Sprinter 2005 VA Service Manual – PDF DOWNLOAD

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Sprinter 2005 VA Service Manual – PDF DOWNLOAD

FILE DETAILS:

Sprinter 2005 VA Service Manual – PDF DOWNLOAD

Language : English
Pages : 1232
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Sprinter 2005 VA Service Manual – PDF DOWNLOAD

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 0
DESCRIPTION 0
0-LUBRICATION & MAINTENANCE 11
FLUID TYPES 11
DESCRIPTION 11
DESCRIPTION – FUEL REQUIREMENTS – DIESEL ENGINE 11
DESCRIPTION 11
DESCRIPTION – ENGINE COOLANT 11
ETHYLENE-GLYCOL MIXTURES 11
PROPYLENE-GLYCOL MIXTURES 12
DESCRIPTION – HOAT COOLANT 12
COOLANT PERFORMANCE 12
COOLANT SELECTION AND ADDITIVES 13
DESCRIPTION – AXLE 13
REAR AXLE 13
DESCRIPTION – BRAKE FLUID 13
BRAKE FLUID 13
DESCRIPTION – POWER STEERING FLUID 13
POWER STEERING FLUID 13
DESCRIPTION – ENGINE OIL – DIESEL ENGINES 13
SAE VISCOSITY GRADE 13
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID – NAG1 14
FLUID ADDITIVES 14
OPERATION – AUTOMATIC TRANSMISSION FLUID 14
FLUID CAPACITIES 14
SPECIFICATIONS – FLUID CAPACITIES 14
FLUID FILL/CHECK LOCATIONS 14
INSPECTION – FLUID FILL/CHECK LOCATIONS 14
PARTS & LUBRICANT RECOMMENDATION 15
STANDARD PROCEDURE – PARTS & LUBRICANT RECOMMENDATIONS 15
HOISTING 15
STANDARD PROCEDURE – HOISTING 15
FLOOR JACK 15
HOIST 15
JUMP STARTING 16
STANDARD PROCEDURE – JUMP STARTING 16
TO JUMP START A DISABLED VEHICLE: 16
DISCONNECT CABLE CLAMPS AS FOLLOWS: 16
TOWING 16
STANDARD PROCEDURE – TOWING 16
If the Engine is Damaged 17
If the Transmission is Damaged 17
If the Front Axle is Damaged 17
If the Rear Axle is Damaged 17
SAFETY PRECAUTIONS 17
GROUND CLEARANCE 17
RAMP ANGLE 17
TOWING WHEN KEYS ARE NOT AVAILABLE 17
MAINTENANCE SCHEDULES 17
DESCRIPTION 17
MAINTENANCE – WITHOUT ASSYST MAINTENANCE COMPUTER 17
MAINTENANCE – WITH ASSYST MAINTENANCE COMPUTER 18
REGULAR CHECK-UPS 18
SPECIAL MAINTENANCE REQUIREMENTS 18
ENGINE OIL CHANGE AND FILTER REPLACEMENT 18
SCOPE OF WORK FOR MAINTENANCE SERVICE 18
ADDITIONAL MAINTENANCE WORK 19
ADDITIONAL MAINTENANCE WORK AFTER YEARS 19
INTERNATIONAL SYMBOLS 19
DESCRIPTION 19
2-SUSPENSION 21
FRONT 21
FRONT 22
SPECIFICATIONS – TORQUE CHART 22
SPECIAL TOOLS 22
FRONT SUSPENSION 22
BUSHINGS 23
REMOVAL 23
INSTALLATION 23
HUB / BEARING 24
DIAGNOSIS AND TESTING – 24
REMOVAL 24
INSTALLATION 25
KNUCKLE 25
REMOVAL 25
INSTALLATION 25
LOWER BALL JOINT 26
REMOVAL 26
INSTALLATION 26
LOWER CONTROL ARM 26
REMOVAL 26
INSTALLATION 26
SPRING 27
REMOVAL 27
INSTALLATION 28
SPRING CLAMP PLATES 28
REMOVAL 28
INSTALLATION 28
SPRING STOP PLATES 29
REMOVAL 29
INSTALLATION 29
STABILIZER BAR 29
DESCRIPTION 29
OPERATION 29
REMOVAL 29
INSTALLATION 29
STABILIZER LINK 29
REMOVAL 29
INSTALLATION 29
STRUT 30
REMOVAL 30
INSTALLATION 30
REAR 31
REAR 31
DESCRIPTION 31
DIAGNOSIS AND TESTING – SPRING AND SHOCK 31
SPECIFICATIONS – TORQUE CHART 32
SHOCK 33
DIAGNOSIS AND TESTING – SHOCK 33
REMOVAL 33
INSTALLATION 33
SPRING 34
DESCRIPTION 34
OPERATION 34
REMOVAL 34
REMOVAL – (SRW) 34
REMOVAL – (DRW) 34
INSTALLATION 34
INSTALLATION – (SRW) 34
INSTALLATION – (DRW) 35
SPRING SHACKLE 35
REMOVAL 35
INSTALLATION 35
STABILIZER BAR 35
REMOVAL 35
INSTALLATION 35
STABILIZER LINK 36
REMOVAL 36
INSTALLATION 36
WHEEL ALIGNMENT 37
WHEEL ALIGNMENT 37
DESCRIPTION 37
DIAGNOSIS AND TESTING – PRE-ALIGNMENT INSPECTION 37
STANDARD PROCEDURE – TOE ADJUSTMENT 39
SPECIFICATIONS 39
3-DIFFERENTIAL & DRIVELINE 41
PROPELLER SHAFT 41
PROPELLER SHAFT 41
DIAGNOSIS AND TESTING 41
PROPELLER SHAFT VIBRATION 41
PROPELLER SHAFT BALANCE 42
PROPELLER SHAFT RUNOUT 43
STANDARD PROCEDURE 43
PROPELLER SHAFT ANGLE 43
TWO/THREE-PIECE PROPELLER SHAFT 44
SPECIFICATIONS 45
SPECIAL TOOLS 45
PROPELLER SHAFT 46
REMOVAL 46
INSTALLATION 46
CENTER BEARING 48
REMOVAL 48
INSTALLATION 49
REAR AXLE 50
REAR AXLE 50
DESCRIPTION 50
OPERATION 50
DIAGNOSIS AND TESTING 50
GEAR NOISE 50
BEARING NOISE 50
LOW SPEED KNOCK 51
VIBRATION 51
DRIVELINE SNAP 51
STANDARD PROCEDURE – DRAIN AND FILL 51
REMOVAL 51
INSTALLATION 52
SPECIFICATIONS 53
SPECIAL TOOLS 54
AXLE SHAFTS 55
REMOVAL 55
INSTALLATION 55
AXLE BEARINGS/SEALS 57
REMOVAL 57
INSTALLATION 57
AXLE SHAFTS – DUAL REAR WHEELS 59
REMOVAL 59
INSTALLATION 59
AXLE HUB BEARINGS/SEALS 60
REMOVAL 60
INSTALLATION 60
PINION SEAL 62
REMOVAL 62
INSTALLATION 62
5-BRAKES 65
BRAKES – BASE 65
BRAKES – BASE 66
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 66
PRELIMINARY BRAKE CHECK 66
ROAD TESTING 67
BRAKE NOISES 68
STANDARD PROCEDURE 68
STANDARD PROCEDURE – MANUAL BLEEDING 68
STANDARD PROCEDURE – PRESSURE BLEEDING 69
HYDRAULIC/MECHANICAL 69
SPECIFICATIONS 69
SPECIFICATIONS – TORQUE CHART 69
BASE BRAKE 70
SPECIAL TOOLS 71
BRAKES 71
BRAKE LINES 72
STANDARD PROCEDURE 72
STANDARD PROCEDURE – ISO FLARING 72
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 72
BRAKE PADS/SHOES 73
REMOVAL 73
REMOVAL – FRONT (SRW) 73
REMOVAL – FRONT (DRW) 73
REMOVAL – REAR (16” WHEELS) (SRW) 73
REMOVAL – REAR (15” WHEELS) (SRW) 73
REMOVAL – REAR (DRW) 74
INSTALLATION 74
INSTALLATION – FRONT (SRW) 74
INSTALLATION – FRONT (DRW) 75
INSTALLATION – REAR (16” WHEELS) (SRW) 75
INSTALLATION – REAR (16” WHEELS) (SRW) 75
INSTALLATION – REAR (DRW) 75
DISC BRAKE CALIPERS 75
REMOVAL 75
REMOVAL – FRONT (SRW) 75
REMOVAL – FRONT (DRW) 76
REMOVAL – REAR (SRW) 76
REMOVAL – REAR (DRW) 76
INSTALLATION 76
INSTALLATION – FRONT (SRW) 76
INSTALLATION – FRONT (DRW) 77
INSTALLATION – REAR (SRW) 77
INSTALLATION – REAR (DRW) 77
DISC BRAKE CALIPER ADAPTER 77
REMOVAL 77
REMOVAL – FRONT 77
REMOVAL – REAR 77
INSTALLATION 78
INSTALLATION – FRONT 78
INSTALLATION – REAR 78
FLUID 78
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 78
STANDARD PROCEDURE – BRAKE FLUID LEVEL 78
SPECIFICATIONS 78
BRAKE FLUID 78
FLUID RESERVOIR 79
REMOVAL 79
INSTALLATION 79
ALB LEVER 79
REMOVAL 79
INSTALLATION 79
ALB CONTROLLER 79
REMOVAL 79
INSTALLATION 79
ADJUSTMENTS 80
ADJUSTMENT 80
MASTER CYLINDER 80
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 80
POWER BOOSTER VACUUM TEST 81
POWER BOOSTER CHECK VALVE TEST 81
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 81
REMOVAL 81
INSTALLATION 82
PEDAL 82
REMOVAL 82
INSTALLATION 83
POWER BRAKE BOOSTER 83
DESCRIPTION 83
OPERATION 83
REMOVAL 83
INSTALLATION 83
ROTORS 83
REMOVAL 83
REMOVAL – FRONT (SRW) 83
REMOVAL – REAR (SRW) 84
REMOVAL – FRONT (DRW) 84
REMOVAL – REAR (DRW) 84
INSTALLATION 85
INSTALLATION – FRONT (SRW) 85
INSTALLATION – REAR (SRW) 85
INSTALLATION – FRONT (DRW) 85
INSTALLATION – REAR (DRW) 85
SUPPORT PLATE 86
REMOVAL – REAR 86
INSTALLATION – REAR 86
PARKING BRAKE 86
SPECIFICATIONS 86
TORQUE CHART 86
SPECIAL TOOLS 87
PARK BRAKE 87
CABLE TENSIONER 87
REMOVAL 87
INSTALLATION 87
CABLES 88
REMOVAL 88
REMOVAL – FRONT 88
REMOVAL – REAR 88
INSTALLATION 88
INSTALLATION – FRONT 88
INSTALLATION – REAR 89
ADJUSTMENTS 89
ADJUSTMENT – PARKING BRAKE CABLES 89
LEVER 90
REMOVAL 90
INSTALLATION 90
SHOES 90
REMOVAL 90
REMOVAL – (SRW) 90
REMOVAL – (DRW) 90
CLEANING – REAR DRUM IN HAT BRAKE 91
INSTALLATION 91
INSTALLATION – (SRW) 91
INSTALLATION – (DRW) 91
ADJUSTMENTS 91
ADJUSTMENT 91
BRAKES – ABS 93
BRAKES – ABS 93
SPECIFICATIONS – TORQUE CHART 93
ELECTRICAL 93
DESCRIPTION 93
OPERATION 93
FRONT WHEEL SPEED SENSOR 94
REMOVAL 94
INSTALLATION 94
REAR WHEEL SPEED SENSOR 94
REMOVAL 94
INSTALLATION 95
TONE WHEEL 95
REMOVAL 95
INSTALLATION 95
HCU (HYDRAULIC CONTROL UNIT) 95
DESCRIPTION 95
REMOVAL 95
INSTALLATION 96
7-COOLING 97
COOLING 97
OPERATION—COOLING SYSTEM 97
DIAGNOSIS AND TESTING 97
DIAGNOSIS AND TESTING – PRELIMINARY CHECKS 97
ENGINE COOLING SYSTEM OVERHEATING 97
DIAGNOSIS AND TESTING – COOLING SYSTEM 98
ACCESSORY DRIVE 101
BELT TENSIONERS 101
DESCRIPTION 101
OPERATION 101
DRIVE BELTS 101
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT 101
VISUAL DIAGNOSIS 101
NOISE DIAGNOSIS 102
REMOVAL 104
INSTALLATION 104
ENGINE 105
COOLANT 105
DESCRIPTION 105
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAKS 106
ULTRAVIOLET LIGHT METHOD 106
PRESSURE TESTER METHOD 106
INTERNAL LEAKAGE INSPECTION 107
COMBUSTION LEAKAGE TEST – WITHOUT PRESSURE TESTER 107
STANDARD PROCEDURE 107
STANDARD PROCEDURE – ADDING ADDITIONAL COOLANT 107
STANDARD PROCEDURE – DRAINING COOLING SYSTEM 108
STANDARD PROCEDURE – REFILLING COOLING SYSTEM 108
COOLANT LEVEL SENSOR 109
REMOVAL 109
INSTALLATION 109
RADIATOR FAN 109
REMOVAL 109
INSTALLATION 109
ENGINE BLOCK HEATER 110
REMOVAL 110
INSTALLATION 110
ENGINE COOLANT TEMP SENSOR 110
DESCRIPTION 110
REMOVAL 110
INSTALLATION 111
ENGINE COOLANT THERMOSTAT 111
REMOVAL 111
INSTALLATION 112
FAN DRIVE VISCOUS CLUTCH 112
REMOVAL 112
INSTALLATION 112
RADIATOR 112
REMOVAL 112
INSTALLATION 113
RADIATOR PRESSURE CAP 114
DESCRIPTION 114
OPERATION 114
DIAGNOSIS AND TESTING – RADIATOR PRESSURE CAP 115
WATER PUMP 115
REMOVAL 115
INSTALLATION 116
8a-AUDIO/VIDEO 117
AUDIO 117
SPECIAL TOOLS 117
AUDIO 117
ANTENNA BODY & CABLE 117
REMOVAL 117
INSTALLATION 117
INSTRUMENT PANEL ANTENNA CABLE 117
REMOVAL 117
INSTALLATION 118
RADIO 118
REMOVAL 118
INSTALLATION 118
SPEAKER 118
REMOVAL 118
INSTALLATION 118
8b-CHIME/BUZZER 119
CHIME/BUZZER 119
DESCRIPTION 119
OPERATION 119
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 120
8e-ELECTRONIC CONTROL MODULES 121
CENTRAL TIMER MODULE 121
DESCRIPTION 121
OPERATION 122
DIAGNOSIS AND TESTING – CENTRAL TIMER MODULE 122
REMOVAL 122
INSTALLATION 122
CONTROLLER ANTILOCK BRAKE 123
DESCRIPTION 123
REMOVAL 123
INSTALLATION 123
ENGINE CONTROL MODULE 123
DESCRIPTION 123
REMOVAL 124
INSTALLATION 124
TRANSMISSION CONTROL MODULE 125
DESCRIPTION 125
OPERATION 125
TCM SIGNALS 126
BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI) 126
SHIFT SCHEDULES 126
DOWNSHIFT SAFETY 127
ADAPTATION 127
CONTROLLER MODES OF OPERATION 128
STANDARD PROCEDURE – TCM ADAPTATION 128
8f-ENGINE SYSTEMS 129
BATTERY SYSTEM 129
BATTERY SYSTEM 129
DESCRIPTION 129
OPERATION 130
DIAGNOSIS AND TESTING – BATTERY SYSTEM 130
MICRO 420 BATTERY TESTER 130
ABNORMAL BATTERY DISCHARGING 133
CLEANING 133
INSPECTION 134
SPECIAL TOOLS 134
BATTERY SYSTEM SPECIAL TOOLS 134
BATTERY 134
DESCRIPTION 134
OPERATION 135
DIAGNOSIS AND TESTING – BATTERY 135
MICRO 420 BATTERY TESTER 135
STANDARD PROCEDURE 136
STANDARD PROCEDURE – BATTERY CHARGING 136
CHARGING A COMPLETELY DISCHARGED BATTERY 137
CHARGING TIME REQUIRED 137
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 138
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 138
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 139
BATTERY TESTING 139
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVEL 140
REMOVAL 140
UNDER HOOD BATTERY REMOVAL 140
AUXILIARY BATTERY REMOVAL 141
INSTALLATION 141
UNDER HOOD BATTERY INSTALLATION 141
AUXILIARY BATTERY INSTALLATION 141
BATTERY HOLDDOWN 142
DESCRIPTION 142
REMOVAL 142
INSTALLATION 142
BATTERY CABLES 142
DESCRIPTION 142
OPERATION 142
DIAGNOSIS AND TESTING – BATTERY CABLES 142
REMOVAL 144
INSTALLATION 144
BATTERY TRAY 144
DESCRIPTION 144
OPERATION 144
REMOVAL 144
INSTALLATION 144
CHARGING SYSTEM 145
CHARGING SYSTEM 145
SPECIFICATIONS 145
TORQUE – 27L DIESEL 145
SPECIAL TOOLS 145
GENERATOR 146
DESCRIPTION 146
OPERATION 146
REMOVAL 146
INSTALLATION 146
GENERATOR DECOUPLER PULLEY 147
DESCRIPTION 147
OPERATION 147
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER 147
REMOVAL 148
INSTALLATION 149
VOLTAGE REGULATOR 151
DESCRIPTION 151
STARTING SYSTEM 152
STARTING SYSTEM 152
DESCRIPTION 152
OPERATION 152
DIAGNOSIS AND TESTING – STARTING SYSTEM 153
INSPECTION 154
TESTING 154
SPECIFICATIONS 157
TORQUE – STARTER – DIESEL 157
SPECIFICATIONS – STARTER MOTOR – DIESEL 157
STARTER MOTOR 157
DIAGNOSIS AND TESTING – STARTER MOTOR 157
REMOVAL 158
INSTALLATION 159
STARTER MOTOR RELAY 159
DESCRIPTION 159
REMOVAL 159
INSTALLATION 160
8g-HEATED SYSTEMS 161
HEATED SEATS 161
DESCRIPTION 161
OPERATION 162
DIAGNOSIS AND TESTING – HEATED SEATS 162
DRIVER HEATED SEAT SWITCH 162
DESCRIPTION 162
OPERATION 162
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCH 162
REMOVAL 163
INSTALLATION 163
HEATED SEAT ELEMENT 163
DESCRIPTION 163
OPERATION 163
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENT 163
HEATED SEAT RELAY 164
DESCRIPTION 164
OPERATION 164
DIAGNOSIS AND TESTING – HEATED SEAT RELAY 164
REMOVAL 164
INSTALLATION 164
HEATED SEAT SENSOR 164
DESCRIPTION 164
DIAGNOSIS AND TESTING – HEATED SEAT SENSOR 164
PASSENGER HEATED SEAT SWITCH 165
DESCRIPTION 165
OPERATION 165
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCH 165
REMOVAL 165
INSTALLATION 165
8h-HORN 167
HORN 167
REMOVAL 167
INSTALLATION 167
HORN SWITCH 167
REMOVAL 167
INSTALLATION 167
8i-IGNITION CONTROL 169
IGNITION CONTROL 169
SPECIAL TOOLS 169
GLOW PLUG 169
REMOVAL 169
INSTALLATION 169
GLOW PLUG RELAY 170
DESCRIPTION 170
OPERATION 170
DIAGNOSIS AND TESTING – GLOW PLUG RELAYS 170
8j-INSTRUMENT CLUSTER 171
INSTRUMENT CLUSTER 172
DESCRIPTION 172
OPERATION 175
INPUT AND OUTPUT CIRCUITS 176
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER 177
REMOVAL 177
INSTALLATION 179
ABS INDICATOR 179
DESCRIPTION 179
OPERATION 179
AIRBAG INDICATOR 180
DESCRIPTION 180
OPERATION 180
AMBIENT TEMPERATURE INDICATOR 181
DESCRIPTION 181
OPERATION 181
BRAKE/PARK BRAKE INDICATOR 181
DESCRIPTION 181
OPERATION 182
BRAKE WEAR INDICATOR 182
DESCRIPTION 182
OPERATION 182
CHARGING INDICATOR 183
DESCRIPTION 183
OPERATION 183
CLOCK 183
DESCRIPTION 183
OPERATION 184
COOLANT LOW INDICATOR 184
DESCRIPTION 184
OPERATION 184
ENGINE TEMPERATURE GAUGE 185
DESCRIPTION 185
OPERATION 185
FUEL FILTER CLOGGED INDICATOR 185
DESCRIPTION 185
OPERATION 185
FUEL GAUGE 186
DESCRIPTION 186
OPERATION 186
GEAR SELECTOR INDICATOR 187
DESCRIPTION 187
OPERATION 187
HIGH BEAM INDICATOR 187
DESCRIPTION 187
OPERATION 187
LOW FUEL INDICATOR 188
DESCRIPTION 188
OPERATION 188
LOW OIL LEVEL INDICATOR 188
DESCRIPTION 188
OPERATION 188
MAINTENANCE INDICATOR 189
DESCRIPTION 189
OPERATION 189
MALFUNCTION INDICATOR LAMP (MIL) 190
DESCRIPTION 190
OPERATION 190
MULTI-FUNCTION INDICATOR 190
DESCRIPTION 190
OPERATION 191
ODOMETER 191
DESCRIPTION 191
OPERATION 192
SEATBELT INDICATOR 192
DESCRIPTION 192
OPERATION 192
SPEEDOMETER 193
DESCRIPTION 193
OPERATION 193
TACHOMETER 193
DESCRIPTION 193
OPERATION 194
TRACTION CONTROL INDICATOR 194
DESCRIPTION 194
OPERATION 194
TRACTION CONTROL MALFUNCTION INDICATOR 195
DESCRIPTION 195
OPERATION 195
TURN SIGNAL INDICATOR 195
DESCRIPTION 195
OPERATION 195
WAIT-TO-START INDICATOR 196
DESCRIPTION 196
OPERATION 196
WASHER FLUID INDICATOR 197
DESCRIPTION 197
OPERATION 197
WATER-IN-FUEL INDICATOR 197
DESCRIPTION 197
OPERATION 198
8l-LAMPS 199
LAMPS/LIGHTING – EXTERIOR 199
LAMPS/LIGHTING – EXTERIOR 200
DESCRIPTION 200
OPERATION 201
SPECIFICATIONS – LAMPS/LIGHTING – EXTERIOR 203
BACKUP LAMP BULB 203
REMOVAL 203
INSTALLATION 204
BRAKE LAMP SWITCH 204
REMOVAL0 – 2 VA (Continued) 204
INSTALLATION 204
BRAKE/PARK LAMP BULB 205
REMOVAL 205
INSTALLATION 205
CENTER HIGH MOUNTED STOP LAMP BULB 205
REMOVAL 205
INSTALLATION 205
CENTER HIGH MOUNTED STOP LAMP UN 206
REMOVAL 206
INSTALLATION 206
CLEARANCE LAMP BULB 206
REMOVAL 206
INSTALLATION 206
CLEARANCE LAMP UNIT 206
REMOVAL 206
INSTALLATION 207
DAYTIME RUNNING LAMP RELAY 207
REMOVAL 207
INSTALLATION 207
FOG LAMP BULB 208
REMOVAL 208
INSTALLATION 208
FOG LAMP RELAY 208
REMOVAL 208
INSTALLATION 209
FOG LAMP SWITCH 209
REMOVAL 209
INSTALLATION 210
FRONT LAMP UNIT 210
REMOVAL 210
INSTALLATION 210
ADJUSTMENTS 210
ADJUSTMENT – FRONT LAMP UNIT 210
VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT 210
FRONT LAMP UNIT ALIGNMENT 211
FRONT POSITION LAMP BULB 212
REMOVAL 212
INSTALLATION 212
FRONT TURN/PARK/SIDE MARKER LAMP BULB 212
REMOVAL 212
INSTALLATION 213
HEADLAMP LEVELING MOTOR 213
REMOVAL 213
INSTALLATION 214
HEADLAMP LEVELING SWITCH 214
REMOVAL 214
INSTALLATION 215
HIGH BEAM HEADLAMP BULB 215
REMOVAL 215
INSTALLATION 215
LICENSE PLATE LAMP BULB 215
REMOVAL 215
INSTALLATION 216
LICENSE PLATE LAMP UNIT 216
REMOVAL 216
INSTALLATION 216
LOW BEAM HEADLAMP BULB 216
REMOVAL 216
INSTALLATION 217
MULTI-FUNCTION SWITCH 217
REMOVAL 217
INSTALLATION 218
PARK BRAKE SWITCH 218
REMOVAL 218
INSTALLATION 218
REAR SIDE MARKER LAMP BULB 219
REMOVAL 219
INSTALLATION 219
REAR TURN LAMP BULB 219
REMOVAL 219
INSTALLATION 220
REPEATER LAMP BULB 220
REMOVAL 220
INSTALLATION 220
REPEATER LAMP UNIT 220
REMOVAL 220
INSTALLATION 221
TAIL LAMP UNIT 221
REMOVAL 221
INSTALLATION 221
TURN SIGNAL RELAY 222
REMOVAL 222
INSTALLATION 222
LAMPS/LIGHTING – INTERIOR 223
LAMPS/LIGHTING – INTERIOR 223
DESCRIPTION 223
OPERATION 224
INTERIOR LIGHTING CIRCUIT 224
EXTERIOR LIGHTING CIRCUIT 224
SPECIFICATIONS – INTERIOR LIGHTING 224
ASH RECEIVER/CIGAR LIGHTER LAMP UNIT 225
REMOVAL 225
INSTALLATION 225
CARGO/DOME LAMP BULB 225
REMOVAL 225
INSTALLATION 225
CARGO/DOME LAMP UNIT 226
REMOVAL 226
INSTALLATION 226
CARGO LAMP SWITCH 226
REMOVAL 226
REMOVAL – INSTRUMENT PANEL 226
REMOVAL – BULKHEAD 226
REMOVAL – REAR PILLAR 226
INSTALLATION 227
INSTALLATION – INSTRUMENT PANEL 227
INSTALLATION – BULKHEAD 227
INSTALLATION – REAR PILLAR 227
DOME/READING LAMP BULB 227
REMOVAL 227
INSTALLATION 227
DOME/READING LAMP UNIT 228
REMOVAL 228
INSTALLATION 228
DOME LAMP/INTRUSION SENSOR BULB 228
REMOVAL 228
INSTALLATION 228
DOME LAMP/INTRUSION SENSOR 229
REMOVAL 229
INSTALLATION 229
DOOR JAMB SWITCH 229
REMOVAL 229
INSTALLATION 229
ENTRY/EXIT LAMP BULB 229
REMOVAL 229
INSTALLATION 230
ENTRY/EXIT LAMP UNIT 230
REMOVAL 230
INSTALLATION 230
TIME DELAY RELAY 230
REMOVAL 230
INSTALLATION 231
8n-POWER SYSTEMS 233
POWER LOCKS 233
POWER LOCKS 233
DESCRIPTION 233
CENTRAL LOCKING 233
REMOTE KEYLESS ENTRY 233
AUTO DOOR LOCKS 233
ACCIDENT RESPONSE 233
DOOR LOCK MOTOR 233
REMOVAL 233
INSTALLATION 233
REMOTE KEYLESS ENTRY TRANSMITTER 234
DESCRIPTION 234
MASTER LOCK SWITCH 234
DESCRIPTION 234
DIAGNOSIS AND TESTING – MASTER LOCK SWITCH 234
REMOVAL 234
INSTALLATION 234
POWER MIRRORS 235
POWER MIRRORS 235
DESCRIPTION 235
POWER MIRROR SWITCH 235
DIAGNOSIS AND TESTING – POWER MIRROR SWITCH 235
REMOVAL 235
INSTALLATION 236
POWER WINDOWS 237
POWER WINDOWS 237
DESCRIPTION 237
OPERATION 237
WINDOW SWITCH 237
WINDOW MOTOR 237
WINDOW MOTOR 237
REMOVAL 237
POWER WINDOW SWITCH 237
DIAGNOSIS AND TESTING – POWER WINDOW SWITCH 237
REMOVAL 238
INSTALLATION 238
8o-RESTRAINTS 239
RESTRAINTS 240
DESCRIPTION 240
ACTIVE RESTRAINTS 241
PASSIVE RESTRAINTS 241
OPERATION 242
ACTIVE RESTRAINTS 242
PASSIVE RESTRAINTS 242
WARNING 243
WARNINGS – RESTRAINT SYSTEM 243
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEM 243
STANDARD PROCEDURE 244
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 244
SUPPLEMENTAL RESTRAINT STORAGE 244
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT 244
CLEANUP PROCEDURE 244
STANDARD PROCEDURE – VERIFICATION TEST 245
AIRBAG CONTROL MODULE 246
DESCRIPTION 246
OPERATION 247
REMOVAL 248
INSTALLATION 249
CLOCKSPRING 250
DESCRIPTION 250
OPERATION 251
STANDARD PROCEDURE – CLOCKSPRING CENTERING 251
REMOVAL 252
INSTALLATION 253
DRIVER AIRBAG 254
DESCRIPTION 254
OPERATION 255
REMOVAL 255
INSTALLATION 256
FRONT SEAT BELT & RETRACTOR 257
REMOVAL 257
INSTALLATION 259
FRONT SEAT BELT BUCKLE 260
REMOVAL 260
INSTALLATION 261
PASSENGER AIRBAG 261
DESCRIPTION 261
OPERATION 262
REMOVAL 262
INSTALLATION 264
PASSENGER AIRBAG BRACKET 265
REMOVAL 265
INSTALLATION 265
REAR SEAT BELT & RETRACTOR 265
REMOVAL 265
INSTALLATION 267
REAR SEAT BELT BUCKLE 267
REMOVAL 267
REMOVAL – INBOARD 267
REMOVAL – OUTBOARD 268
INSTALLATION 268
INSTALLATION – INBOARD 268
INSTALLATION – OUTBOARD 269
SEAT BELT SWITCH 269
DESCRIPTION 269
OPERATION 269
SEAT BELT TENSIONER 269
DESCRIPTION 269
OPERATION 270
SEAT BELT TURNING LOOP ADJUSTER 271
REMOVAL 271
INSTALLATION 272
8p-SPEED CONTROL 273
SPEED CONTROL 273
DESCRIPTION 273
OPERATION 273
SPECIFICATIONS 274
TORQUE 274
CABLE 275
DESCRIPTION 275
SERVO 275
DESCRIPTION 275
SWITCH 275
REMOVAL 275
INSTALLATION 275
8q-VEHICLE THEFT SECURITY 277
VEHICLE THEFT SECURITY 277
DESCRIPTION 277
OPERATION 277
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY 277
INTRUSION SENSOR 278
REMOVAL 278
INSTALLATION 278
SECURITY SYSTEM MODULE 278
REMOVAL 278
INSTALLATION 278
SENTRY KEY REMOTE ENTRY MODULE 278
DESCRIPTION 278
SENTRY KEY IMMOBILIZER 279
REMOTE KEYLESS ENTRY (RKE) 279
OPERATION 279
SENTRY KEY IMMOBILIZER 279
REMOTE KEYLESS ENTRY 279
REMOVAL 279
SENTRY KEY REMOTE ENTRY MODULE 279
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING 280
INSTALLATION 280
SENTRY KEY REMOTE ENTRY MODULE 280
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING 280
SIREN 280
REMOVAL 280
INSTALLATION 280
TRANSPONDER KEY 281
DESCRIPTION 281
OPERATION 281
8r-WIPERS/WASHERS 283
WIPERS/WASHERS 283
DESCRIPTION 283
OPERATING MODES 285
OPERATION 285
DIAGNOSIS AND TESTING – WIPER & WASHER SYSTEM 287
CLEANING – WIPER & WASHER SYSTEM 287
WIPER SYSTEM 287
WASHER SYSTEM 287
INSPECTION – WIPER & WASHER SYSTEM 288
WIPER SYSTEM 288
WASHER SYSTEM 288
CHECK VALVE 289
DESCRIPTION 289
OPERATION 289
REMOVAL 289
INSTALLATION 289
WASHER FLUID LEVEL SWITCH 289
DESCRIPTION 289
OPERATION 290
WASHER HOSES/TUBES 290
DESCRIPTION 290
OPERATION 291
WASHER NOZZLE 291
DESCRIPTION 291
OPERATION 291
REMOVAL 291
INSTALLATION 291
WASHER PUMP/MOTOR 291
DESCRIPTION 291
OPERATION 292
REMOVAL 292
INSTALLATION 292
WASHER RESERVOIR 293
DESCRIPTION 293
OPERATION 293
REMOVAL 293
INSTALLATION 294
WIPER ARM 295
DESCRIPTION 295
OPERATION 296
REMOVAL 296
INSTALLATION 296
WIPER BLADE 297
DESCRIPTION 297
OPERATION 297
REMOVAL 298
INSTALLATION 298
WIPER LINKAGE 299
DESCRIPTION 299
OPERATION 299
REMOVAL 299
INSTALLATION 300
WIPER MOTOR 301
DESCRIPTION 301
OPERATION 301
REMOVAL 301
INSTALLATION 301
WIPER RELAY 302
DESCRIPTION 302
OPERATION 303
REMOVAL 304
INSTALLATION 304
8w-WIRING 305
8W-01 WIRING DIAGRAM INFORMATION 307
WIRING DIAGRAM INFORMATION 307
DESCRIPTION 307
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 307
SYMBOLS 307
TERMINOLOGY 311
DESCRIPTION – CIRCUIT INFORMATION 311
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 311
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 311
IDENTIFICATION 311
LOCATIONS 312
WARNING 312
WARNINGS – GENERAL 312
DIAGNOSIS AND TESTING – WIRING HARNESS 312
TROUBLESHOOTING TOOLS 312
INTERMITTENT AND POOR CONNECTIONS 313
TROUBLESHOOTING WIRING PROBLEMS 313
STANDARD PROCEDURE 313
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 313
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 313
STANDARD PROCEDURE – TESTING FOR CONTINUITY 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 314
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 314
CONNECTOR 314
REMOVAL 314
INSTALLATION 315
DIODE 315
REMOVAL 315
INSTALLATION 315
TERMINAL 315
REMOVAL 315
INSTALLATION 316
WIRE 316
STANDARD PROCEDURE – WIRE SPLICING 316
8W-02 COMPONENT INDEX 317
8W-10 POWER DISTRIBUTION 319
8W-11 FUSE BLOCK 353
8W-15 GROUND DISTRIBUTION 393
8W-18 BUS COMMUNICATIONS 421
8W-20 CHARGING SYSTEM 427
8W-21 STARTING SYSTEM 433
8W-30 FUEL/IGNITION SYSTEM 435
8W-31 TRANSMISSION CONTROL SYSTEM 453
8W-33 VEHICLE SPEED CONTROL 463
8W-35 ANTILOCK BRAKES 467
8W-39 VEHICLE THEFT SECURITY SYSTEM 475
8W-40 INSTRUMENT CLUSTER 489
8W-41 HORN/CIGAR LIGHTER 497
8W-42 AIR CONDITIONER/HEATER 501
8W-43 AIRBAG SYSTEM 525
8W-44 INTERIOR LIGHTING 529
8W-45 CENTRAL TIMER MODULE 541
8W-47 AUDIO SYSTEM 549
8W-48 REAR WINDOW DEFOGGER 555
8W-50 FRONT LIGHTING 561
8W-51 REAR LIGHTING 577
8W-52 TURN SIGNALS 587
8W-53 WIPERS 593
8W-54 TRAILER TOW 597
8W-55 NAVIGATION/TELECOMMUNICATIONS 601
8W-60 POWER WINDOWS 605
8W-61 POWER DOOR LOCKS 609
8W-62 POWER MIRRORS 617
8W-63 POWER SEATS 621
8W-70 SPLICE INFORMATION 625
8W-80 CONNECTOR PIN-OUTS 627
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 695
CONNECTOR/GROUND/SPLICE LOCATION 695
DESCRIPTION 695
8W-97 POWER DISTRIBUTION 733
POWER DISTRIBUTION 733
DESCRIPTION 733
OPERATION 733
CIGAR LIGHTER OUTLET 733
DESCRIPTION 733
OPERATION 734
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLET 734
REMOVAL 734
CIRCUIT BREAKER 734
DESCRIPTION 734
OPERATION 734
DIAGNOSIS AND TESTING – CIRCUIT BREAKER 734
FUSE BLOCK #1 734
DESCRIPTION 734
OPERATION 734
REMOVAL 735
INSTALLATION 735
FUSE BLOCK #2 735
DESCRIPTION 735
OPERATION 735
POWER DISTRIBUTION CENTER 735
DESCRIPTION 735
OPERATION 735
POWER OUTLET 735
DESCRIPTION 735
OPERATION 736
DIAGNOSIS AND TESTING – POWER OUTLET 736
REMOVAL 736
INSTALLATION 736
RELAY 736
DESCRIPTION 736
OPERATION 737
DIAGNOSIS AND TESTING – RELAY 737
DIAGNOSIS AND TESTING – RELAY CIRCUIT TEST 737
REMOVAL 737
INSTALLATION 737
9-ENGINE 739
ENGINE 740
DESCRIPTION 740
STANDARD PROCEDURE 741
STANDARD PROCEDURE – COMPRESSION TESTING ENGINE 741
STANDARD PROCEDURE – CYLINDER LEAK DOWN TEST 741
INSPECTING 741
STANDARD PROCEDURE – DETERMINING CYLINDER PRESSURE LOSS 742
REMOVAL 742
REMOVAL – ENGINE COVER 742
REMOVAL 742
INSTALLATION 745
INSTALLATION – ENGINE COVER 745
INSTALLATION 745
SPECIFICATIONS – TORQUE SPECIFICATIONS 746
SPECIAL TOOLS 752
AIR CLEANER ELEMENT 758
REMOVAL 758
INSTALLATION 758
AIR CLEANER HOUSING 758
REMOVAL 758
INSTALLATION 758
CYLINDER HEAD 759
STANDARD PROCEDURE 759
STANDARD PROCEDURE – CYLINDER HEAD BOLT INSPECTION 759
STANDARD PROCEDURE – MEASURE CYLINDER HEAD SURFACE 759
REMOVAL 760
REMOVAL – CYLINDER HEAD 760
REMOVAL – CYLINDER HEAD FRONT COVER 761
REMOVAL – CYLINDER HEAD GUIDE RAIL 762
INSTALLATION 763
INSTALLATION – CYLINDER HEAD 763
CYLINDER HEAD BOLT TORQUE SEQUENCE 763
INSTALLATION – CYLINDER HEAD FRONT COVER 764
INSTALLATION – CYLINDER HEAD GUIDE RAIL 764
CAMSHAFT(S) 765
STANDARD PROCEDURE – CHECKING CAMSHAFT POSITION 765
REMOVAL 766
INSTALLATION 767
CYLINDER HEAD COVER(S) 768
REMOVAL 768
INSTALLATION 768
VALVE SPRINGS 769
REMOVAL 769
REMOVAL – VALVE SPRINGS 769
REMOVAL – VALVES 769
INSTALLATION 770
INSTALLATION – VALVE SPRINGS 770
INSTALLATION – VALVES 771
ENGINE BLOCK 772
STANDARD PROCEDURE 772
STANDARD PROCEDURE – REPLACING ENGINE CORE AND OIL GALLERY PLUGS 772
STANDARD PROCEDURE – MEASURING CYLINDER BORES 772
CRANKSHAFT 773
STANDARD PROCEDURE – MEASURE CRANKSHAFT AND BLOCK JOURNALS 773
ASSIGN CRANKSHAFT BEARING SHELLS 773
REMOVAL 773
INSTALLATION 774
CRANKSHAFT OIL SEAL – REAR 775
REMOVAL 775
INSTALLATION 775
CRANKSHAFT OIL SEAL – FRONT 776
REMOVAL 776
INSTALLATION 776
FLYWHEEL 777
REMOVAL 777
INSTALLATION 777
INSTALLATION 777
INSTALLATION 777
PISTON & CONNECTING ROD 778
DESCRIPTION 778
STANDARD PROCEDURE 778
STANDARD PROCEDURE – CHECKING AND REPAIRING CONNECTING RODS 778
CONNECTING ROD SPECIFICATIONS 780
STANDARD PROCEDURE – MEASURING PISTON PROTRUSION 780
REMOVAL 780
INSTALLATION 781
PISTON RINGS 784
STANDARD PROCEDURE – PISTON RING FITTING 784
VIBRATION DAMPER 785
REMOVAL 785
INSTALLATION 786
VACUUM PUMP 786
DESCRIPTION 786
OPERATION 786
REMOVAL 786
INSTALLATION 787
LEFT MOUNT 787
REMOVAL 787
INSTALLATION 787
RIGHT MOUNT 787
REMOVAL 787
INSTALLATION 787
OIL 788
REMOVAL – OIL SEPARATOR 788
INSTALLATION – OIL SEPARATOR 788
OIL COOLER & LINES 788
REMOVAL 788
INSTALLATION 788
OIL FILTER 789
REMOVAL 789
INSTALLATION 789
OIL JET 789
DESCRIPTION 789
REMOVAL 789
INSTALLATION 789
OIL PAN 790
REMOVAL 790
INSTALLATION 790
OIL PUMP 791
REMOVAL 791
REMOVAL 791
REMOVAL- OIL PUMP CHAIN 791
INSTALLATION 792
INSTALLATION 792
INSTALLATION – OIL PUMP CHAIN 792
OIL TEMPERATURE SENSOR 794
DESCRIPTION 794
OPERATION 794
REMOVAL 795
INSTALLATION 795
INTAKE MANIFOLD 795
REMOVAL 795
INSTALLATION 796
EXHAUST MANIFOLD 797
REMOVAL 797
INSTALLATION 797
TIMING CHAIN COVER 797
REMOVAL 797
INSTALLATION 798
TIMING BELT/CHAIN AND SPROCKETS 799
REMOVAL 799
REMOVAL – TENSIONING AND SLIDE RAILS 799
REMOVAL – INTERMEDIATE GEAR 799
REMOVAL – TIMING CHAIN TENSIONING RAIL 801
REMOVAL – TIMING CHAIN 801
INSTALLATION 804
INSTALLATION – TENSIONING AND SLIDE RAIL 804
INSTALLATION – INTERMEDIATE GEAR 804
INSTALLATION – TIMING CHAIN TENSIONING RAIL 804
ADJUSTMENTS 805
INSTALLATION – TIMING CHAIN 805
TIMING CHAIN TENSIONER 808
REMOVAL 808
INSTALLATION 809
11-EXHAUST SYSTEM 811
EXHAUST SYSTEM 811
DESCRIPTION – 27L DIESEL 811
DIAGNOSIS AND TESTING – DIESEL ENGINE 812
CATALYTIC CONVERTER 813
REMOVAL 813
INSTALLATION 813
EXHAUST PIPE 813
REMOVAL 813
INSTALLATION 813
TAILPIPE 813
REMOVAL 813
INSTALLATION 813
TURBOCHARGER SYSTEM 813
DESCRIPTION 813
OPERATION 814
CHARGE AIR COOLER AND PLUMBING 814
DESCRIPTION 814
OPERATION 814
DIAGNOSIS AND TESTING – CHARGE AIR COOLER SYSTEM – LEAKS 814
REMOVAL 815
CLEANING 815
INSPECTION 815
INSTALLATION 815
TURBOCHARGER 816
DESCRIPTION 816
OPERATION 816
REMOVAL 817
REMOVAL 817
REMOVAL – VACUUM TRANSDUCER 817
INSTALLATION 818
INSTALLATION 818
INSTALLATION – VACUUM TRANSDUCER 818
13-FRAME & BUMPERS 819
BUMPERS 819
SPECIFICATIONS – TORQUE 819
FRONT BUMPER – STEPS 820
REMOVAL 820
INSTALLATION 820
FRONT FASCIA 820
REMOVAL 820
INSTALLATION 820
REAR BUMPER – STEP 821
REMOVAL 821
INSTALLATION 821
REAR FASCIA 821
REMOVAL 821
INSTALLATION 821
FRAME 822
SPECIFICATIONS 822
SPECIFICATIONS – FRAME DIMENSIONS 822
VEHICLE PREPARATION 822
SPECIFICATIONS – TORQUE 824
ENGINE CRADLE CROSSMEMBER 824
REMOVAL 824
INSTALLATION 826
REAR CROSSMEMBER – TRANSMISSION 827
REMOVAL 827
INSTALLATION 827
TRAILER HITCH 827
REMOVAL 827
INSTALLATION 828
14-FUEL SYSTEM 829
FUEL SYSTEM 829
WARNING 829
WARNING – HIGH FUEL SYSTEM PRESSURE 829
WARNING 829
DIAGNOSIS AND TESTING 829
DIAGNOSIS AND TESTING – HIGH PRESSURE FUEL LINES 829
DIAGNOSIS AND TESTING – AIR IN FUEL SYSTEM 830
STANDARD PROCEDURE 830
STANDARD PROCEDURES – CLEANING FUEL SYSTEM COMPONENTS 830
STANDARD PROCEDURE – DISCONNECTING AND CONNECTING FUEL LINES 830
STANDARD PROCEDURES – DRAINING WATER FROM FUEL FILTER 830
STANDARD PROCEDURE – LOW PRESSURE FUEL PUMP TEST 831
FUEL DELIVERY 832
FUEL DELIVERY 832
SPECIFICATIONS 832
TORQUE 832
SPECIAL TOOLS 833
FUEL SYSTEM 833
FUEL DRAIN TUBES 833
DIAGNOSIS AND TESTING – FUEL SUPPLY RESTRICTIONS 833
LOW-PRESSURE LINES0 – 4 VA (Continued) 833
HIGH-PRESSURE LINES 833
FUEL FILTER 833
DESCRIPTION 833
OPERATION 833
REMOVAL 833
INSTALLATION 834
FUEL LINES 834
REMOVAL – HIGH PRESSURE LINES 834
INSTALLATION – HIGH PRESSURE LINES 835
FUEL PUMP 835
DESCRIPTION 835
DESCRIPTION – HIGH PRESSURE PUMP 835
DESCRIPTION – LOW PRESSURE PUMP 835
OPERATION 835
OPERATION 835
LOW PRESSURE SIDE 835
HIGH PRESSURE SIDE 836
OPERATION – LOW PRESSURE PUMP 836
REMOVAL 836
REMOVAL – HIGH PRESSURE PUMP 836
REMOVAL – LOW PRESSURE PUMP 837
INSTALLATION 838
INSTALLATION – HIGH PRESSURE PUMP 838
INSTALLATION – LOW PRESSURE PUMP 839
FUEL RAIL 839
DESCRIPTION 839
OPERATION 839
REMOVAL 839
INSTALLATION 839
FUEL TANK 840
DESCRIPTION 840
REMOVAL 840
INSTALLATION 841
FUEL TANK MODULE 841
DESCRIPTION 841
REMOVAL 841
INSTALLATION 842
FUEL LEVEL SENDING UNIT / SENSOR 843
DESCRIPTION 843
REMOVAL 843
INSTALLATION 843
HI PRESSURE FUEL SHUTOFF SOL 844
DESCRIPTION 844
OPERATION 844
WATER IN FUEL SENSOR 844
DESCRIPTION 844
OPERATION 844
FUEL INJECTION 845
ACCELERATOR PEDAL POSITION SENSOR 845
DESCRIPTION 845
BOOST PRESSURE SENSOR 845
DESCRIPTION 845
OPERATION 846
DIAGNOSIS AND TESTING – BOOST PRESSURE SENSOR 846
REMOVAL 846
INSTALLATION 846
CAMSHAFT POSITION SENSOR 847
DESCRIPTION 847
OPERATION 847
REMOVAL 847
INSTALLATION 847
CRANKSHAFT POSITION SENSOR 848
DESCRIPTION 848
OPERATION 848
REMOVAL 848
INSTALLATION 848
FUEL INJECTOR 848
DESCRIPTION 848
FUEL INJECTOR 848
OPERATION 848
Injector closed (with high pressure applied) 849
Injector opens (start of injection) 849
Injector opens fully 850
Injector closes (end of injection) 850
STANDARD PROCEDURE 850
STANDARD PROCEDURE – INJECTOR CLASSIFICATION 850
INJECTOR CLASSIFICATION PROCEDURE 850
STANDARD PROCEDURE – CLEANING FUEL INJECTORS 850
REMOVAL 851
INSTALLATION 851
FUEL PRESSURE SENSOR 853
DESCRIPTION 853
DESCRIPTION 853
DESCRIPTION 853
OPERATION 853
OPERATION 853
OPERATION 853
REMOVAL 854
REMOVAL 854
REMOVAL 854
INSTALLATION 854
INSTALLATION 854
INSTALLATION 855
FUEL PRESSURE SOLENOID 855
DESCRIPTION 855
OPERATION 855
REMOVAL 856
INSTALLATION 856
FUEL TEMPERATURE SENSOR 857
DESCRIPTION 857
OPERATION 857
REMOVAL 857
INSTALLATION 857
INLET AIR TEMPERATURE SENSOR 857
DESCRIPTION 857
OPERATION 857
REMOVAL 858
INSTALLATION 858
MANIFOLD AIR FLOW (MAF) SENSOR 858
DESCRIPTION 858
OPERATION 858
REMOVAL 859
INSTALLATION 859
19-STEERING 861
STEERING 861
DESCRIPTION 861
OPERATION 861
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM 862
COLUMN 865
COLUMN 865
SPECIFICATIONS – TORQUE CHART 865
INTERMEDIATE SHAFT 865
REMOVAL 865
INSTALLATION 865
KEY/LOCK CYLINDER 866
REMOVAL 866
INSTALLATION 867
STEERING WHEEL 867
REMOVAL 867
INSTALLATION 867
GEAR 868
GEAR 868
DESCRIPTION 868
REMOVAL 868
INSTALLATION 868
SPECIFICATIONS – TORQUE CHART 869
LINKAGE 870
LINKAGE 870
DIAGNOSIS AND TESTING – OUTER TIE ROD END 870
SPECIFICATIONS – TORQUE CHART 870
SPECIAL TOOLS 871
FRONT SUSPENSION 871
TIE ROD END 871
REMOVAL 871
INSTALLATION 871
PUMP 872
PUMP 872
DESCRIPTION 872
OPERATION 872
DIAGNOSIS AND TESTING – PUMP LEAKAGE 872
STANDARD PROCEDURE 872
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATION 872
STANDARD PROCEDURE – FLUSHING POWER STEERING SYSTEM 873
REMOVAL 873
INSTALLATION 873
SPECIFICATIONS – TORQUE CHART 874
FLUID 874
STANDARD PROCEDURE 874
POWER STEERING PUMP FILL AND BLEED PROCEDURE 874
FLUID COOLER TUBE 874
REMOVAL 874
INSTALLATION 874
HOSES 875
REMOVAL 875
REMOVAL – PRESSURE HOSE 875
REMOVAL – RETURN LINE FROM PUMP TO COOLER TUBE 875
REMOVAL – RETURN HOSE FROM GEAR TO COOLER TUBE 875
INSTALLATION 875
INSTALLATION – PRESSURE HOSE 875
INSTALLATION – RETURN LINE FROM PUMP TO COOLER TUBE 875
INSTALLATION – RETURN HOSE FROM GEAR TO COOLER TUBE 875
21-TRANSMISSION 877
AUTOMATIC TRANSMISSION – NAG1 877
AUTOMATIC TRANSMISSION – NAG1 878
DESCRIPTION 878
TRANSMISSION IDENTIFICATION 878
TRANSMISSION GEAR RATIOS 878
TRANSMISSION HOUSING 878
MECHANICAL SECTION 879
ELECTROHYDRAULIC CONTROL UNIT 879
SHIFT GROUPS 880
OPERATION 880
EMERGENCY RUNNING FUNCTION 880
CLUTCH APPLICATION 880
FIRST GEAR POWERFLOW 881
SECOND GEAR POWERFLOW 883
THIRD GEAR POWERFLOW 885
FOURTH GEAR POWERFLOW 887
FIFTH GEAR POWERFLOW 889
REVERSE GEAR POWERFLOW 891
SHIFT GROUPS/ SHIFT SEQUENCE 893
DIAGNOSIS AND TESTING 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 899
DIAGNOSIS AND TESTING – PRELIMINARY 899
VEHICLE IS DRIVABLE 899
VEHICLE IS DISABLED 899
DIAGNOSIS AND TESTING – ROAD TESTING 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 900
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 903
REMOVAL 903
DISASSEMBLY 906
ASSEMBLY 910
INSTALLATION 917
SCHEMATICS AND DIAGRAMS 923
SPECIFICATIONS – NAG1 AUTOMATIC TRANSMISSION 944
SPECIAL TOOLS – NAG1 AUTOMATIC TRANSMISSION 945
DRIVING CLUTCHES 948
DESCRIPTION 948
OPERATION 948
DRIVING CLUTCH K1 950
DISASSEMBLY 950
ASSEMBLY 951
DRIVING CLUTCH K2 952
DISASSEMBLY 952
ASSEMBLY 954
DRIVING CLUTCH K3 956
DISASSEMBLY 956
ASSEMBLY 956
ELECTROHYDRAULIC UNIT 958
DESCRIPTION 958
ELECTRICAL CONTROL UNIT 958
HYDRAULIC CONTROL UNIT 958
OPERATION 963
ELECTRICAL CONTROL UNIT 963
HYDRAULIC CONTROL UNIT 964
REMOVAL 968
DISASSEMBLY 968
ASSEMBLY 971
INSTALLATION 976
FLUID AND FILTER 977
DESCRIPTION 977
OPERATION 977
DIAGNOSIS AND TESTING 978
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 978
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 978
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 978
STANDARD PROCEDURE 978
STANDARD PROCEDURE – CHECK OIL LEVEL 978
STANDARD PROCEDURE – TRANSMISSION FILL 979
STANDARD PROCEDURE – FLUID/FILTER SERVICE 980
FREEWHEELING CLUTCH 981
DESCRIPTION 981
OPERATION 981
DISASSEMBLY 982
ASSEMBLY 983
GEARSHIFT CABLE 985
DIAGNOSIS AND TESTING – GEARSHIFT CABLE 985
REMOVAL 985
INSTALLATION 985
HOLDING CLUTCHES 987
DESCRIPTION 987
OPERATION 988
HOLDING CLUTCH B1 988
DISASSEMBLY 988
ASSEMBLY 989
HOLDING CLUTCH B2 991
DISASSEMBLY 991
ASSEMBLY 992
INPUT SPEED SENSORS 995
DESCRIPTION 995
OPERATION 995
OIL PUMP 996
DESCRIPTION 996
OPERATION 996
DISASSEMBLY 996
ASSEMBLY 997
OUTPUT SHAFT BEARING 998
REMOVAL 998
INSTALLATION 998
OUTPUT SHAFT SEAL1001
REMOVAL1001
INSTALLATION1001
PARK LOCK CABLE1001
REMOVAL1001
INSTALLATION1002
PISTONS1004
DESCRIPTION1004
OPERATION1004
PRESSURE1005
PRESSURE ON A CONFINED FLUID1005
FORCE MULTIPLICATION1005
PISTON TRAVEL1005
PLANETARY GEARTRAIN1006
DESCRIPTION1006
OPERATION1006
DISASSEMBLY1007
ASSEMBLY1007
SHIFT MECHANISM1009
DESCRIPTION1009
OPERATION1009
REMOVAL1010
INSTALLATION1011
SOLENOID1012
DESCRIPTION1012
UPSHIFT/DOWNSHIFT SOLENOID VALVES1013
MODULATING PRESSURE CONTROL SOLENOID VALVE1013
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE1013
SHIFT PRESSURE CONTROL SOLENOID VALVE1014
OPERATION1014
UPSHIFT/DOWNSHIFT SOLENOID VALVES1015
MODULATING PRESSURE CONTROL SOLENOID VALVE1015
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE1015
SHIFT PRESSURE CONTROL SOLENOID VALVE1015
TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT1015
DESCRIPTION1015
DESCRIPTION – PARK/NEUTRAL CONTACT1015
DESCRIPTION – TRANSMISSION TEMPERATURE SENSOR1016
OPERATION1016
OPERATION – PARK/NEUTRAL CONTACT1016
OPERATION – TRANSMISSION TEMPERATURE SENSOR1017
TORQUE CONVERTER1017
DESCRIPTION1017
IMPELLER1018
TURBINE1018
STATOR1018
TORQUE CONVERTER CLUTCH (TCC)1019
OPERATION1019
TURBINE1020
STATOR1021
TORQUE CONVERTER CLUTCH (TCC)1022
REMOVAL1022
INSTALLATION1022
TORQUE CONVERTER HUB SEAL1023
REMOVAL1023
INSTALLATION1023
22-TIRES/WHEELS1025
TIRES/WHEELS1025
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT1025
METHOD 1 (RELOCATE WHEEL ON HUB)1026
METHOD 2 (RELOCATE TIRE ON WHEEL)1026
STANDARD PROCEDURE1026
STANDARD PROCEDURE – MATCH MOUNTING1026
STANDARD PROCEDURE – TIRE AND WHEEL BALANCE1027
STANDARD PROCEDURE – TIRE ROTATION1029
SPECIFICATIONS1029
TORQUE CHART1029
TIRES1030
DESCRIPTION1030
DESCRIPTION – TIRES1030
TIRE IDENTIFICATION1030
TIRE CHAINS1030
DESCRIPTION – RADIAL – PLY TIRES1030
DESCRIPTION – TIRE PRESSURE FOR HIGH SPEEDS1030
DESCRIPTION – REPLACEMENT TIRES1031
DESCRIPTION – TIRE INFLATION PRESSURES1031
DIAGNOSIS AND TESTING1032
DIAGNOSIS AND TESTING – PRESSURE GAUGES1032
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION1032
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS1032
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS1032
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD1032
STANDARD PROCEDURE – REPAIRING LEAKS1034
CLEANING1034
SPECIFICATIONS1034
TIRES1034
SPARE TIRE CARRIER1034
REMOVAL1034
INSTALLATION1034
WHEELS1035
DESCRIPTION1035
OPERATION1035
DIAGNOSIS AND TESTING1035
WHEEL INSPECTION1035
STANDARD PROCEDURE1035
STANDARD PROCEDURE – WHEEL REPLACEMENT1035
STANDARD PROCEDURE – DUAL REAR WHEEL INSTALLATION1036
REMOVAL1037
INSTALLATION1037
23-BODY1039
BODY1039
WARNING1039
SAFETY PRECAUTIONS AND WARNINGS1039
DIAGNOSIS AND TESTING1039
DIAGNOSIS AND TESTING – WATER LEAKS1039
VISUAL INSPECTION BEFORE WATER LEAK TESTS1040
WATER LEAK TESTS1040
WATER LEAK DETECTION1040
DIAGNOSIS AND TESTING – WIND NOISE1040
VISUAL INSPECTION BEFORE TESTS1040
STANDARD PROCEDURE1041
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR1041
Rigid Plastics:1041
Semi-Rigid Plastics:1041
Flexible Plastics:1041
Repair Procedure:1041
Adhesion Promoter/Surface Modifier:1041
SAFETY PRECAUTION AND WARNINGS1041
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES1042
PANEL SECTIONING1044
PANEL REINFORCEMENT1044
VISUAL INSPECTION1045
PANEL SURFACE PREPARATION1045
PATCHING PANELS1045
PANEL PATCH FABRICATIONS1045
PANEL PATCH INSTALLATION1046
PATCHED PANEL SURFACING1048
STANDARD PROCEDURE – BUZZ, SQUEAK & RATTLE1048
SPECIFICATIONS1050
DOOR – FRONT1051
CHECK1051
REMOVAL1051
INSTALLATION1051
DOOR1052
REMOVAL1052
INSTALLATION1052
ADJUSTMENTS1053
ADJUSTMENT1053
DOOR GLASS1053
REMOVAL1053
INSTALLATION1053
EXTERIOR HANDLE1054
REMOVAL1054
INSTALLATION1054
HINGE1055
REMOVAL1055
INSTALLATION1055
LATCH1056
REMOVAL1056
INSTALLATION1056
LATCH STRIKER1056
REMOVAL1056
INSTALLATION1056
LOCK CYLINDER1056
REMOVAL1056
INSTALLATION1056
TRIM PANEL1057
REMOVAL1057
INSTALLATION1058
WINDOW REGULATOR – POWER1058
REMOVAL1058
INSTALLATION1059
WINDOW REGULATOR – MANUAL1060
REMOVAL1060
INSTALLATION1061
DOORS – REAR1062
CHECK1062
REMOVAL1062
INSTALLATION1062
DOOR1063
REMOVAL1063
DISASSEMBLY1064
RIGHT DOOR 1064
LEFT DOOR 1065
ASSEMBLY1066
RIGHT DOOR 1066
LEFT DOOR 1067
INSTALLATION1068
ADJUSTMENTS1068
ADJUSTMENT1068
DOOR GLASS1069
REMOVAL1069
INSTALLATION1069
EXTERIOR HANDLE1070
REMOVAL1070
INSTALLATION1071
HINGE1072
REMOVAL1072
INSTALLATION1072
INSIDE HANDLE ACTUATOR1072
REMOVAL1072
INSTALLATION1072
LATCH1072
REMOVAL1072
INSTALLATION1073
TRIM PANEL1073
REMOVAL1073
INSTALLATION1073
DOORS – SLIDING1074
EXTERIOR HANDLE1074
REMOVAL1074
INSTALLATION1074
INSIDE HANDLE ACTUATOR1075
REMOVAL1075
INSTALLATION1075
UPPER ROLLER ARM1075
REMOVAL1075
INSTALLATION1075
CENTER ROLLER ARM1075
REMOVAL1075
INSTALLATION1076
LOWER ROLLER ARM1076
REMOVAL1076
INSTALLATION1076
CENTER TRACK1076
REMOVAL1076
INSTALLATION1077
LATCH / LOCK CONTROL1077
REMOVAL1077
INSTALLATION1078
REAR LATCH1078
REMOVAL1078
INSTALLATION1078
REAR LATCH STRIKER1079
REMOVAL1079
INSTALLATION1079
SLIDING DOOR1079
REMOVAL1079
DISASSEMBLY1080
ASSEMBLY1081
INSTALLATION1082
ADJUSTMENTS1082
ADJUSTMENT1082
Gaps and Ridge Adjustment1082
Flush Adjustment1083
Door Stop Bumper Adjust1083
STABILIZER1083
REMOVAL1083
INSTALLATION1083
TRIM PANEL1084
REMOVAL1084
Upper1084
Lower1084
INSTALLATION1084
Upper1084
Lower1084
DOOR GLASS1084
REMOVAL1084
INSTALLATION1084
EXTERIOR1085
FUEL FILL DOOR1085
REMOVAL1085
INSTALLATION1085
GRILLE1085
REMOVAL1085
INSTALLATION1085
LICENSE PLATE BRACKET1085
REMOVAL1085
INSTALLATION1085
RADIATOR CROSSMEMBER1085
REMOVAL1085
INSTALLATION1086
SIDE VIEW MIRROR1086
REMOVAL1086
Driver’s Side1086
Passenger Side1086
INSTALLATION1086
Driver’s Side1086
Passenger Side1087
SIDE VIEW MIRROR – GLASS1087
REMOVAL1087
INSTALLATION1087
HOOD1088
HINGE1088
REMOVAL1088
INSTALLATION1088
HOOD1088
REMOVAL1088
INSTALLATION1088
ADJUSTMENTS1089
ADJUSTMENT1089
LATCH1089
REMOVAL1089
INSTALLATION1089
LATCH RELEASE CABLE1089
REMOVAL1089
INSTALLATION1089
LATCH RELEASE HANDLE1090
REMOVAL1090
INSTALLATION1090
PROP ROD1090
REMOVAL1090
INSTALLATION1090
SAFETY LATCH1090
REMOVAL1090
INSTALLATION1090
INSTRUMENT PANEL1091
CLUSTER BEZEL1091
REMOVAL1091
INSTALLATION1092
ACCESSORY SWITCH BEZEL1092
REMOVAL1092
INSTALLATION1092
INSTRUMENT PANEL CENTER BEZEL1093
REMOVAL1093
INSTALLATION1093
ASH RECEIVER1093
REMOVAL1093
INSTALLATION1093
CUP HOLDER1093
REMOVAL1093
INSTALLATION1094
GLOVE BOX1094
REMOVAL1094
INSTALLATION1094
INSTRUMENT PANEL ASSEMBLY1095
REMOVAL1095
INSTALLATION1099
TOP COVER – CLUSTER1100
REMOVAL1100
INSTALLATION1100
TOP COVER – TRAY1101
REMOVAL1101
INSTALLATION1102
TOP COVER1102
REMOVAL1102
INSTALLATION1103
STEERING COLUMN OPENING COVER1104
REMOVAL1104
INSTALLATION1104
INTERIOR1105
INTERIOR1105
CAUTION1105
A-PILLAR TRIM1105
REMOVAL1105
INSTALLATION1106
ASSIST HANDLE1106
REMOVAL1106
INSTALLATION1106
B-PILLAR TRIM1106
REMOVAL1106
INSTALLATION1107
BULKHEAD TRIM PANEL1107
REMOVAL1107
INSTALLATION1107
CARPETS AND FLOOR MATS1107
REMOVAL1107
Cargo/Passenger Van – Front1107
Passenger Van – Rear1107
Cargo Van – Rear1108
INSTALLATION1108
Cargo/Passenger Van – Front1108
Passenger Van – Rear1108
Cargo Van – Rear1108
COWL TRIM1108
REMOVAL1108
INSTALLATION1108
D-PILLAR TRIM1108
REMOVAL1108
INSTALLATION1108
HEADLINER1108
REMOVAL1108
Cab Section1108
Number 2 Section1108
Number 3 Section1108
Number 4 Section1109
INSTALLATION1109
Cab Section1109
Number 2 Section1109
Number 3 Section1109
Number 4 Section1109
QUARTER TRIM PANEL1109
REMOVAL1109
Passenger Van1109
Cargo Van1110
INSTALLATION1110
Passenger Van1110
Cargo Van1110
REAR VIEW MIRROR1110
REMOVAL1110
INSTALLATION1110
INSTALLATION1110
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKET1110
STEPWELL SCUFF PADS1110
REMOVAL1110
INSTALLATION1111
SUN VISOR1111
REMOVAL1111
INSTALLATION1111
PAINT1112
PAINT1112
SPECIFICATIONS – PAINT CODES1112
BASECOAT/CLEARCOAT FINISH1112
DESCRIPTION1112
PAINT TOUCH-UP1112
DESCRIPTION1112
STANDARD PROCEDURE – PAINT TOUCH-UP1113
FINESSE SANDING/BUFFING & POLISH1113
DESCRIPTION1113
SEATS1114
ARMREST1114
REMOVAL1114
INSTALLATION1114
HEADREST1114
REMOVAL1114
INSTALLATION1114
SEAT – FRONT1115
REMOVAL1115
INSTALLATION0 – 6 VA (Continued)1115
SEAT BACK – FRONT1115
REMOVAL1115
INSTALLATION1115
SEAT CUSHION – FRONT1116
REMOVAL1116
INSTALLATION1116
SEAT ADJUSTERS – FRONT1116
REMOVAL1116
INSTALLATION1116
SEAT – REAR1117
REMOVAL1117
INSTALLATION1117
REAR SEAT BACK SHIELD1117
REMOVAL1117
INSTALLATION1117
SEAT BACK CUSHION/COVER – REAR1118
REMOVAL1118
INSTALLATION1118
SEAT CUSHION/COVER – REAR1118
REMOVAL1118
INSTALLATION1118
STATIONARY GLASS1119
BACKLITE – BULKHEAD TRIM PANEL1119
REMOVAL1119
INSTALLATION1119
QUARTER WINDOW1119
REMOVAL1119
INSTALLATION1119
WINDSHIELD1120
WARNING1120
WINDSHIELD SAFETY PRECAUTIONS1120
REMOVAL1120
INSTALLATION1121
Windshield Preparation – Installing A Previously Installed Windshield1122
Windshield Preparation – Installing A New Windshield1123
Windshield Opening Preparation1123
Windshield Installation1123
WEATHERSTRIP/SEALS1125
FRONT DOOR INNER BELT WEATHERSTRIP1125
REMOVAL1125
INSTALLATION1125
FRONT DOOR OUTER BELT WEATHERSTRIP1125
REMOVAL1125
INSTALLATION1125
DOOR OPENING SEALS1125
REMOVAL1125
INSTALLATION1125
BODY STRUCTURE1126
GAP AND FLUSH1126
SPECIFICATIONS1126
OPENING DIMENSIONS1128
SPECIFICATIONS1128
24-HEATING & AIR CONDITIONING1129
HEATING & AIR CONDITIONING1129
DESCRIPTION1129
DESCRIPTION – COOLING SYSTEM REQUIREMENTS1129
DESCRIPTION – HEATER AND AIR CONDITIONER1129
OPERATION – HEATER AND AIR CONDITIONER1130
DIAGNOSIS AND TESTING1131
DIAGNOSIS AND TESTING – FUNCTION TEST1131
DIAGNOSIS AND TESTING – A/C PERFORMANCE TEST1131
DIAGNOSIS AND TESTING – HEATER PERFORMANCE1132
MAXIMUM HEATER OUTPUT1132
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW1132
POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT1132
TEMPERATURE CONTROL1132
SPECIFICATIONS1133
A/C SYSTEM1133
CONTROLS – FRONT1136
A/C COMPRESSOR CLUTCH1136
DESCRIPTION1136
OPERATION1136
STANDARD PROCEDURE1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH AIR GAP1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH BREAK-IN1137
REMOVAL1137
INSPECTION – COMPRESSOR CLUTCH/COIL1138
INSTALLATION1139
A/C COMPRESSOR CLUTCH COIL1140
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH COIL1140
A/C HEATER CONTROL1140
DESCRIPTION1140
OPERATION1140
REMOVAL1140
INSTALLATION1141
A/C PRESSURE TRANSDUCER1141
DESCRIPTION1141
OPERATION1141
DIAGNOSIS AND TESTING – A/C PRESSURE TRANSDUCER1141
REMOVAL1142
INSTALLATION1142
AIR OUTLET TEMPERATURE SENSOR1142
DESCRIPTION1142
OPERATION1143
REMOVAL1143
INSTALLATION1143
AMBIENT TEMPERATURE SENSOR1143
DESCRIPTION1143
OPERATION1143
REMOVAL1143
INSTALLATION1144
BLOWER MOTOR RESISTOR BLOCK1144
DESCRIPTION1144
OPERATION1144
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR BLOCK1144
REMOVAL1144
INSTALLATION1145
BLOWER MOTOR SWITCH1145
DESCRIPTION1145
OPERATION1145
DIAGNOSIS AND TESTING – BLOWER MOTOR SWITCH1145
REMOVAL1145
EVAPORATOR TEMPERATURE SENSOR1145
DESCRIPTION1145
OPERATION1146
REMOVAL1146
INSTALLATION1146
IN-CAR TEMPERATURE SENSOR1147
DESCRIPTION1147
OPERATION1147
DIAGNOSIS AND TESTING1147
REMOVAL1147
MODE DOOR CABLES1147
REMOVAL1147
INSTALLATION1147
RECIRCULATION DOOR ACTUATOR1148
DESCRIPTION1148
OPERATION1148
REMOVAL1149
INSTALLATION1149
CONTROLS – REAR1150
BLOWER MOTOR SWITCH1150
DESCRIPTION1150
OPERATION1150
DIAGNOSIS AND TESTING1151
REMOVAL1151
INSTALLATION1151
BLOWER MOTOR RELAY1151
DESCRIPTION1151
OPERATION1151
DIAGNOSIS AND TESTING1152
REMOVAL1152
INSTALLATION1152
CONTROL MODULE1152
DESCRIPTION1152
OPERATION1152
DIAGNOSIS AND TESTING1152
REMOVAL1152
INSTALLATION1153
EVAPORATOR TEMPERATURE SENSOR1153
DESCRIPTION1153
OPERATION1154
DIAGNOSIS AND TESTING1154
REMOVAL1154
INSTALLATION1154
SOLENOID VALVE1155
DESCRIPTION1155
OPERATION1155
DIAGNOSIS AND TESTING1155
REMOVAL1155
INSTALLATION1156
TEMPERATURE CONTROL1157
DESCRIPTION1157
OPERATION1157
DIAGNOSIS AND TESTING1157
REMOVAL1157
INSTALLATION1157
TEMPERATURE SENSOR1158
DESCRIPTION1158
OPERATION1158
DIAGNOSIS AND TESTING1158
REMOVAL1158
INSTALLATION1158
DISTRIBUTION – FRONT1159
AIR FILTER1159
REMOVAL1159
INSTALLATION1159
AIR OUTLETS1159
REMOVAL1159
INSTALLATION1160
BLOWER MOTOR1160
REMOVAL1160
INSTALLATION1161
DEFROSTER DUCTS1161
REMOVAL1161
INSTALLATION1161
FLOOR DISTRIBUTION DUCTS1161
REMOVAL1161
INSTALLATION1162
HVAC HOUSING1162
REMOVAL1162
DISASSEMBLY1164
ASSEMBLY1164
INSTALLATION1164
INSTRUMENT PANEL DUCTS1165
REMOVAL1165
INSTALLATION1166
DISTRIBUTION – REAR1167
AIR FILTER1167
REMOVAL1167
INSTALLATION1167
BLOWER MOTOR1167
REMOVAL1167
INSTALLATION1168
REAR A/C HOUSING1168
REMOVAL1168
INSTALLATION1169
PLUMBING1171
PLUMBING1172
DESCRIPTION – REFRIGERANT LINE1172
OPERATION – REFRIGERANT LINE1172
WARNING1172
CAUTION1173
CAUTION1173
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS1173
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKS1174
SYSTEM EMPTY1174
SYSTEM LOW1174
STANDARD PROCEDURE1174
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENT1174
MANIFOLD GAUGE SET CONNECTIONS1175
STANDARD PROCEDURE – REFRIGERANT RECOVERY1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE1176
PARTIAL CHARGE METHOD1176
SPECIFICATIONS1177
CHARGE CAPACITY1177
A/C COMPRESSOR1177
DESCRIPTION1177
OPERATION1177
DIAGNOSIS AND TESTING – COMPRESSOR NOISE1177
REMOVAL1178
INSTALLATION1179
A/C CONDENSER1180
DESCRIPTION1180
OPERATION1180
REMOVAL1180
INSTALLATION1180
A/C DISCHARGE LINE1181
REMOVAL1181
INSTALLATION1182
A/C EVAPORATOR1182
DESCRIPTION1182
OPERATION1182
REMOVAL1183
INSTALLATION1183
A/C EXPANSION VALVE1183
DESCRIPTION1183
OPERATION1183
DIAGNOSIS AND TESTING – A/C EXPANSION VALVE1184
REMOVAL1184
INSTALLATION1184
ELECTRIC COOLANT PUMP1185
DESCRIPTION1185
OPERATION1185
REMOVAL1185
INSTALLATION1185
HEATER CORE1185
DESCRIPTION1185
OPERATION1185
REMOVAL1186
INSTALLATION1186
LIQUID LINE1186
REMOVAL1186
INSTALLATION1187
REAR EVAPORATOR1188
REMOVAL1188
INSTALLATION1189
REAR EXPANSION VALVE1190
REMOVAL1190
INSTALLATION1191
RECEIVER/DRIER1192
DESCRIPTION1192
OPERATION1192
REMOVAL1192
INSTALLATION1192
REFRIGERANT1193
DESCRIPTION1193
OPERATION1193
REFRIGERANT OIL1193
DESCRIPTION1193
OPERATION1193
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL1193
SUCTION LINE1194
REMOVAL1194
INSTALLATION1194
WATER VALVE1195
REMOVAL1195
INSTALLATION1195
UNDERBODY LINES1196
REMOVAL1196
INSTALLATION1197
CABIN HEATER1200
CABIN HEATER1200
DESCRIPTION1200
OPERATION1200
DIAGNOSIS AND TESTING – DIESEL SUPPLEMENTAL HEATER – DCHA1200
EXHAUST TUBE1201
REMOVAL1201
INSTALLATION1201
FUEL DOSING PUMP1202
DESCRIPTION1202
OPERATION1202
REMOVAL1202
INSTALLATION1202
FUEL LINE1203
STANDARD PROCEDURE – CLEANING1203
REMOVAL1203
INSTALLATION1204
HEATER UNIT1205
REMOVAL1205
REMOVAL1205
REMOVAL1205
INSTALLATION1206
INSTALLATION1206
INSTALLATION1206
INLET HOSE1206
REMOVAL1206
INSTALLATION1206
25-EMISSIONS CONTROL1209
EXHAUST GAS RECIRCULATION1209
VALVE1209
DESCRIPTION1209
OPERATION1209
REMOVAL1210
INSTALLATION1210
INDEX1211
COMMENTS1231

DESCRIPTION:

Sprinter 2005 VA Service Manual – PDF DOWNLOAD

INTRODUCTION:

VEHICLE IDENTIFICATION:

NUMBER DESCRIPTION:

• The Vehicle Identification Number (VIN) plate is located on the lower windshield fence next to the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle.
• Refer to the VIN DECODING INFORMATION table to determine the identification of a vehicle. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number.
• The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

INTERNATIONAL SYMBOLS DESCRIPTION:

• The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 1) are used to identify various instrument controls.
• The symbols correspond to the controls and displays that are located on the instrument panel.

FASTENER IDENTIFICATION DESCRIPTION:

• The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head.
• The actual bolt strength grade corresponds to the number of line marks plus
• 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt.
• The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3).

G.B 05/04/25