 CLUSTER BEZEL........................................................................1169 REMOVAL..........................................................................1169 INSTALLATION.....................................................................1170 ACCESSORY SWITCH BEZEL...............................................................1170 REMOVAL..........................................................................1170 INSTALLATION.....................................................................1170 INSTRUMENT PANEL CENTER BEZEL........................................................1171 REMOVAL..........................................................................1171 INSTALLATION.....................................................................1171 ASH RECEIVER.........................................................................1171 REMOVAL..........................................................................1171 INSTALLATION.....................................................................1171 CUP HOLDER...........................................................................1171 REMOVAL..........................................................................1171 INSTALLATION.....................................................................1172 GLOVE BOX............................................................................1172 REMOVAL..........................................................................1172 INSTALLATION.....................................................................1172 INSTRUMENT PANEL ASSEMBLY............................................................1173 REMOVAL..........................................................................1173 INSTALLATION.....................................................................1177 TOP COVER - CLUSTER..................................................................1178 REMOVAL..........................................................................1178 INSTALLATION.....................................................................1178 TOP COVER - TRAY.....................................................................1179 REMOVAL..........................................................................1179 INSTALLATION.....................................................................1180 TOP COVER............................................................................1180 REMOVAL..........................................................................1180 INSTALLATION.....................................................................1181 STEERING COLUMN OPENING COVER........................................................1182 REMOVAL..........................................................................1182 INSTALLATION.....................................................................1182 INTERIOR.................................................................................1183 CAUTION..............................................................................1183 A-PILLAR TRIM........................................................................1183 REMOVAL..........................................................................1183 INSTALLATION.....................................................................1184 ASSIST HANDLE........................................................................1184 REMOVAL..........................................................................1184 INSTALLATION.....................................................................1184 B-PILLAR TRIM........................................................................1184 REMOVAL..........................................................................1184 INSTALLATION.....................................................................1185 BULKHEAD TRIM PANEL..................................................................1185 REMOVAL..........................................................................1185 INSTALLATION.....................................................................1185 CARPETS AND FLOOR MATS...............................................................1185 REMOVAL..........................................................................1185 Cargo/Passenger Van - Front..................................................1185 Passenger Van - Rear.........................................................1185 Cargo Van - Rear.............................................................1186 INSTALLATION.....................................................................1186 Cargo/Passenger Van - Front..................................................1186 Passenger Van - Rear.........................................................1186 Cargo Van - Rear.............................................................1186 COWL TRIM............................................................................1186 REMOVAL..........................................................................1186 INSTALLATION.....................................................................1186 D-PILLAR TRIM........................................................................1186 REMOVAL..........................................................................1186 INSTALLATION.....................................................................1186 HEADLINER............................................................................1186 REMOVAL..........................................................................1186 Cab Section..................................................................1186 Number 2 Section.............................................................1186 Number 3 Section.............................................................1186 Number 4 Section.............................................................1187 INSTALLATION.....................................................................1187 Cab Section..................................................................1187 Number 2 Section.............................................................1187 Number 3 Section.............................................................1187 Number 4 Section.............................................................1187 QUARTER TRIM PANEL...................................................................1187 REMOVAL..........................................................................1187 Passenger Van................................................................1187 Cargo Van....................................................................1188 INSTALLATION.....................................................................1188 Passenger Van................................................................1188 Cargo Van....................................................................1188 REAR VIEW MIRROR.....................................................................1188 REMOVAL..........................................................................1188 INSTALLATION.....................................................................1188 INSTALLATION - REAR VIEW MIRROR SUPPORT BRACKET..............................1188 STEPWELL SCUFF PADS..................................................................1188 REMOVAL..........................................................................1188 INSTALLATION.....................................................................1189 SUN VISOR............................................................................1189 REMOVAL..........................................................................1189 INSTALLATION.....................................................................1189 PAINT....................................................................................1190 SPECIFICATIONS - PAINT CODES.........................................................1190 BASECOAT/CLEARCOAT FINISH............................................................1190 DESCRIPTION......................................................................1190 PAINT TOUCH-UP.......................................................................1190 DESCRIPTION......................................................................1190 STANDARD PROCEDURE - PAINT TOUCH-UP..............................................1191 FINESSE SANDING/BUFFING & POLISH.....................................................1191 DESCRIPTION......................................................................1191 SEATS....................................................................................1192 ARMREST..............................................................................1192 REMOVAL..........................................................................1192 INSTALLATION.....................................................................1192 HEADREST.............................................................................1192 REMOVAL..........................................................................1192 INSTALLATION.....................................................................1192 SEAT - FRONT.........................................................................1193 REMOVAL..........................................................................1193 INSTALLATION.....................................................................1193 SEAT BACK - FRONT....................................................................1193 REMOVAL..........................................................................1193 INSTALLATION.....................................................................1193 SEAT CUSHION - FRONT.................................................................1194 REMOVAL..........................................................................1194 INSTALLATION.....................................................................1194 SEAT ADJUSTERS - FRONT...............................................................1194 REMOVAL..........................................................................1194 INSTALLATION.....................................................................1194 SEAT - REAR..........................................................................1195 REMOVAL..........................................................................1195 INSTALLATION.....................................................................1195 REAR SEAT BACK SHIELD................................................................1195 REMOVAL..........................................................................1195 INSTALLATION.....................................................................1195 SEAT BACK CUSHION/COVER - REAR.......................................................1196 REMOVAL..........................................................................1196 INSTALLATION.....................................................................1196 SEAT CUSHION/COVER - REAR............................................................1196 REMOVAL..........................................................................1196 INSTALLATION.....................................................................1196 STATIONARY GLASS.........................................................................1197 BACKLITE - BULKHEAD TRIM PANEL.......................................................1197 REMOVAL..........................................................................1197 INSTALLATION.....................................................................1197 QUARTER WINDOW.......................................................................1197 REMOVAL..........................................................................1197 INSTALLATION.....................................................................1197 WINDSHIELD...........................................................................1198 WARNING..........................................................................1198 WINDSHIELD SAFETY PRECAUTIONS................................................1198 REMOVAL..........................................................................1198 INSTALLATION.....................................................................1199 Windshield Preparation - Installing A Previously Installed Windshield........1200 Windshield Preparation - Installing A New Windshield.........................1201 Windshield Opening Preparation...............................................1201 Windshield Installation......................................................1201 WEATHERSTRIP/SEALS.......................................................................1203 FRONT DOOR INNER BELT WEATHERSTRIP...................................................1203 REMOVAL..........................................................................1203 INSTALLATION.....................................................................1203 FRONT DOOR OUTER BELT WEATHERSTRIP...................................................1203 REMOVAL..........................................................................1203 INSTALLATION.....................................................................1203 DOOR OPENING SEALS...................................................................1203 REMOVAL..........................................................................1203 INSTALLATION.....................................................................1203 24-HEATING & AIR CONDITIONING................................................................1207 HEATING & AIR CONDITIONING...............................................................1207 DESCRIPTION..........................................................................1207 OPERATION............................................................................1208 DIAGNOSIS AND TESTING................................................................1209 A/C PERFORMANCE TEST.............................................................1209 HEATER PERFORMANCE TEST..........................................................1210 MAXIMUM HEATER OUTPUT........................................................1210 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.......................1210 POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT.............................1210 TEMPERATURE CONTROL..........................................................1210 ATC FUNCTION TEST................................................................1210 SPECIFICATIONS.......................................................................1211 A/C SYSTEM.......................................................................1211 FASTENER TORQUE..................................................................1212 CONTROLS.................................................................................1213 A/C COMPRESSOR CLUTCH................................................................1213 DESCRIPTION......................................................................1213 OPERATION........................................................................1213 STANDARD PROCEDURE...............................................................1214 A/C COMPRESSOR CLUTCH AIR GAP................................................1214 A/C COMPRESSOR CLUTCH BREAK-IN...............................................1214 REMOVAL..........................................................................1214 INSPECTION.......................................................................1215 INSTALLATION.....................................................................1216 A/C COMPRESSOR CLUTCH COIL...........................................................1217 DIAGNOSIS AND TESTING............................................................1217 A/C COMPRESSOR CLUTCH COIL...................................................1217 A/C HEATER CONTROL...................................................................1217 DESCRIPTION......................................................................1217 OPERATION........................................................................1217 REMOVAL..........................................................................1218 INSTALLATION.....................................................................1218 A/C PRESSURE TRANSDUCER..............................................................1218 DESCRIPTION......................................................................1218 OPERATION........................................................................1218 DIAGNOSIS AND TESTING............................................................1219 A/C PRESSURE TRANSDUCER......................................................1219 REMOVAL..........................................................................1220 INSTALLATION.....................................................................1220 AIR OUTLET TEMPERATURE SENSOR........................................................1220 DESCRIPTION......................................................................1220 OPERATION........................................................................1220 REMOVAL..........................................................................1220 INSTALLATION.....................................................................1221 AMBIENT TEMPERATURE SENSOR...........................................................1221 DESCRIPTION......................................................................1221 OPERATION........................................................................1221 REMOVAL..........................................................................1221 INSTALLATION.....................................................................1221 BLOWER MOTOR RESISTOR BLOCK..........................................................1222 DESCRIPTION......................................................................1222 OPERATION........................................................................1222 DIAGNOSIS AND TESTING............................................................1222 BLOWER MOTOR RESISTOR BLOCK..................................................1222 REMOVAL..........................................................................1222 INSTALLATION.....................................................................1222 BLOWER MOTOR SWITCH..................................................................1223 DESCRIPTION......................................................................1223 OPERATION........................................................................1223 DIAGNOSIS AND TESTING............................................................1223 BLOWER MOTOR SWITCH..........................................................1223 EVAPORATOR TEMPERATURE SENSOR........................................................1223 DESCRIPTION......................................................................1223 OPERATION........................................................................1223 REMOVAL..........................................................................1223 INSTALLATION.....................................................................1224 IN-CAR TEMPERATURE SENSOR............................................................1224 DESCRIPTION......................................................................1224 OPERATION........................................................................1224 DIAGNOSIS AND TESTING............................................................1225 IN-CAR TEMPERATURE SENSOR....................................................1225 MODE DOOR CABLES.....................................................................1225 REMOVAL..........................................................................1225 INSTALLATION.....................................................................1225 RECIRCULATION DOOR ACTUATOR..........................................................1226 DESCRIPTION......................................................................1226 OPERATION........................................................................1226 REMOVAL..........................................................................1226 INSTALLATION.....................................................................1226 DISTRIBUTION.............................................................................1227 AIR FILTER...........................................................................1227 REMOVAL..........................................................................1227 INSTALLATION.....................................................................1227 AIR OUTLETS..........................................................................1227 REMOVAL..........................................................................1227 INSTALLATION.....................................................................1228 BLOWER MOTOR.........................................................................1229 REMOVAL..........................................................................1229 INSTALLATION.....................................................................1229 DEFROSTER DUCTS......................................................................1229 REMOVAL..........................................................................1229 INSTALLATION.....................................................................1229 FLOOR DISTRIBUTION DUCTS.............................................................1230 REMOVAL..........................................................................1230 INSTALLATION.....................................................................1230 HVAC HOUSING.........................................................................1230 REMOVAL..........................................................................1230 DISASSEMBLY......................................................................1231 ASSEMBLY.........................................................................1232 INSTALLATION.....................................................................1232 INSTRUMENT PANEL DUCTS...............................................................1234 REMOVAL..........................................................................1234 INSTALLATION.....................................................................1234 PLUMBING.................................................................................1235 DESCRIPTION..........................................................................1235 OPERATION............................................................................1236 WARNING..............................................................................1236 ENGINE COOLING SYSTEM............................................................1236 A/C SYSTEM.......................................................................1236 CAUTION - A/C SYSTEM.................................................................1236 DIAGNOSIS AND TESTING................................................................1237 REFRIGERANT SYSTEM LEAKS.........................................................1237 SYSTEM EMPTY.................................................................1237 SYSTEM LOW...................................................................1237 STANDARD PROCEDURE...................................................................1237 REFRIGERANT SYSTEM SERVICE EQUIPMENT.............................................1237 MANIFOLD GAUGE SET CONNECTIONS...............................................1238 REFRIGERANT SYSTEM RECOVERY......................................................1238 REFRIGERANT SYSTEM EVACUATE......................................................1238 REFRIGERANT SYSTEM CHARGE........................................................1239 PARTIAL CHARGE METHOD........................................................1239 A/C COMPRESSOR.......................................................................1240 DESCRIPTION......................................................................1240 OPERATION........................................................................1240 DIAGNOSIS AND TESTING............................................................1240 A/C COMPRESSOR NOISE.........................................................1240 REMOVAL..........................................................................1241 DENSO 7SBU16C A/C COMPRESSOR.................................................1241 DENSO 10S17 A/C COMPRESSOR...................................................1242 INSTALLATION.....................................................................1242 DENSO 7SBU16C A/C COMPRESSOR.................................................1242 DENSO 10S17 A/C COMPRESSOR...................................................1243 A/C CONDENSER........................................................................1243 DESCRIPTION......................................................................1243 OPERATION........................................................................1243 REMOVAL..........................................................................1244 INSTALLATION.....................................................................1244 A/C DISCHARGE LINE...................................................................1245 REMOVAL..........................................................................1245 INSTALLATION.....................................................................1245 A/C EVAPORATOR.......................................................................1246 DESCRIPTION......................................................................1246 OPERATION........................................................................1246 REMOVAL..........................................................................1246 INSTALLATION.....................................................................1246 A/C EXPANSION VALVE0 - 6 VA (Continued)..........................................1247 DESCRIPTION......................................................................1247 OPERATION........................................................................1247 DIAGNOSIS AND TESTING............................................................1247 A/C EXPANSION VALVE..........................................................1247 REMOVAL..........................................................................1247 INSTALLATION.....................................................................1247 ELECTRIC COOLANT PUMP................................................................1248 DESCRIPTION......................................................................1248 OPERATION........................................................................1248 REMOVAL..........................................................................1248 INSTALLATION.....................................................................1249 HEATER CORE..........................................................................1249 DESCRIPTION......................................................................1249 OPERATION........................................................................1249 REMOVAL..........................................................................1249 INSTALLATION.....................................................................1250 LIQUID LINE..........................................................................1250 REMOVAL..........................................................................1250 INSTALLATION.....................................................................1251 RECEIVER/DRIER.......................................................................1252 DESCRIPTION......................................................................1252 OPERATION........................................................................1252 REMOVAL..........................................................................1252 INSTALLATION.....................................................................1252 REFRIGERANT..........................................................................1253 DESCRIPTION......................................................................1253 OPERATION........................................................................1253 REFRIGERANT OIL......................................................................1253 DESCRIPTION......................................................................1253 OPERATION........................................................................1253 STANDARD PROCEDURE...............................................................1253 REFRIGERANT OIL LEVEL........................................................1253 SUCTION LINE.........................................................................1254 REMOVAL..........................................................................1254 INSTALLATION.....................................................................1255 WATER VALVE..........................................................................1255 REMOVAL..........................................................................1255 INSTALLATION.....................................................................1255 25-EMISSIONS CONTROL.........................................................................1265 EVAPORATIVE EMISSIONS....................................................................1265 CRANKCASE VENTILATION HEATER.........................................................1265 REMOVAL..........................................................................1265 INSTALLATION.....................................................................1265 CRANKCASE VENTILATION BREATHER.......................................................1266 DESCRIPTION......................................................................1266 REMOVAL..........................................................................1266 INSTALLATION.....................................................................1266 EXHAUST GAS RECIRCULATION................................................................1268 DESCRIPTION..........................................................................1268 VALVE................................................................................1270 DESCRIPTION......................................................................1270 OPERATION........................................................................1270 REMOVAL..........................................................................1270 INSTALLATION.....................................................................1271 VALVE COOLER.........................................................................1271 DESCRIPTION......................................................................1271 INDEX........................................................................................1273 COMMENTS.....................................................................................1275
G.B 05/04/25
