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2005 dodge-mercedes Sprinter Parts Manual 
2005 dodge-mercedes Sprinter Parts Manual
2005 dodge-mercedes Sprinter Parts Manual
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2005 dodge-mercedes Sprinter Parts Manual – PDF DOWNLOAD
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2005 dodge-mercedes Sprinter Parts Manual – PDF DOWNLOAD
- DESCRIPTION The Vehicle Identification Number (VIN) plate is located on the lower windshield fence next to the left a-pillar.
- The VIN contains 17 characters that provide data concerning the vehicle.
- Refer to the VIN DECODING INFORMATION table to determine the identification of a vehicle.
- To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number.
- The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation.
- The formula to use the check digit is not released to the general public.
TABLE OF CONTENTS:
2005 dodge-mercedes Sprinter Parts Manual – PDF DOWNLOAD
VA Service Manual......................................................................................... 1 GROUP TAB LOCATOR..................................................................................... 1 in-INTRODUCTION....................................................................................... 3 VEHICLE IDENTIFICATION NUMBER..................................................................... 3 DESCRIPTION................................................................................... 3 INTERNATIONAL SYMBOLS............................................................................. 4 DESCRIPTION................................................................................... 4 FASTENER IDENTIFICATION........................................................................... 4 DESCRIPTION................................................................................... 4 FASTENER USAGE.................................................................................... 7 DESCRIPTION - FASTENER USAGE.................................................................. 7 THREADED HOLE REPAIR.............................................................................. 7 DESCRIPTION - THREADED HOLE REPAIR............................................................ 7 METRIC SYSTEM..................................................................................... 7 DESCRIPTION................................................................................... 7 TORQUE REFERENCES................................................................................. 9 DESCRIPTION................................................................................... 9 0-LUBRICATION & MAINTENANCE........................................................................... 11 FLUID TYPES....................................................................................... 11 DESCRIPTION................................................................................... 11 DESCRIPTION - FUEL REQUIREMENTS - DIESEL ENGINE........................................... 11 DESCRIPTION........................................................................... 11 DESCRIPTION - ENGINE COOLANT.............................................................. 11 ETHYLENE-GLYCOL MIXTURES.............................................................. 11 PROPYLENE-GLYCOL MIXTURES............................................................. 12 DESCRIPTION - HOAT COOLANT................................................................ 12 COOLANT PERFORMANCE................................................................... 12 COOLANT SELECTION AND ADDITIVES....................................................... 13 DESCRIPTION - AXLE........................................................................ 13 REAR AXLE............................................................................. 13 DESCRIPTION - BRAKE FLUID................................................................. 13 BRAKE FLUID........................................................................... 13 DESCRIPTION - POWER STEERING FLUID........................................................ 13 POWER STEERING FLUID.................................................................. 13 DESCRIPTION - ENGINE OIL - DIESEL ENGINES................................................. 13 SAE VISCOSITY GRADE................................................................... 13 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - NAG1......................................... 14 FLUID ADDITIVES....................................................................... 14 OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 14 FLUID CAPACITIES.................................................................................. 14 SPECIFICATIONS - FLUID CAPACITIES............................................................. 14 FLUID FILL/CHECK LOCATIONS........................................................................ 14 INSPECTION - FLUID FILL/CHECK LOCATIONS....................................................... 14 PARTS & LUBRICANT RECOMMENDATION.................................................................. 15 STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS........................................ 15 HOISTING.......................................................................................... 15 STANDARD PROCEDURE - HOISTING................................................................. 15 FLOOR JACK................................................................................ 15 HOIST..................................................................................... 15 JUMP STARTING..................................................................................... 16 STANDARD PROCEDURE - JUMP STARTING............................................................ 16 TO JUMP START A DISABLED VEHICLE:......................................................... 16 DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 16 TOWING............................................................................................ 16 STANDARD PROCEDURE - TOWING................................................................... 16 If the Engine is Damaged.................................................................. 17 If the Transmission is Damaged............................................................ 17 If the Front Axle is Damaged.............................................................. 17 If the Rear Axle is Damaged............................................................... 17 SAFETY PRECAUTIONS........................................................................ 17 GROUND CLEARANCE.......................................................................... 17 RAMP ANGLE................................................................................ 17 TOWING WHEN KEYS ARE NOT AVAILABLE........................................................ 17 MAINTENANCE SCHEDULES............................................................................. 17 DESCRIPTION................................................................................... 17 MAINTENANCE - WITHOUT ASSYST MAINTENANCE COMPUTER......................................... 17 MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER............................................ 18 REGULAR CHECK-UPS......................................................................... 18 SPECIAL MAINTENANCE REQUIREMENTS.......................................................... 18 ENGINE OIL CHANGE AND FILTER REPLACEMENT.................................................. 18 SCOPE OF WORK FOR MAINTENANCE SERVICE..................................................... 18 ADDITIONAL MAINTENANCE WORK............................................................... 19 ADDITIONAL MAINTENANCE WORK AFTER YEARS................................................... 19 INTERNATIONAL SYMBOLS............................................................................. 19 DESCRIPTION................................................................................... 19 2-SUSPENSION.......................................................................................... 21 FRONT............................................................................................. 21 FRONT......................................................................................... 22 SPECIFICATIONS - TORQUE CHART............................................................. 22 SPECIAL TOOLS............................................................................. 22 FRONT SUSPENSION...................................................................... 22 BUSHINGS...................................................................................... 23 REMOVAL................................................................................... 23 INSTALLATION.............................................................................. 23 HUB / BEARING................................................................................. 24 DIAGNOSIS AND TESTING -................................................................... 24 REMOVAL................................................................................... 24 INSTALLATION.............................................................................. 25 KNUCKLE....................................................................................... 25 REMOVAL................................................................................... 25 INSTALLATION.............................................................................. 25 LOWER BALL JOINT.............................................................................. 26 REMOVAL................................................................................... 26 INSTALLATION.............................................................................. 26 LOWER CONTROL ARM............................................................................. 26 REMOVAL................................................................................... 26 INSTALLATION.............................................................................. 26 SPRING........................................................................................ 27 REMOVAL................................................................................... 27 INSTALLATION.............................................................................. 28 SPRING CLAMP PLATES........................................................................... 28 REMOVAL................................................................................... 28 INSTALLATION.............................................................................. 28 SPRING STOP PLATES............................................................................ 29 REMOVAL................................................................................... 29 INSTALLATION.............................................................................. 29 STABILIZER BAR................................................................................ 29 DESCRIPTION............................................................................... 29 OPERATION................................................................................. 29 REMOVAL................................................................................... 29 INSTALLATION.............................................................................. 29 STABILIZER LINK............................................................................... 29 REMOVAL................................................................................... 29 INSTALLATION.............................................................................. 29 STRUT......................................................................................... 30 REMOVAL................................................................................... 30 INSTALLATION.............................................................................. 30 REAR.............................................................................................. 31 REAR.......................................................................................... 31 DESCRIPTION............................................................................... 31 DIAGNOSIS AND TESTING - SPRING AND SHOCK.................................................. 31 SPECIFICATIONS - TORQUE CHART............................................................. 32 SHOCK......................................................................................... 33 DIAGNOSIS AND TESTING - SHOCK............................................................. 33 REMOVAL................................................................................... 33 INSTALLATION.............................................................................. 33 SPRING........................................................................................ 34 DESCRIPTION............................................................................... 34 OPERATION................................................................................. 34 REMOVAL................................................................................... 34 REMOVAL - (SRW)....................................................................... 34 REMOVAL - (DRW)....................................................................... 34 INSTALLATION.............................................................................. 34 INSTALLATION - (SRW).................................................................. 34 INSTALLATION - (DRW).................................................................. 35 SPRING SHACKLE................................................................................ 35 REMOVAL................................................................................... 35 INSTALLATION.............................................................................. 35 STABILIZER BAR................................................................................ 35 REMOVAL................................................................................... 35 INSTALLATION.............................................................................. 35 STABILIZER LINK............................................................................... 36 REMOVAL................................................................................... 36 INSTALLATION.............................................................................. 36 WHEEL ALIGNMENT................................................................................... 37 WHEEL ALIGNMENT............................................................................... 37 DESCRIPTION............................................................................... 37 DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION.......................................... 37 STANDARD PROCEDURE - TOE ADJUSTMENT....................................................... 39 SPECIFICATIONS............................................................................ 39 3-DIFFERENTIAL & DRIVELINE............................................................................ 41 PROPELLER SHAFT................................................................................... 41 PROPELLER SHAFT............................................................................... 41 DIAGNOSIS AND TESTING..................................................................... 41 PROPELLER SHAFT VIBRATION............................................................. 41 PROPELLER SHAFT BALANCE............................................................... 42 PROPELLER SHAFT RUNOUT................................................................ 43 STANDARD PROCEDURE........................................................................ 43 PROPELLER SHAFT ANGLE................................................................. 43 TWO/THREE-PIECE PROPELLER SHAFT....................................................... 44 SPECIFICATIONS............................................................................ 45 SPECIAL TOOLS............................................................................. 45 PROPELLER SHAFT............................................................................... 46 REMOVAL................................................................................... 46 INSTALLATION.............................................................................. 46 CENTER BEARING................................................................................ 48 REMOVAL................................................................................... 48 INSTALLATION.............................................................................. 49 REAR AXLE......................................................................................... 50 REAR AXLE..................................................................................... 50 DESCRIPTION............................................................................... 50 OPERATION................................................................................. 50 DIAGNOSIS AND TESTING..................................................................... 50 GEAR NOISE............................................................................ 50 BEARING NOISE......................................................................... 50 LOW SPEED KNOCK....................................................................... 51 VIBRATION............................................................................. 51 DRIVELINE SNAP........................................................................ 51 STANDARD PROCEDURE - DRAIN AND FILL....................................................... 51 REMOVAL................................................................................... 51 INSTALLATION.............................................................................. 52 SPECIFICATIONS............................................................................ 53 SPECIAL TOOLS............................................................................. 54 AXLE SHAFTS................................................................................... 55 REMOVAL................................................................................... 55 INSTALLATION.............................................................................. 55 AXLE BEARINGS/SEALS........................................................................... 57 REMOVAL................................................................................... 57 INSTALLATION.............................................................................. 57 AXLE SHAFTS - DUAL REAR WHEELS................................................................ 59 REMOVAL................................................................................... 59 INSTALLATION.............................................................................. 59 AXLE HUB BEARINGS/SEALS....................................................................... 60 REMOVAL................................................................................... 60 INSTALLATION.............................................................................. 60 PINION SEAL................................................................................... 62 REMOVAL................................................................................... 62 INSTALLATION.............................................................................. 62 5-BRAKES.............................................................................................. 65 BRAKES - BASE..................................................................................... 65 BRAKES - BASE................................................................................. 66 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM................................................. 66 PRELIMINARY BRAKE CHECK............................................................... 66 ROAD TESTING.......................................................................... 67 BRAKE NOISES.......................................................................... 68 STANDARD PROCEDURE........................................................................ 68 STANDARD PROCEDURE - MANUAL BLEEDING.................................................. 68 STANDARD PROCEDURE - PRESSURE BLEEDING................................................ 69 HYDRAULIC/MECHANICAL.......................................................................... 69 SPECIFICATIONS............................................................................ 69 SPECIFICATIONS - TORQUE CHART......................................................... 69 BASE BRAKE............................................................................ 70 SPECIAL TOOLS............................................................................. 71 BRAKES................................................................................ 71 BRAKE LINES................................................................................... 72 STANDARD PROCEDURE........................................................................ 72 STANDARD PROCEDURE - ISO FLARING...................................................... 72 STANDARD PROCEDURE - DOUBLE INVERTED FLARING.......................................... 72 BRAKE PADS/SHOES.............................................................................. 73 REMOVAL................................................................................... 73 REMOVAL - FRONT (SRW)................................................................. 73 REMOVAL - FRONT (DRW)................................................................. 73 REMOVAL - REAR (16” WHEELS) (SRW)..................................................... 73 REMOVAL - REAR (15” WHEELS) (SRW)..................................................... 73 REMOVAL - REAR (DRW).................................................................. 74 INSTALLATION.............................................................................. 74 INSTALLATION - FRONT (SRW)............................................................ 74 INSTALLATION - FRONT (DRW)............................................................ 75 INSTALLATION - REAR (16” WHEELS) (SRW)................................................ 75 INSTALLATION - REAR (16” WHEELS) (SRW)................................................ 75 INSTALLATION - REAR (DRW)............................................................. 75 DISC BRAKE CALIPERS........................................................................... 75 REMOVAL................................................................................... 75 REMOVAL - FRONT (SRW)................................................................. 75 REMOVAL - FRONT (DRW)................................................................. 76 REMOVAL - REAR (SRW).................................................................. 76 REMOVAL - REAR (DRW).................................................................. 76 INSTALLATION.............................................................................. 76 INSTALLATION - FRONT (SRW)............................................................ 76 INSTALLATION - FRONT (DRW)............................................................ 77 INSTALLATION - REAR (SRW)............................................................. 77 INSTALLATION - REAR (DRW)............................................................. 77 DISC BRAKE CALIPER ADAPTER.................................................................... 77 REMOVAL................................................................................... 77 REMOVAL - FRONT....................................................................... 77 REMOVAL - REAR........................................................................ 77 INSTALLATION.............................................................................. 78 INSTALLATION - FRONT.................................................................. 78 INSTALLATION - REAR................................................................... 78 FLUID......................................................................................... 78 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................... 78 STANDARD PROCEDURE - BRAKE FLUID LEVEL.................................................... 78 SPECIFICATIONS............................................................................ 78 BRAKE FLUID........................................................................... 78 FLUID RESERVOIR............................................................................... 79 REMOVAL................................................................................... 79 INSTALLATION.............................................................................. 79 ALB LEVER..................................................................................... 79 REMOVAL................................................................................... 79 INSTALLATION.............................................................................. 79 ALB CONTROLLER................................................................................ 79 REMOVAL................................................................................... 79 INSTALLATION.............................................................................. 79 ADJUSTMENTS............................................................................... 80 ADJUSTMENT............................................................................ 80 MASTER CYLINDER............................................................................... 80 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 80 POWER BOOSTER VACUUM TEST............................................................. 81 POWER BOOSTER CHECK VALVE TEST........................................................ 81 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 81 REMOVAL................................................................................... 81 INSTALLATION.............................................................................. 82 PEDAL......................................................................................... 82 REMOVAL................................................................................... 82 INSTALLATION.............................................................................. 83 POWER BRAKE BOOSTER........................................................................... 83 DESCRIPTION............................................................................... 83 OPERATION................................................................................. 83 REMOVAL................................................................................... 83 INSTALLATION.............................................................................. 83 ROTORS........................................................................................ 83 REMOVAL................................................................................... 83 REMOVAL - FRONT (SRW)................................................................. 83 REMOVAL - REAR (SRW).................................................................. 84 REMOVAL - FRONT (DRW)................................................................. 84 REMOVAL - REAR (DRW).................................................................. 84 INSTALLATION.............................................................................. 85 INSTALLATION - FRONT (SRW)............................................................ 85 INSTALLATION - REAR (SRW)............................................................. 85 INSTALLATION - FRONT (DRW)............................................................ 85 INSTALLATION - REAR (DRW)............................................................. 85 SUPPORT PLATE................................................................................. 86 REMOVAL - REAR............................................................................ 86 INSTALLATION - REAR....................................................................... 86 PARKING BRAKE................................................................................. 86 SPECIFICATIONS............................................................................ 86 TORQUE CHART.......................................................................... 86 SPECIAL TOOLS............................................................................. 87 PARK BRAKE............................................................................ 87 CABLE TENSIONER............................................................................... 87 REMOVAL................................................................................... 87 INSTALLATION.............................................................................. 87 CABLES........................................................................................ 88 REMOVAL................................................................................... 88 REMOVAL - FRONT....................................................................... 88 REMOVAL - REAR........................................................................ 88 INSTALLATION.............................................................................. 88 INSTALLATION - FRONT.................................................................. 88 INSTALLATION - REAR................................................................... 89 ADJUSTMENTS............................................................................... 89 ADJUSTMENT - PARKING BRAKE CABLES..................................................... 89 LEVER......................................................................................... 90 REMOVAL................................................................................... 90 INSTALLATION.............................................................................. 90 SHOES......................................................................................... 90 REMOVAL................................................................................... 90 REMOVAL - (SRW)....................................................................... 90 REMOVAL - (DRW)....................................................................... 90 CLEANING - REAR DRUM IN HAT BRAKE......................................................... 91 INSTALLATION.............................................................................. 91 INSTALLATION - (SRW).................................................................. 91 INSTALLATION - (DRW).................................................................. 91 ADJUSTMENTS............................................................................... 91 ADJUSTMENT............................................................................ 91 BRAKES - ABS...................................................................................... 93 BRAKES - ABS.................................................................................. 93 SPECIFICATIONS - TORQUE CHART............................................................. 93 ELECTRICAL.................................................................................... 93 DESCRIPTION............................................................................... 93 OPERATION................................................................................. 93 FRONT WHEEL SPEED SENSOR...................................................................... 94 REMOVAL................................................................................... 94 INSTALLATION.............................................................................. 94 REAR WHEEL SPEED SENSOR....................................................................... 94 REMOVAL................................................................................... 94 INSTALLATION.............................................................................. 95 TONE WHEEL.................................................................................... 95 REMOVAL................................................................................... 95 INSTALLATION.............................................................................. 95 HCU (HYDRAULIC CONTROL UNIT).................................................................. 95 DESCRIPTION............................................................................... 95 REMOVAL................................................................................... 95 INSTALLATION.............................................................................. 96 7-COOLING............................................................................................. 97 COOLING........................................................................................... 97 OPERATION—COOLING SYSTEM...................................................................... 97 DIAGNOSIS AND TESTING......................................................................... 97 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS................................................ 97 ENGINE COOLING SYSTEM OVERHEATING..................................................... 97 DIAGNOSIS AND TESTING - COOLING SYSTEM.................................................... 98 ACCESSORY DRIVE................................................................................... 101 BELT TENSIONERS............................................................................... 101 DESCRIPTION............................................................................... 101 OPERATION................................................................................. 101 DRIVE BELTS................................................................................... 101 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT.............................................. 101 VISUAL DIAGNOSIS...................................................................... 101 NOISE DIAGNOSIS....................................................................... 102 REMOVAL................................................................................... 104 INSTALLATION.............................................................................. 104 ENGINE............................................................................................ 105 COOLANT....................................................................................... 105 DESCRIPTION............................................................................... 105 DIAGNOSIS AND TESTING - COOLING SYSTEM LEAKS.............................................. 106 ULTRAVIOLET LIGHT METHOD.............................................................. 106 PRESSURE TESTER METHOD................................................................ 106 INTERNAL LEAKAGE INSPECTION........................................................... 107 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER..................................... 107 STANDARD PROCEDURE........................................................................ 107 STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................ 107 STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................... 108 STANDARD PROCEDURE - REFILLING COOLING SYSTEM......................................... 108 COOLANT LEVEL SENSOR.......................................................................... 109 REMOVAL................................................................................... 109 INSTALLATION.............................................................................. 109 RADIATOR FAN.................................................................................. 109 REMOVAL................................................................................... 109 INSTALLATION.............................................................................. 109 ENGINE BLOCK HEATER........................................................................... 110 REMOVAL................................................................................... 110 INSTALLATION.............................................................................. 110 ENGINE COOLANT TEMP SENSOR.................................................................... 110 DESCRIPTION............................................................................... 110 REMOVAL................................................................................... 110 INSTALLATION.............................................................................. 111 ENGINE COOLANT THERMOSTAT..................................................................... 111 REMOVAL................................................................................... 111 INSTALLATION.............................................................................. 112 FAN DRIVE VISCOUS CLUTCH...................................................................... 112 REMOVAL................................................................................... 112 INSTALLATION.............................................................................. 112 RADIATOR...................................................................................... 112 REMOVAL................................................................................... 112 INSTALLATION.............................................................................. 113 RADIATOR PRESSURE CAP......................................................................... 114 DESCRIPTION............................................................................... 114 OPERATION................................................................................. 114 DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP............................................. 115 WATER PUMP.................................................................................... 115 REMOVAL................................................................................... 115 INSTALLATION.............................................................................. 116 8a-AUDIO/VIDEO........................................................................................ 117 AUDIO............................................................................................. 117 SPECIAL TOOLS................................................................................. 117 AUDIO..................................................................................... 117 ANTENNA BODY & CABLE.............................................................................. 117 REMOVAL....................................................................................... 117 INSTALLATION.................................................................................. 117 INSTRUMENT PANEL ANTENNA CABLE.................................................................... 117 REMOVAL....................................................................................... 117 INSTALLATION.................................................................................. 118 RADIO............................................................................................. 118 REMOVAL....................................................................................... 118 INSTALLATION.................................................................................. 118 SPEAKER........................................................................................... 118 REMOVAL....................................................................................... 118 INSTALLATION.................................................................................. 118 8b-CHIME/BUZZER....................................................................................... 119 CHIME/BUZZER...................................................................................... 119 DESCRIPTION................................................................................... 119 OPERATION..................................................................................... 119 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM.................................................. 120 8e-ELECTRONIC CONTROL MODULES......................................................................... 121 CENTRAL TIMER MODULE.............................................................................. 121 DESCRIPTION................................................................................... 121 OPERATION..................................................................................... 122 DIAGNOSIS AND TESTING - CENTRAL TIMER MODULE.................................................. 122 REMOVAL....................................................................................... 122 INSTALLATION.................................................................................. 122 CONTROLLER ANTILOCK BRAKE......................................................................... 123 DESCRIPTION................................................................................... 123 REMOVAL....................................................................................... 123 INSTALLATION.................................................................................. 123 ENGINE CONTROL MODULE............................................................................. 123 DESCRIPTION................................................................................... 123 REMOVAL....................................................................................... 124 INSTALLATION.................................................................................. 124 TRANSMISSION CONTROL MODULE....................................................................... 125 DESCRIPTION................................................................................... 125 OPERATION..................................................................................... 125 TCM SIGNALS............................................................................... 126 BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)................................................. 126 SHIFT SCHEDULES........................................................................... 126 DOWNSHIFT SAFETY.......................................................................... 127 ADAPTATION................................................................................ 127 CONTROLLER MODES OF OPERATION............................................................. 128 STANDARD PROCEDURE - TCM ADAPTATION........................................................... 128 8f-ENGINE SYSTEMS..................................................................................... 129 BATTERY SYSTEM.................................................................................... 129 BATTERY SYSTEM................................................................................ 129 DESCRIPTION............................................................................... 129 OPERATION................................................................................. 130 DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................... 130 MICRO 420 BATTERY TESTER.............................................................. 130 ABNORMAL BATTERY DISCHARGING.......................................................... 133 CLEANING.................................................................................. 133 INSPECTION................................................................................ 134 SPECIAL TOOLS............................................................................. 134 BATTERY SYSTEM SPECIAL TOOLS.......................................................... 134 BATTERY....................................................................................... 134 DESCRIPTION............................................................................... 134 OPERATION................................................................................. 135 DIAGNOSIS AND TESTING - BATTERY........................................................... 135 MICRO 420 BATTERY TESTER.............................................................. 135 STANDARD PROCEDURE........................................................................ 136 STANDARD PROCEDURE - BATTERY CHARGING................................................. 136 CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 137 CHARGING TIME REQUIRED............................................................ 137 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 138 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 138 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 139 BATTERY TESTING................................................................... 139 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL............................... 140 REMOVAL................................................................................... 140 UNDER HOOD BATTERY REMOVAL............................................................ 140 AUXILIARY BATTERY REMOVAL............................................................. 141 INSTALLATION.............................................................................. 141 UNDER HOOD BATTERY INSTALLATION....................................................... 141 AUXILIARY BATTERY INSTALLATION........................................................ 141 BATTERY HOLDDOWN.............................................................................. 142 DESCRIPTION............................................................................... 142 REMOVAL................................................................................... 142 INSTALLATION.............................................................................. 142 BATTERY CABLES................................................................................ 142 DESCRIPTION............................................................................... 142 OPERATION................................................................................. 142 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 142 REMOVAL................................................................................... 144 INSTALLATION.............................................................................. 144 BATTERY TRAY.................................................................................. 144 DESCRIPTION............................................................................... 144 OPERATION................................................................................. 144 REMOVAL................................................................................... 144 INSTALLATION.............................................................................. 144 CHARGING SYSTEM................................................................................... 145 CHARGING SYSTEM............................................................................... 145 SPECIFICATIONS............................................................................ 145 TORQUE – 2.7L DIESEL.................................................................. 145 SPECIAL TOOLS............................................................................. 145 GENERATOR..................................................................................... 146 DESCRIPTION............................................................................... 146 OPERATION................................................................................. 146 REMOVAL................................................................................... 146 INSTALLATION.............................................................................. 146 GENERATOR DECOUPLER PULLEY.................................................................... 147 DESCRIPTION............................................................................... 147 OPERATION................................................................................. 147 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 147 REMOVAL................................................................................... 148 INSTALLATION.............................................................................. 149 VOLTAGE REGULATOR............................................................................. 151 DESCRIPTION............................................................................... 151 STARTING SYSTEM................................................................................... 152 STARTING SYSTEM............................................................................... 152 DESCRIPTION............................................................................... 152 OPERATION................................................................................. 152 DIAGNOSIS AND TESTING - STARTING SYSTEM................................................... 153 INSPECTION............................................................................ 154 TESTING............................................................................... 154 SPECIFICATIONS............................................................................ 157 TORQUE - STARTER - DIESEL............................................................. 157 SPECIFICATIONS - STARTER MOTOR - DIESEL............................................... 157 STARTER MOTOR................................................................................. 157 DIAGNOSIS AND TESTING - STARTER MOTOR..................................................... 157 REMOVAL................................................................................... 158 INSTALLATION.............................................................................. 159 STARTER MOTOR RELAY........................................................................... 159 DESCRIPTION............................................................................... 159 REMOVAL................................................................................... 159 INSTALLATION.............................................................................. 160 8g-HEATED SYSTEMS..................................................................................... 161 HEATED SEATS...................................................................................... 161 DESCRIPTION................................................................................... 161 OPERATION..................................................................................... 162 DIAGNOSIS AND TESTING - HEATED SEATS.......................................................... 162 DRIVER HEATED SEAT SWITCH......................................................................... 162 DESCRIPTION................................................................................... 162 OPERATION..................................................................................... 162 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH............................................. 162 REMOVAL....................................................................................... 163 INSTALLATION.................................................................................. 163 HEATED SEAT ELEMENT............................................................................... 163 DESCRIPTION................................................................................... 163 OPERATION..................................................................................... 163 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT................................................... 163 HEATED SEAT RELAY................................................................................. 164 DESCRIPTION................................................................................... 164 OPERATION..................................................................................... 164 DIAGNOSIS AND TESTING - HEATED SEAT RELAY..................................................... 164 REMOVAL....................................................................................... 164 INSTALLATION.................................................................................. 164 HEATED SEAT SENSOR................................................................................ 164 DESCRIPTION................................................................................... 164 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR.................................................... 164 PASSENGER HEATED SEAT SWITCH...................................................................... 165 DESCRIPTION................................................................................... 165 OPERATION..................................................................................... 165 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH.......................................... 165 REMOVAL....................................................................................... 165 INSTALLATION.................................................................................. 165 8h-HORN............................................................................................... 167 HORN.............................................................................................. 167 REMOVAL....................................................................................... 167 INSTALLATION.................................................................................. 167 HORN SWITCH....................................................................................... 167 REMOVAL....................................................................................... 167 INSTALLATION.................................................................................. 167 8i-IGNITION CONTROL................................................................................... 169 IGNITION CONTROL.................................................................................. 169 SPECIAL TOOLS................................................................................. 169 GLOW PLUG......................................................................................... 169 REMOVAL....................................................................................... 169 INSTALLATION.................................................................................. 169 GLOW PLUG RELAY................................................................................... 170 DESCRIPTION................................................................................... 170 OPERATION..................................................................................... 170 DIAGNOSIS AND TESTING - GLOW PLUG RELAYS...................................................... 170 8j-INSTRUMENT CLUSTER................................................................................. 171 INSTRUMENT CLUSTER................................................................................ 172 DESCRIPTION................................................................................... 172 OPERATION..................................................................................... 175 INPUT AND OUTPUT CIRCUITS................................................................. 176 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER.................................................... 177 REMOVAL....................................................................................... 177 INSTALLATION.................................................................................. 179 ABS INDICATOR..................................................................................... 179 DESCRIPTION................................................................................... 179 OPERATION..................................................................................... 179 AIRBAG INDICATOR.................................................................................. 180 DESCRIPTION................................................................................... 180 OPERATION..................................................................................... 180 AMBIENT TEMPERATURE INDICATOR..................................................................... 181 DESCRIPTION................................................................................... 181 OPERATION..................................................................................... 181 BRAKE/PARK BRAKE INDICATOR........................................................................ 181 DESCRIPTION................................................................................... 181 OPERATION..................................................................................... 182 BRAKE WEAR INDICATOR.............................................................................. 182 DESCRIPTION................................................................................... 182 OPERATION..................................................................................... 182 CHARGING INDICATOR................................................................................ 183 DESCRIPTION................................................................................... 183 OPERATION..................................................................................... 183 CLOCK............................................................................................. 183 DESCRIPTION................................................................................... 183 OPERATION..................................................................................... 184 COOLANT LOW INDICATOR............................................................................. 184 DESCRIPTION................................................................................... 184 OPERATION..................................................................................... 184 ENGINE TEMPERATURE GAUGE.......................................................................... 185 DESCRIPTION................................................................................... 185 OPERATION..................................................................................... 185 FUEL FILTER CLOGGED INDICATOR..................................................................... 185 DESCRIPTION................................................................................... 185 OPERATION..................................................................................... 185 FUEL GAUGE........................................................................................ 186 DESCRIPTION................................................................................... 186 OPERATION..................................................................................... 186 GEAR SELECTOR INDICATOR........................................................................... 187 DESCRIPTION................................................................................... 187 OPERATION..................................................................................... 187 HIGH BEAM INDICATOR............................................................................... 187 DESCRIPTION................................................................................... 187 OPERATION..................................................................................... 187 LOW FUEL INDICATOR................................................................................ 188 DESCRIPTION................................................................................... 188 OPERATION..................................................................................... 188 LOW OIL LEVEL INDICATOR........................................................................... 188 DESCRIPTION................................................................................... 188 OPERATION..................................................................................... 188 MAINTENANCE INDICATOR............................................................................. 189 DESCRIPTION................................................................................... 189 OPERATION..................................................................................... 189 MALFUNCTION INDICATOR LAMP (MIL).................................................................. 190 DESCRIPTION................................................................................... 190 OPERATION..................................................................................... 190 MULTI-FUNCTION INDICATOR.......................................................................... 190 DESCRIPTION................................................................................... 190 OPERATION..................................................................................... 191 ODOMETER.......................................................................................... 191 DESCRIPTION................................................................................... 191 OPERATION..................................................................................... 192 SEATBELT INDICATOR................................................................................ 192 DESCRIPTION................................................................................... 192 OPERATION..................................................................................... 192 SPEEDOMETER....................................................................................... 193 DESCRIPTION................................................................................... 193 OPERATION..................................................................................... 193 TACHOMETER........................................................................................ 193 DESCRIPTION................................................................................... 193 OPERATION..................................................................................... 194 TRACTION CONTROL INDICATOR........................................................................ 194 DESCRIPTION................................................................................... 194 OPERATION..................................................................................... 194 TRACTION CONTROL MALFUNCTION INDICATOR............................................................ 195 DESCRIPTION................................................................................... 195 OPERATION..................................................................................... 195 TURN SIGNAL INDICATOR............................................................................. 195 DESCRIPTION................................................................................... 195 OPERATION..................................................................................... 195 WAIT-TO-START INDICATOR........................................................................... 196 DESCRIPTION................................................................................... 196 OPERATION..................................................................................... 196 WASHER FLUID INDICATOR............................................................................ 197 DESCRIPTION................................................................................... 197 OPERATION..................................................................................... 197 WATER-IN-FUEL INDICATOR........................................................................... 197 DESCRIPTION................................................................................... 197 OPERATION..................................................................................... 198 8l-LAMPS.............................................................................................. 199 LAMPS/LIGHTING - EXTERIOR......................................................................... 199 LAMPS/LIGHTING - EXTERIOR..................................................................... 200 DESCRIPTION............................................................................... 200 OPERATION................................................................................. 201 SPECIFICATIONS - LAMPS/LIGHTING - EXTERIOR................................................ 203 BACKUP LAMP BULB.............................................................................. 203 REMOVAL................................................................................... 203 INSTALLATION.............................................................................. 204 BRAKE LAMP SWITCH............................................................................. 204 REMOVAL0 - 2 VA (Continued)........................................................... 204 INSTALLATION.............................................................................. 204 BRAKE/PARK LAMP BULB.......................................................................... 205 REMOVAL................................................................................... 205 INSTALLATION.............................................................................. 205 CENTER HIGH MOUNTED STOP LAMP BULB............................................................ 205 REMOVAL................................................................................... 205 INSTALLATION.............................................................................. 205 CENTER HIGH MOUNTED STOP LAMP UN.............................................................. 206 REMOVAL................................................................................... 206 INSTALLATION.............................................................................. 206 CLEARANCE LAMP BULB........................................................................... 206 REMOVAL................................................................................... 206 INSTALLATION.............................................................................. 206 CLEARANCE LAMP UNIT........................................................................... 206 REMOVAL................................................................................... 206 INSTALLATION.............................................................................. 207 DAYTIME RUNNING LAMP RELAY.................................................................... 207 REMOVAL................................................................................... 207 INSTALLATION.............................................................................. 207 FOG LAMP BULB................................................................................. 208 REMOVAL................................................................................... 208 INSTALLATION.............................................................................. 208 FOG LAMP RELAY................................................................................ 208 REMOVAL................................................................................... 208 INSTALLATION.............................................................................. 209 FOG LAMP SWITCH............................................................................... 209 REMOVAL................................................................................... 209 INSTALLATION.............................................................................. 210 FRONT LAMP UNIT............................................................................... 210 REMOVAL................................................................................... 210 INSTALLATION.............................................................................. 210 ADJUSTMENTS............................................................................... 210 ADJUSTMENT - FRONT LAMP UNIT.......................................................... 210 VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT................................. 210 FRONT LAMP UNIT ALIGNMENT......................................................... 211 FRONT POSITION LAMP BULB...................................................................... 212 REMOVAL................................................................................... 212 INSTALLATION.............................................................................. 212 FRONT TURN/PARK/SIDE MARKER LAMP BULB......................................................... 212 REMOVAL................................................................................... 212 INSTALLATION.............................................................................. 213 HEADLAMP LEVELING MOTOR....................................................................... 213 REMOVAL................................................................................... 213 INSTALLATION.............................................................................. 214 HEADLAMP LEVELING SWITCH...................................................................... 214 REMOVAL................................................................................... 214 INSTALLATION.............................................................................. 215 HIGH BEAM HEADLAMP BULB....................................................................... 215 REMOVAL................................................................................... 215 INSTALLATION.............................................................................. 215 LICENSE PLATE LAMP BULB....................................................................... 215 REMOVAL................................................................................... 215 INSTALLATION.............................................................................. 216 LICENSE PLATE LAMP UNIT....................................................................... 216 REMOVAL................................................................................... 216 INSTALLATION.............................................................................. 216 LOW BEAM HEADLAMP BULB........................................................................ 216 REMOVAL................................................................................... 216 INSTALLATION.............................................................................. 217 MULTI-FUNCTION SWITCH......................................................................... 217 REMOVAL................................................................................... 217 INSTALLATION.............................................................................. 218 PARK BRAKE SWITCH............................................................................. 218 REMOVAL................................................................................... 218 INSTALLATION.............................................................................. 218 REAR SIDE MARKER LAMP BULB.................................................................... 219 REMOVAL................................................................................... 219 INSTALLATION.............................................................................. 219 REAR TURN LAMP BULB........................................................................... 219 REMOVAL................................................................................... 219 INSTALLATION.............................................................................. 220 REPEATER LAMP BULB............................................................................ 220 REMOVAL................................................................................... 220 INSTALLATION.............................................................................. 220 REPEATER LAMP UNIT............................................................................ 220 REMOVAL................................................................................... 220 INSTALLATION.............................................................................. 221 TAIL LAMP UNIT................................................................................ 221 REMOVAL................................................................................... 221 INSTALLATION.............................................................................. 221 TURN SIGNAL RELAY............................................................................. 222 REMOVAL................................................................................... 222 INSTALLATION.............................................................................. 222 LAMPS/LIGHTING - INTERIOR......................................................................... 223 LAMPS/LIGHTING - INTERIOR..................................................................... 223 DESCRIPTION............................................................................... 223 OPERATION................................................................................. 224 INTERIOR LIGHTING CIRCUIT............................................................. 224 EXTERIOR LIGHTING CIRCUIT............................................................. 224 SPECIFICATIONS - INTERIOR LIGHTING........................................................ 224 ASH RECEIVER/CIGAR LIGHTER LAMP UNIT.......................................................... 225 REMOVAL................................................................................... 225 INSTALLATION.............................................................................. 225 CARGO/DOME LAMP BULB.......................................................................... 225 REMOVAL................................................................................... 225 INSTALLATION.............................................................................. 225 CARGO/DOME LAMP UNIT.......................................................................... 226 REMOVAL................................................................................... 226 INSTALLATION.............................................................................. 226 CARGO LAMP SWITCH............................................................................. 226 REMOVAL................................................................................... 226 REMOVAL - INSTRUMENT PANEL............................................................ 226 REMOVAL - BULKHEAD.................................................................... 226 REMOVAL - REAR PILLAR................................................................. 226 INSTALLATION.............................................................................. 227 INSTALLATION - INSTRUMENT PANEL....................................................... 227 INSTALLATION - BULKHEAD............................................................... 227 INSTALLATION - REAR PILLAR............................................................ 227 DOME/READING LAMP BULB........................................................................ 227 REMOVAL................................................................................... 227 INSTALLATION.............................................................................. 227 DOME/READING LAMP UNIT........................................................................ 228 REMOVAL................................................................................... 228 INSTALLATION.............................................................................. 228 DOME LAMP/INTRUSION SENSOR BULB............................................................... 228 REMOVAL................................................................................... 228 INSTALLATION.............................................................................. 228 DOME LAMP/INTRUSION SENSOR.................................................................... 229 REMOVAL................................................................................... 229 INSTALLATION.............................................................................. 229 DOOR JAMB SWITCH.............................................................................. 229 REMOVAL................................................................................... 229 INSTALLATION.............................................................................. 229 ENTRY/EXIT LAMP BULB.......................................................................... 229 REMOVAL................................................................................... 229 INSTALLATION.............................................................................. 230 ENTRY/EXIT LAMP UNIT.......................................................................... 230 REMOVAL................................................................................... 230 INSTALLATION.............................................................................. 230 TIME DELAY RELAY.............................................................................. 230 REMOVAL................................................................................... 230 INSTALLATION.............................................................................. 231 8n-POWER SYSTEMS...................................................................................... 233 POWER LOCKS....................................................................................... 233 POWER LOCKS................................................................................... 233 DESCRIPTION............................................................................... 233 CENTRAL LOCKING....................................................................... 233 REMOTE KEYLESS ENTRY.................................................................. 233 AUTO DOOR LOCKS....................................................................... 233 ACCIDENT RESPONSE..................................................................... 233 DOOR LOCK MOTOR............................................................................... 233 REMOVAL................................................................................... 233 INSTALLATION.............................................................................. 233 REMOTE KEYLESS ENTRY TRANSMITTER.............................................................. 234 DESCRIPTION............................................................................... 234 MASTER LOCK SWITCH............................................................................ 234 DESCRIPTION............................................................................... 234 DIAGNOSIS AND TESTING - MASTER LOCK SWITCH................................................ 234 REMOVAL................................................................................... 234 INSTALLATION.............................................................................. 234 POWER MIRRORS..................................................................................... 235 POWER MIRRORS................................................................................. 235 DESCRIPTION............................................................................... 235 POWER MIRROR SWITCH........................................................................... 235 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH............................................... 235 REMOVAL................................................................................... 235 INSTALLATION.............................................................................. 236 POWER WINDOWS..................................................................................... 237 POWER WINDOWS................................................................................. 237 DESCRIPTION............................................................................... 237 OPERATION................................................................................. 237 WINDOW SWITCH......................................................................... 237 WINDOW MOTOR.......................................................................... 237 WINDOW MOTOR.................................................................................. 237 REMOVAL................................................................................... 237 POWER WINDOW SWITCH........................................................................... 237 DIAGNOSIS AND TESTING - POWER WINDOW SWITCH............................................... 237 REMOVAL................................................................................... 238 INSTALLATION.............................................................................. 238 8o-RESTRAINTS......................................................................................... 239 RESTRAINTS........................................................................................ 240 DESCRIPTION................................................................................... 240 ACTIVE RESTRAINTS......................................................................... 241 PASSIVE RESTRAINTS........................................................................ 241 OPERATION..................................................................................... 242 ACTIVE RESTRAINTS......................................................................... 242 PASSIVE RESTRAINTS........................................................................ 242 WARNING....................................................................................... 243 WARNINGS - RESTRAINT SYSTEM............................................................... 243 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM......................................... 243 STANDARD PROCEDURE............................................................................ 244 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 244 SUPPLEMENTAL RESTRAINT STORAGE........................................................ 244 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 244 CLEANUP PROCEDURE..................................................................... 244 STANDARD PROCEDURE - VERIFICATION TEST.................................................... 245 AIRBAG CONTROL MODULE............................................................................. 246 DESCRIPTION................................................................................... 246 OPERATION..................................................................................... 247 REMOVAL....................................................................................... 248 INSTALLATION.................................................................................. 249 CLOCKSPRING....................................................................................... 250 DESCRIPTION................................................................................... 250 OPERATION..................................................................................... 251 STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 251 REMOVAL....................................................................................... 252 INSTALLATION.................................................................................. 253 DRIVER AIRBAG..................................................................................... 254 DESCRIPTION................................................................................... 254 OPERATION..................................................................................... 255 REMOVAL....................................................................................... 255 INSTALLATION.................................................................................. 256 FRONT SEAT BELT & RETRACTOR....................................................................... 257 REMOVAL....................................................................................... 257 INSTALLATION.................................................................................. 259 FRONT SEAT BELT BUCKLE............................................................................ 260 REMOVAL....................................................................................... 260 INSTALLATION.................................................................................. 261 PASSENGER AIRBAG.................................................................................. 261 DESCRIPTION................................................................................... 261 OPERATION..................................................................................... 262 REMOVAL....................................................................................... 262 INSTALLATION.................................................................................. 264 PASSENGER AIRBAG BRACKET.......................................................................... 265 REMOVAL....................................................................................... 265 INSTALLATION.................................................................................. 265 REAR SEAT BELT & RETRACTOR........................................................................ 265 REMOVAL....................................................................................... 265 INSTALLATION.................................................................................. 267 REAR SEAT BELT BUCKLE............................................................................. 267 REMOVAL....................................................................................... 267 REMOVAL - INBOARD......................................................................... 267 REMOVAL - OUTBOARD........................................................................ 268 INSTALLATION.................................................................................. 268 INSTALLATION - INBOARD.................................................................... 268 INSTALLATION - OUTBOARD................................................................... 269 SEAT BELT SWITCH.................................................................................. 269 DESCRIPTION................................................................................... 269 OPERATION..................................................................................... 269 SEAT BELT TENSIONER............................................................................... 269 DESCRIPTION................................................................................... 269 OPERATION..................................................................................... 270 SEAT BELT TURNING LOOP ADJUSTER................................................................... 271 REMOVAL....................................................................................... 271 INSTALLATION.................................................................................. 272 8p-SPEED CONTROL...................................................................................... 273 SPEED CONTROL..................................................................................... 273 DESCRIPTION................................................................................... 273 OPERATION..................................................................................... 273 SPECIFICATIONS................................................................................ 274 TORQUE.................................................................................... 274 CABLE............................................................................................. 275 DESCRIPTION................................................................................... 275 SERVO............................................................................................. 275 DESCRIPTION................................................................................... 275 SWITCH............................................................................................ 275 REMOVAL....................................................................................... 275 INSTALLATION.................................................................................. 275 8q-VEHICLE THEFT SECURITY............................................................................. 277 VEHICLE THEFT SECURITY............................................................................ 277 DESCRIPTION................................................................................... 277 OPERATION..................................................................................... 277 DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY................................................ 277 INTRUSION SENSOR.................................................................................. 278 REMOVAL....................................................................................... 278 INSTALLATION.................................................................................. 278 SECURITY SYSTEM MODULE............................................................................ 278 REMOVAL....................................................................................... 278 INSTALLATION.................................................................................. 278 SENTRY KEY REMOTE ENTRY MODULE.................................................................... 278 DESCRIPTION................................................................................... 278 SENTRY KEY IMMOBILIZER.................................................................... 279 REMOTE KEYLESS ENTRY (RKE)................................................................ 279 OPERATION..................................................................................... 279 SENTRY KEY IMMOBILIZER.................................................................... 279 REMOTE KEYLESS ENTRY...................................................................... 279 REMOVAL....................................................................................... 279 SENTRY KEY REMOTE ENTRY MODULE............................................................ 279 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING........................................... 280 INSTALLATION.................................................................................. 280 SENTRY KEY REMOTE ENTRY MODULE............................................................ 280 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING........................................... 280 SIREN............................................................................................. 280 REMOVAL....................................................................................... 280 INSTALLATION.................................................................................. 280 TRANSPONDER KEY................................................................................... 281 DESCRIPTION................................................................................... 281 OPERATION..................................................................................... 281 8r-WIPERS/WASHERS..................................................................................... 283 WIPERS/WASHERS.................................................................................... 283 DESCRIPTION................................................................................... 283 OPERATING MODES........................................................................... 285 OPERATION..................................................................................... 285 DIAGNOSIS AND TESTING - WIPER & WASHER SYSTEM................................................. 287 CLEANING - WIPER & WASHER SYSTEM.............................................................. 287 WIPER SYSTEM.............................................................................. 287 WASHER SYSTEM............................................................................. 287 INSPECTION - WIPER & WASHER SYSTEM............................................................ 288 WIPER SYSTEM.............................................................................. 288 WASHER SYSTEM............................................................................. 288 CHECK VALVE....................................................................................... 289 DESCRIPTION................................................................................... 289 OPERATION..................................................................................... 289 REMOVAL....................................................................................... 289 INSTALLATION.................................................................................. 289 WASHER FLUID LEVEL SWITCH......................................................................... 289 DESCRIPTION................................................................................... 289 OPERATION..................................................................................... 290 WASHER HOSES/TUBES................................................................................ 290 DESCRIPTION................................................................................... 290 OPERATION..................................................................................... 291 WASHER NOZZLE..................................................................................... 291 DESCRIPTION................................................................................... 291 OPERATION..................................................................................... 291 REMOVAL....................................................................................... 291 INSTALLATION.................................................................................. 291 WASHER PUMP/MOTOR................................................................................. 291 DESCRIPTION................................................................................... 291 OPERATION..................................................................................... 292 REMOVAL....................................................................................... 292 INSTALLATION.................................................................................. 292 WASHER RESERVOIR.................................................................................. 293 DESCRIPTION................................................................................... 293 OPERATION..................................................................................... 293 REMOVAL....................................................................................... 293 INSTALLATION.................................................................................. 294 WIPER ARM......................................................................................... 295 DESCRIPTION................................................................................... 295 OPERATION..................................................................................... 296 REMOVAL....................................................................................... 296 INSTALLATION.................................................................................. 296 WIPER BLADE....................................................................................... 297 DESCRIPTION................................................................................... 297 OPERATION..................................................................................... 297 REMOVAL....................................................................................... 298 INSTALLATION.................................................................................. 298 WIPER LINKAGE..................................................................................... 299 DESCRIPTION................................................................................... 299 OPERATION..................................................................................... 299 REMOVAL....................................................................................... 299 INSTALLATION.................................................................................. 300 WIPER MOTOR....................................................................................... 301 DESCRIPTION................................................................................... 301 OPERATION..................................................................................... 301 REMOVAL....................................................................................... 301 INSTALLATION.................................................................................. 301 WIPER RELAY....................................................................................... 302 DESCRIPTION................................................................................... 302 OPERATION..................................................................................... 303 REMOVAL....................................................................................... 304 INSTALLATION.................................................................................. 304 8w-WIRING............................................................................................. 305 8W-01 WIRING DIAGRAM INFORMATION.................................................................. 307 WIRING DIAGRAM INFORMATION.................................................................... 307 DESCRIPTION............................................................................... 307 DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................. 307 SYMBOLS........................................................................... 307 TERMINOLOGY....................................................................... 311 DESCRIPTION - CIRCUIT INFORMATION..................................................... 311 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................. 311 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................ 311 IDENTIFICATION.................................................................... 311 LOCATIONS......................................................................... 312 WARNING................................................................................... 312 WARNINGS - GENERAL.................................................................... 312 DIAGNOSIS AND TESTING - WIRING HARNESS.................................................... 312 TROUBLESHOOTING TOOLS................................................................. 312 INTERMITTENT AND POOR CONNECTIONS..................................................... 313 TROUBLESHOOTING WIRING PROBLEMS....................................................... 313 STANDARD PROCEDURE........................................................................ 313 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................. 313 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................... 313 STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................... 314 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................... 314 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 314 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................... 314 CONNECTOR..................................................................................... 314 REMOVAL................................................................................... 314 INSTALLATION.............................................................................. 315 DIODE......................................................................................... 315 REMOVAL................................................................................... 315 INSTALLATION.............................................................................. 315 TERMINAL...................................................................................... 315 REMOVAL................................................................................... 315 INSTALLATION.............................................................................. 316 WIRE.......................................................................................... 316 STANDARD PROCEDURE - WIRE SPLICING........................................................ 316 8W-02 COMPONENT INDEX............................................................................. 317 8W-10 POWER DISTRIBUTION.......................................................................... 319 8W-11 FUSE BLOCK.................................................................................. 353 8W-15 GROUND DISTRIBUTION......................................................................... 393 8W-18 BUS COMMUNICATIONS.......................................................................... 421 8W-20 CHARGING SYSTEM............................................................................. 427 8W-21 STARTING SYSTEM............................................................................. 433 8W-30 FUEL/IGNITION SYSTEM........................................................................ 435 8W-31 TRANSMISSION CONTROL SYSTEM................................................................. 453 8W-33 VEHICLE SPEED CONTROL....................................................................... 463 8W-35 ANTILOCK BRAKES............................................................................. 467 8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................... 475 8W-40 INSTRUMENT CLUSTER.......................................................................... 489 8W-41 HORN/CIGAR LIGHTER.......................................................................... 497 8W-42 AIR CONDITIONER/HEATER...................................................................... 501 8W-43 AIRBAG SYSTEM............................................................................... 525 8W-44 INTERIOR LIGHTING........................................................................... 529 8W-45 CENTRAL TIMER MODULE........................................................................ 541 8W-47 AUDIO SYSTEM................................................................................ 549 8W-48 REAR WINDOW DEFOGGER........................................................................ 555 8W-50 FRONT LIGHTING.............................................................................. 561 8W-51 REAR LIGHTING............................................................................... 577 8W-52 TURN SIGNALS................................................................................ 587 8W-53 WIPERS...................................................................................... 593 8W-54 TRAILER TOW................................................................................. 597 8W-55 NAVIGATION/TELECOMMUNICATIONS............................................................... 601 8W-60 POWER WINDOWS............................................................................... 605 8W-61 POWER DOOR LOCKS............................................................................ 609 8W-62 POWER MIRRORS............................................................................... 617 8W-63 POWER SEATS................................................................................. 621 8W-70 SPLICE INFORMATION.......................................................................... 625 8W-80 CONNECTOR PIN-OUTS.......................................................................... 627 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................ 695 CONNECTOR/GROUND/SPLICE LOCATION.............................................................. 695 DESCRIPTION............................................................................... 695 8W-97 POWER DISTRIBUTION.......................................................................... 733 POWER DISTRIBUTION............................................................................ 733 DESCRIPTION............................................................................... 733 OPERATION................................................................................. 733 CIGAR LIGHTER OUTLET.......................................................................... 733 DESCRIPTION............................................................................... 733 OPERATION................................................................................. 734 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET.............................................. 734 REMOVAL................................................................................... 734 CIRCUIT BREAKER............................................................................... 734 DESCRIPTION............................................................................... 734 OPERATION................................................................................. 734 DIAGNOSIS AND TESTING - CIRCUIT BREAKER................................................... 734 FUSE BLOCK #1................................................................................. 734 DESCRIPTION............................................................................... 734 OPERATION................................................................................. 734 REMOVAL................................................................................... 735 INSTALLATION.............................................................................. 735 FUSE BLOCK #2................................................................................. 735 DESCRIPTION............................................................................... 735 OPERATION................................................................................. 735 POWER DISTRIBUTION CENTER..................................................................... 735 DESCRIPTION............................................................................... 735 OPERATION................................................................................. 735 POWER OUTLET.................................................................................. 735 DESCRIPTION............................................................................... 735 OPERATION................................................................................. 736 DIAGNOSIS AND TESTING - POWER OUTLET...................................................... 736 REMOVAL................................................................................... 736 INSTALLATION.............................................................................. 736 RELAY......................................................................................... 736 DESCRIPTION............................................................................... 736 OPERATION................................................................................. 737 DIAGNOSIS AND TESTING - RELAY............................................................. 737 DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST............................................ 737 REMOVAL................................................................................... 737 INSTALLATION.............................................................................. 737 9-ENGINE.............................................................................................. 739 ENGINE............................................................................................ 740 DESCRIPTION................................................................................... 740 STANDARD PROCEDURE............................................................................ 741 STANDARD PROCEDURE - COMPRESSION TESTING ENGINE........................................... 741 STANDARD PROCEDURE - CYLINDER LEAK DOWN TEST.............................................. 741 INSPECTING............................................................................ 741 STANDARD PROCEDURE - DETERMINING CYLINDER PRESSURE LOSS................................... 742 REMOVAL....................................................................................... 742 REMOVAL - ENGINE COVER.................................................................... 742 REMOVAL................................................................................... 742 INSTALLATION.................................................................................. 745 INSTALLATION - ENGINE COVER............................................................... 745 INSTALLATION.............................................................................. 745 SPECIFICATIONS - TORQUE SPECIFICATIONS........................................................ 746 SPECIAL TOOLS................................................................................. 752 AIR CLEANER ELEMENT............................................................................... 758 REMOVAL....................................................................................... 758 INSTALLATION.................................................................................. 758 AIR CLEANER HOUSING............................................................................... 758 REMOVAL....................................................................................... 758 INSTALLATION.................................................................................. 758 CYLINDER HEAD..................................................................................... 759 STANDARD PROCEDURE............................................................................ 759 STANDARD PROCEDURE - CYLINDER HEAD BOLT INSPECTION........................................ 759 STANDARD PROCEDURE - MEASURE CYLINDER HEAD SURFACE........................................ 759 REMOVAL....................................................................................... 760 REMOVAL - CYLINDER HEAD................................................................... 760 REMOVAL - CYLINDER HEAD FRONT COVER....................................................... 761 REMOVAL - CYLINDER HEAD GUIDE RAIL........................................................ 762 INSTALLATION.................................................................................. 763 INSTALLATION - CYLINDER HEAD.............................................................. 763 CYLINDER HEAD BOLT TORQUE SEQUENCE.................................................... 763 INSTALLATION - CYLINDER HEAD FRONT COVER.................................................. 764 INSTALLATION - CYLINDER HEAD GUIDE RAIL................................................... 764 CAMSHAFT(S)....................................................................................... 765 STANDARD PROCEDURE - CHECKING CAMSHAFT POSITION............................................... 765 REMOVAL....................................................................................... 766 INSTALLATION.................................................................................. 767 CYLINDER HEAD COVER(S)............................................................................ 768 REMOVAL....................................................................................... 768 INSTALLATION.................................................................................. 768 VALVE SPRINGS..................................................................................... 769 REMOVAL....................................................................................... 769 REMOVAL - VALVE SPRINGS................................................................... 769 REMOVAL - VALVES.......................................................................... 769 INSTALLATION.................................................................................. 770 INSTALLATION - VALVE SPRINGS.............................................................. 770 INSTALLATION - VALVES..................................................................... 771 ENGINE BLOCK...................................................................................... 772 STANDARD PROCEDURE............................................................................ 772 STANDARD PROCEDURE - REPLACING ENGINE CORE AND OIL GALLERY PLUGS.......................... 772 STANDARD PROCEDURE - MEASURING CYLINDER BORES............................................. 772 CRANKSHAFT........................................................................................ 773 STANDARD PROCEDURE - MEASURE CRANKSHAFT AND BLOCK JOURNALS.................................... 773 ASSIGN CRANKSHAFT BEARING SHELLS.......................................................... 773 REMOVAL....................................................................................... 773 INSTALLATION.................................................................................. 774 CRANKSHAFT OIL SEAL - REAR........................................................................ 775 REMOVAL....................................................................................... 775 INSTALLATION.................................................................................. 775 CRANKSHAFT OIL SEAL - FRONT....................................................................... 776 REMOVAL....................................................................................... 776 INSTALLATION.................................................................................. 776 FLYWHEEL.......................................................................................... 777 REMOVAL....................................................................................... 777 INSTALLATION.................................................................................. 777 INSTALLATION.............................................................................. 777 INSTALLATION.............................................................................. 777 PISTON & CONNECTING ROD........................................................................... 778 DESCRIPTION................................................................................... 778 STANDARD PROCEDURE............................................................................ 778 STANDARD PROCEDURE - CHECKING AND REPAIRING CONNECTING RODS............................... 778 CONNECTING ROD SPECIFICATIONS......................................................... 780 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION.......................................... 780 REMOVAL....................................................................................... 780 INSTALLATION.................................................................................. 781 PISTON RINGS...................................................................................... 784 STANDARD PROCEDURE - PISTON RING FITTING...................................................... 784 VIBRATION DAMPER.................................................................................. 785 REMOVAL....................................................................................... 785 INSTALLATION.................................................................................. 786 VACUUM PUMP....................................................................................... 786 DESCRIPTION................................................................................... 786 OPERATION..................................................................................... 786 REMOVAL....................................................................................... 786 INSTALLATION.................................................................................. 787 LEFT MOUNT........................................................................................ 787 REMOVAL....................................................................................... 787 INSTALLATION.................................................................................. 787 RIGHT MOUNT....................................................................................... 787 REMOVAL....................................................................................... 787 INSTALLATION.................................................................................. 787 OIL............................................................................................... 788 REMOVAL - OIL SEPARATOR....................................................................... 788 INSTALLATION - OIL SEPARATOR.................................................................. 788 OIL COOLER & LINES................................................................................ 788 REMOVAL....................................................................................... 788 INSTALLATION.................................................................................. 788 OIL FILTER........................................................................................ 789 REMOVAL....................................................................................... 789 INSTALLATION.................................................................................. 789 OIL JET........................................................................................... 789 DESCRIPTION................................................................................... 789 REMOVAL....................................................................................... 789 INSTALLATION.................................................................................. 789 OIL PAN........................................................................................... 790 REMOVAL....................................................................................... 790 INSTALLATION.................................................................................. 790 OIL PUMP.......................................................................................... 791 REMOVAL....................................................................................... 791 REMOVAL................................................................................... 791 REMOVAL- OIL PUMP CHAIN................................................................... 791 INSTALLATION.................................................................................. 792 INSTALLATION.............................................................................. 792 INSTALLATION - OIL PUMP CHAIN............................................................. 792 OIL TEMPERATURE SENSOR............................................................................ 794 DESCRIPTION................................................................................... 794 OPERATION..................................................................................... 794 REMOVAL....................................................................................... 795 INSTALLATION.................................................................................. 795 INTAKE MANIFOLD................................................................................... 795 REMOVAL....................................................................................... 795 INSTALLATION.................................................................................. 796 EXHAUST MANIFOLD.................................................................................. 797 REMOVAL....................................................................................... 797 INSTALLATION.................................................................................. 797 TIMING CHAIN COVER................................................................................ 797 REMOVAL....................................................................................... 797 INSTALLATION.................................................................................. 798 TIMING BELT/CHAIN AND SPROCKETS................................................................... 799 REMOVAL....................................................................................... 799 REMOVAL - TENSIONING AND SLIDE RAILS...................................................... 799 REMOVAL - INTERMEDIATE GEAR............................................................... 799 REMOVAL - TIMING CHAIN TENSIONING RAIL.................................................... 801 REMOVAL - TIMING CHAIN.................................................................... 801 INSTALLATION.................................................................................. 804 INSTALLATION - TENSIONING AND SLIDE RAIL.................................................. 804 INSTALLATION - INTERMEDIATE GEAR.......................................................... 804 INSTALLATION - TIMING CHAIN TENSIONING RAIL............................................... 804 ADJUSTMENTS................................................................................... 805 INSTALLATION - TIMING CHAIN............................................................... 805 TIMING CHAIN TENSIONER............................................................................ 808 REMOVAL....................................................................................... 808 INSTALLATION.................................................................................. 809 11-EXHAUST SYSTEM..................................................................................... 811 EXHAUST SYSTEM.................................................................................... 811 DESCRIPTION - 2.7L DIESEL..................................................................... 811 DIAGNOSIS AND TESTING - DIESEL ENGINE......................................................... 812 CATALYTIC CONVERTER............................................................................... 813 REMOVAL....................................................................................... 813 INSTALLATION.................................................................................. 813 EXHAUST PIPE...................................................................................... 813 REMOVAL....................................................................................... 813 INSTALLATION.................................................................................. 813 TAILPIPE.......................................................................................... 813 REMOVAL....................................................................................... 813 INSTALLATION.................................................................................. 813 TURBOCHARGER SYSTEM............................................................................... 813 DESCRIPTION................................................................................... 813 OPERATION..................................................................................... 814 CHARGE AIR COOLER AND PLUMBING.................................................................... 814 DESCRIPTION................................................................................... 814 OPERATION..................................................................................... 814 DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS...................................... 814 REMOVAL....................................................................................... 815 CLEANING...................................................................................... 815 INSPECTION.................................................................................... 815 INSTALLATION.................................................................................. 815 TURBOCHARGER...................................................................................... 816 DESCRIPTION................................................................................... 816 OPERATION..................................................................................... 816 REMOVAL....................................................................................... 817 REMOVAL................................................................................... 817 REMOVAL - VACUUM TRANSDUCER............................................................... 817 INSTALLATION.................................................................................. 818 INSTALLATION.............................................................................. 818 INSTALLATION - VACUUM TRANSDUCER.......................................................... 818 13-FRAME & BUMPERS.................................................................................... 819 BUMPERS........................................................................................... 819 SPECIFICATIONS - TORQUE....................................................................... 819 FRONT BUMPER - STEPS.............................................................................. 820 REMOVAL....................................................................................... 820 INSTALLATION.................................................................................. 820 FRONT FASCIA...................................................................................... 820 REMOVAL....................................................................................... 820 INSTALLATION.................................................................................. 820 REAR BUMPER - STEP................................................................................ 821 REMOVAL....................................................................................... 821 INSTALLATION.................................................................................. 821 REAR FASCIA....................................................................................... 821 REMOVAL....................................................................................... 821 INSTALLATION.................................................................................. 821 FRAME............................................................................................. 822 SPECIFICATIONS................................................................................ 822 SPECIFICATIONS - FRAME DIMENSIONS......................................................... 822 VEHICLE PREPARATION................................................................... 822 SPECIFICATIONS - TORQUE................................................................... 824 ENGINE CRADLE CROSSMEMBER......................................................................... 824 REMOVAL....................................................................................... 824 INSTALLATION.................................................................................. 826 REAR CROSSMEMBER - TRANSMISSION................................................................... 827 REMOVAL....................................................................................... 827 INSTALLATION.................................................................................. 827 TRAILER HITCH..................................................................................... 827 REMOVAL....................................................................................... 827 INSTALLATION.................................................................................. 828 14-FUEL SYSTEM........................................................................................ 829 FUEL SYSTEM....................................................................................... 829 WARNING....................................................................................... 829 WARNING - HIGH FUEL SYSTEM PRESSURE....................................................... 829 WARNING................................................................................... 829 DIAGNOSIS AND TESTING......................................................................... 829 DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES.......................................... 829 DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM................................................ 830 STANDARD PROCEDURE............................................................................ 830 STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS..................................... 830 STANDARD PROCEDURE - DISCONNECTING AND CONNECTING FUEL LINES.............................. 830 STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER..................................... 830 STANDARD PROCEDURE - LOW PRESSURE FUEL PUMP TEST.......................................... 831 FUEL DELIVERY..................................................................................... 832 FUEL DELIVERY................................................................................. 832 SPECIFICATIONS............................................................................ 832 TORQUE................................................................................ 832 SPECIAL TOOLS............................................................................. 833 FUEL SYSTEM........................................................................... 833 FUEL DRAIN TUBES.............................................................................. 833 DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS.......................................... 833 LOW-PRESSURE LINES0 - 4 VA (Continued)............................................ 833 HIGH-PRESSURE LINES................................................................... 833 FUEL FILTER................................................................................... 833 DESCRIPTION............................................................................... 833 OPERATION................................................................................. 833 REMOVAL................................................................................... 833 INSTALLATION.............................................................................. 834 FUEL LINES.................................................................................... 834 REMOVAL - HIGH PRESSURE LINES............................................................. 834 INSTALLATION - HIGH PRESSURE LINES........................................................ 835 FUEL PUMP..................................................................................... 835 DESCRIPTION............................................................................... 835 DESCRIPTION - HIGH PRESSURE PUMP...................................................... 835 DESCRIPTION - LOW PRESSURE PUMP....................................................... 835 OPERATION................................................................................. 835 OPERATION............................................................................. 835 LOW PRESSURE SIDE................................................................. 835 HIGH PRESSURE SIDE................................................................ 836 OPERATION - LOW PRESSURE PUMP......................................................... 836 REMOVAL................................................................................... 836 REMOVAL - HIGH PRESSURE PUMP.......................................................... 836 REMOVAL - LOW PRESSURE PUMP........................................................... 837 INSTALLATION.............................................................................. 838 INSTALLATION - HIGH PRESSURE PUMP..................................................... 838 INSTALLATION - LOW PRESSURE PUMP...................................................... 839 FUEL RAIL..................................................................................... 839 DESCRIPTION............................................................................... 839 OPERATION................................................................................. 839 REMOVAL................................................................................... 839 INSTALLATION.............................................................................. 839 FUEL TANK..................................................................................... 840 DESCRIPTION............................................................................... 840 REMOVAL................................................................................... 840 INSTALLATION.............................................................................. 841 FUEL TANK MODULE.............................................................................. 841 DESCRIPTION............................................................................... 841 REMOVAL................................................................................... 841 INSTALLATION.............................................................................. 842 FUEL LEVEL SENDING UNIT / SENSOR.............................................................. 843 DESCRIPTION............................................................................... 843 REMOVAL................................................................................... 843 INSTALLATION.............................................................................. 843 HI PRESSURE FUEL SHUTOFF SOL.................................................................. 844 DESCRIPTION............................................................................... 844 OPERATION................................................................................. 844 WATER IN FUEL SENSOR.......................................................................... 844 DESCRIPTION............................................................................... 844 OPERATION................................................................................. 844 FUEL INJECTION.................................................................................... 845 ACCELERATOR PEDAL POSITION SENSOR............................................................. 845 DESCRIPTION............................................................................... 845 BOOST PRESSURE SENSOR......................................................................... 845 DESCRIPTION............................................................................... 845 OPERATION................................................................................. 846 DIAGNOSIS AND TESTING - BOOST PRESSURE SENSOR............................................. 846 REMOVAL................................................................................... 846 INSTALLATION.............................................................................. 846 CAMSHAFT POSITION SENSOR...................................................................... 847 DESCRIPTION............................................................................... 847 OPERATION................................................................................. 847 REMOVAL................................................................................... 847 INSTALLATION.............................................................................. 847 CRANKSHAFT POSITION SENSOR.................................................................... 848 DESCRIPTION............................................................................... 848 OPERATION................................................................................. 848 REMOVAL................................................................................... 848 INSTALLATION.............................................................................. 848 FUEL INJECTOR................................................................................. 848 DESCRIPTION............................................................................... 848 FUEL INJECTOR......................................................................... 848 OPERATION................................................................................. 848 Injector closed (with high pressure applied).......................................... 849 Injector opens (start of injection)................................................... 849 Injector opens fully.................................................................. 850 Injector closes (end of injection).................................................... 850 STANDARD PROCEDURE........................................................................ 850 STANDARD PROCEDURE - INJECTOR CLASSIFICATION.......................................... 850 INJECTOR CLASSIFICATION PROCEDURE................................................. 850 STANDARD PROCEDURE - CLEANING FUEL INJECTORS.......................................... 850 REMOVAL................................................................................... 851 INSTALLATION.............................................................................. 851 FUEL PRESSURE SENSOR.......................................................................... 853 DESCRIPTION............................................................................... 853 DESCRIPTION........................................................................... 853 DESCRIPTION........................................................................... 853 OPERATION................................................................................. 853 OPERATION............................................................................. 853 OPERATION............................................................................. 853 REMOVAL................................................................................... 854 REMOVAL............................................................................... 854 REMOVAL............................................................................... 854 INSTALLATION.............................................................................. 854 INSTALLATION.......................................................................... 854 INSTALLATION.......................................................................... 855 FUEL PRESSURE SOLENOID........................................................................ 855 DESCRIPTION............................................................................... 855 OPERATION................................................................................. 855 REMOVAL................................................................................... 856 INSTALLATION.............................................................................. 856 FUEL TEMPERATURE SENSOR....................................................................... 857 DESCRIPTION............................................................................... 857 OPERATION................................................................................. 857 REMOVAL................................................................................... 857 INSTALLATION.............................................................................. 857 INLET AIR TEMPERATURE SENSOR.................................................................. 857 DESCRIPTION............................................................................... 857 OPERATION................................................................................. 857 REMOVAL................................................................................... 858 INSTALLATION.............................................................................. 858 MANIFOLD AIR FLOW (MAF) SENSOR................................................................ 858 DESCRIPTION............................................................................... 858 OPERATION................................................................................. 858 REMOVAL................................................................................... 859 INSTALLATION.............................................................................. 859 19-STEERING........................................................................................... 861 STEERING.......................................................................................... 861 DESCRIPTION................................................................................... 861 OPERATION..................................................................................... 861 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM................................................. 862 COLUMN............................................................................................ 865 COLUMN........................................................................................ 865 SPECIFICATIONS - TORQUE CHART............................................................. 865 INTERMEDIATE SHAFT............................................................................ 865 REMOVAL................................................................................... 865 INSTALLATION.............................................................................. 865 KEY/LOCK CYLINDER............................................................................. 866 REMOVAL................................................................................... 866 INSTALLATION.............................................................................. 867 STEERING WHEEL................................................................................ 867 REMOVAL................................................................................... 867 INSTALLATION.............................................................................. 867 GEAR.............................................................................................. 868 GEAR.......................................................................................... 868 DESCRIPTION............................................................................... 868 REMOVAL................................................................................... 868 INSTALLATION.............................................................................. 868 SPECIFICATIONS - TORQUE CHART............................................................. 869 LINKAGE........................................................................................... 870 LINKAGE....................................................................................... 870 DIAGNOSIS AND TESTING - OUTER TIE ROD END................................................. 870 SPECIFICATIONS - TORQUE CHART............................................................. 870 SPECIAL TOOLS............................................................................. 871 FRONT SUSPENSION...................................................................... 871 TIE ROD END................................................................................... 871 REMOVAL................................................................................... 871 INSTALLATION.............................................................................. 871 PUMP.............................................................................................. 872 PUMP.......................................................................................... 872 DESCRIPTION............................................................................... 872 OPERATION................................................................................. 872 DIAGNOSIS AND TESTING - PUMP LEAKAGE...................................................... 872 STANDARD PROCEDURE........................................................................ 872 STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION.......................... 872 STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM................................... 873 REMOVAL................................................................................... 873 INSTALLATION.............................................................................. 873 SPECIFICATIONS - TORQUE CHART............................................................. 874 FLUID......................................................................................... 874 STANDARD PROCEDURE........................................................................ 874 POWER STEERING PUMP FILL AND BLEED PROCEDURE.......................................... 874 FLUID COOLER TUBE............................................................................. 874 REMOVAL................................................................................... 874 INSTALLATION.............................................................................. 874 HOSES......................................................................................... 875 REMOVAL................................................................................... 875 REMOVAL - PRESSURE HOSE............................................................... 875 REMOVAL - RETURN LINE FROM PUMP TO COOLER TUBE........................................ 875 REMOVAL - RETURN HOSE FROM GEAR TO COOLER TUBE........................................ 875 INSTALLATION.............................................................................. 875 INSTALLATION - PRESSURE HOSE.......................................................... 875 INSTALLATION - RETURN LINE FROM PUMP TO COOLER TUBE................................... 875 INSTALLATION - RETURN HOSE FROM GEAR TO COOLER TUBE................................... 875 21-TRANSMISSION....................................................................................... 877 AUTOMATIC TRANSMISSION - NAG1..................................................................... 877 AUTOMATIC TRANSMISSION - NAG1................................................................. 878 DESCRIPTION............................................................................... 878 TRANSMISSION IDENTIFICATION........................................................... 878 TRANSMISSION GEAR RATIOS.............................................................. 878 TRANSMISSION HOUSING.................................................................. 878 MECHANICAL SECTION.................................................................... 879 ELECTROHYDRAULIC CONTROL UNIT......................................................... 879 SHIFT GROUPS.......................................................................... 880 OPERATION................................................................................. 880 EMERGENCY RUNNING FUNCTION............................................................ 880 CLUTCH APPLICATION.................................................................... 880 FIRST GEAR POWERFLOW.................................................................. 881 SECOND GEAR POWERFLOW................................................................. 883 THIRD GEAR POWERFLOW.................................................................. 885 FOURTH GEAR POWERFLOW................................................................. 887 FIFTH GEAR POWERFLOW.................................................................. 889 REVERSE GEAR POWERFLOW................................................................ 891 SHIFT GROUPS/ SHIFT SEQUENCE.......................................................... 893 DIAGNOSIS AND TESTING..................................................................... 899 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................ 899 DIAGNOSIS AND TESTING - PRELIMINARY................................................... 899 VEHICLE IS DRIVABLE............................................................... 899 VEHICLE IS DISABLED............................................................... 899 DIAGNOSIS AND TESTING - ROAD TESTING.................................................. 899 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................ 900 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR............................................... 903 REMOVAL................................................................................... 903 DISASSEMBLY............................................................................... 906 ASSEMBLY.................................................................................. 910 INSTALLATION.............................................................................. 917 SCHEMATICS AND DIAGRAMS................................................................... 923 SPECIFICATIONS - NAG1 AUTOMATIC TRANSMISSION.............................................. 944 SPECIAL TOOLS - NAG1 AUTOMATIC TRANSMISSION............................................... 945 DRIVING CLUTCHES.............................................................................. 948 DESCRIPTION............................................................................... 948 OPERATION................................................................................. 948 DRIVING CLUTCH K1............................................................................. 950 DISASSEMBLY............................................................................... 950 ASSEMBLY.................................................................................. 951 DRIVING CLUTCH K2............................................................................. 952 DISASSEMBLY............................................................................... 952 ASSEMBLY.................................................................................. 954 DRIVING CLUTCH K3............................................................................. 956 DISASSEMBLY............................................................................... 956 ASSEMBLY.................................................................................. 956 ELECTROHYDRAULIC UNIT......................................................................... 958 DESCRIPTION............................................................................... 958 ELECTRICAL CONTROL UNIT............................................................... 958 HYDRAULIC CONTROL UNIT................................................................ 958 OPERATION................................................................................. 963 ELECTRICAL CONTROL UNIT............................................................... 963 HYDRAULIC CONTROL UNIT................................................................ 964 REMOVAL................................................................................... 968 DISASSEMBLY............................................................................... 968 ASSEMBLY.................................................................................. 971 INSTALLATION.............................................................................. 976 FLUID AND FILTER.............................................................................. 977 DESCRIPTION............................................................................... 977 OPERATION................................................................................. 977 DIAGNOSIS AND TESTING..................................................................... 978 DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL.............................. 978 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID......................................... 978 DIAGNOSIS AND TESTING - FLUID CONTAMINATION........................................... 978 STANDARD PROCEDURE........................................................................ 978 STANDARD PROCEDURE - CHECK OIL LEVEL.................................................. 978 STANDARD PROCEDURE - TRANSMISSION FILL................................................ 979 STANDARD PROCEDURE - FLUID/FILTER SERVICE............................................. 980 FREEWHEELING CLUTCH........................................................................... 981 DESCRIPTION............................................................................... 981 OPERATION................................................................................. 981 DISASSEMBLY............................................................................... 982 ASSEMBLY.................................................................................. 983 GEARSHIFT CABLE............................................................................... 985 DIAGNOSIS AND TESTING - GEARSHIFT CABLE................................................... 985 REMOVAL................................................................................... 985 INSTALLATION.............................................................................. 985 HOLDING CLUTCHES.............................................................................. 987 DESCRIPTION............................................................................... 987 OPERATION................................................................................. 988 HOLDING CLUTCH B1............................................................................. 988 DISASSEMBLY............................................................................... 988 ASSEMBLY.................................................................................. 989 HOLDING CLUTCH B2............................................................................. 991 DISASSEMBLY............................................................................... 991 ASSEMBLY.................................................................................. 992 INPUT SPEED SENSORS........................................................................... 995 DESCRIPTION............................................................................... 995 OPERATION................................................................................. 995 OIL PUMP...................................................................................... 996 DESCRIPTION............................................................................... 996 OPERATION................................................................................. 996 DISASSEMBLY............................................................................... 996 ASSEMBLY.................................................................................. 997 OUTPUT SHAFT BEARING.......................................................................... 998 REMOVAL................................................................................... 998 INSTALLATION.............................................................................. 998 OUTPUT SHAFT SEAL.............................................................................1001 REMOVAL...................................................................................1001 INSTALLATION..............................................................................1001 PARK LOCK CABLE...............................................................................1001 REMOVAL...................................................................................1001 INSTALLATION..............................................................................1002 PISTONS.......................................................................................1004 DESCRIPTION...............................................................................1004 OPERATION.................................................................................1004 PRESSURE..............................................................................1005 PRESSURE ON A CONFINED FLUID..........................................................1005 FORCE MULTIPLICATION..................................................................1005 PISTON TRAVEL.........................................................................1005 PLANETARY GEARTRAIN...........................................................................1006 DESCRIPTION...............................................................................1006 OPERATION.................................................................................1006 DISASSEMBLY...............................................................................1007 ASSEMBLY..................................................................................1007 SHIFT MECHANISM...............................................................................1009 DESCRIPTION...............................................................................1009 OPERATION.................................................................................1009 REMOVAL...................................................................................1010 INSTALLATION..............................................................................1011 SOLENOID......................................................................................1012 DESCRIPTION...............................................................................1012 UPSHIFT/DOWNSHIFT SOLENOID VALVES.....................................................1013 MODULATING PRESSURE CONTROL SOLENOID VALVE............................................1013 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE.....................................1013 SHIFT PRESSURE CONTROL SOLENOID VALVE.................................................1014 OPERATION.................................................................................1014 UPSHIFT/DOWNSHIFT SOLENOID VALVES.....................................................1015 MODULATING PRESSURE CONTROL SOLENOID VALVE............................................1015 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE.....................................1015 SHIFT PRESSURE CONTROL SOLENOID VALVE.................................................1015 TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT.......................................................1015 DESCRIPTION...............................................................................1015 DESCRIPTION - PARK/NEUTRAL CONTACT....................................................1015 DESCRIPTION - TRANSMISSION TEMPERATURE SENSOR.........................................1016 OPERATION.................................................................................1016 OPERATION - PARK/NEUTRAL CONTACT......................................................1016 OPERATION - TRANSMISSION TEMPERATURE SENSOR...........................................1017 TORQUE CONVERTER..............................................................................1017 DESCRIPTION...............................................................................1017 IMPELLER..............................................................................1018 TURBINE...............................................................................1018 STATOR................................................................................1018 TORQUE CONVERTER CLUTCH (TCC).........................................................1019 OPERATION.................................................................................1019 TURBINE...............................................................................1020 STATOR................................................................................1021 TORQUE CONVERTER CLUTCH (TCC).........................................................1022 REMOVAL...................................................................................1022 INSTALLATION..............................................................................1022 TORQUE CONVERTER HUB SEAL.....................................................................1023 REMOVAL...................................................................................1023 INSTALLATION..............................................................................1023 22-TIRES/WHEELS.......................................................................................1025 TIRES/WHEELS......................................................................................1025 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................1025 METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................1026 METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................1026 STANDARD PROCEDURE............................................................................1026 STANDARD PROCEDURE - MATCH MOUNTING.......................................................1026 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE...............................................1027 STANDARD PROCEDURE - TIRE ROTATION........................................................1029 SPECIFICATIONS................................................................................1029 TORQUE CHART..............................................................................1029 TIRES.............................................................................................1030 DESCRIPTION...................................................................................1030 DESCRIPTION - TIRES.......................................................................1030 TIRE IDENTIFICATION...................................................................1030 TIRE CHAINS...........................................................................1030 DESCRIPTION - RADIAL – PLY TIRES..........................................................1030 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEEDS...............................................1030 DESCRIPTION - REPLACEMENT TIRES...........................................................1031 DESCRIPTION - TIRE INFLATION PRESSURES....................................................1031 DIAGNOSIS AND TESTING.........................................................................1032 DIAGNOSIS AND TESTING - PRESSURE GAUGES...................................................1032 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................1032 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................1032 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................1032 DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD.................................................1032 STANDARD PROCEDURE - REPAIRING LEAKS..........................................................1034 CLEANING......................................................................................1034 SPECIFICATIONS................................................................................1034 TIRES.....................................................................................1034 SPARE TIRE CARRIER................................................................................1034 REMOVAL.......................................................................................1034 INSTALLATION..................................................................................1034 WHEELS............................................................................................1035 DESCRIPTION...................................................................................1035 OPERATION.....................................................................................1035 DIAGNOSIS AND TESTING.........................................................................1035 WHEEL INSPECTION..........................................................................1035 STANDARD PROCEDURE............................................................................1035 STANDARD PROCEDURE - WHEEL REPLACEMENT....................................................1035 STANDARD PROCEDURE - DUAL REAR WHEEL INSTALLATION.........................................1036 REMOVAL.......................................................................................1037 INSTALLATION..................................................................................1037 23-BODY...............................................................................................1039 BODY..............................................................................................1039 WARNING.......................................................................................1039 SAFETY PRECAUTIONS AND WARNINGS...........................................................1039 DIAGNOSIS AND TESTING.........................................................................1039 DIAGNOSIS AND TESTING - WATER LEAKS.......................................................1039 VISUAL INSPECTION BEFORE WATER LEAK TESTS.............................................1040 WATER LEAK TESTS......................................................................1040 WATER LEAK DETECTION..................................................................1040 DIAGNOSIS AND TESTING - WIND NOISE........................................................1040 VISUAL INSPECTION BEFORE TESTS........................................................1040 STANDARD PROCEDURE............................................................................1041 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................1041 Rigid Plastics:.......................................................................1041 Semi-Rigid Plastics:..................................................................1041 Flexible Plastics:....................................................................1041 Repair Procedure:.....................................................................1041 Adhesion Promoter/Surface Modifier:...................................................1041 SAFETY PRECAUTION AND WARNINGS........................................................1041 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................1042 PANEL SECTIONING......................................................................1044 PANEL REINFORCEMENT...................................................................1044 VISUAL INSPECTION.....................................................................1045 PANEL SURFACE PREPARATION.............................................................1045 PATCHING PANELS.......................................................................1045 PANEL PATCH FABRICATIONS..............................................................1045 PANEL PATCH INSTALLATION..............................................................1046 PATCHED PANEL SURFACING...............................................................1048 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE................................................1048 SPECIFICATIONS................................................................................1050 DOOR - FRONT......................................................................................1051 CHECK.........................................................................................1051 REMOVAL...................................................................................1051 INSTALLATION..............................................................................1051 DOOR..........................................................................................1052 REMOVAL...................................................................................1052 INSTALLATION..............................................................................1052 ADJUSTMENTS...............................................................................1053 ADJUSTMENT............................................................................1053 DOOR GLASS....................................................................................1053 REMOVAL...................................................................................1053 INSTALLATION..............................................................................1053 EXTERIOR HANDLE...............................................................................1054 REMOVAL...................................................................................1054 INSTALLATION..............................................................................1054 HINGE.........................................................................................1055 REMOVAL...................................................................................1055 INSTALLATION..............................................................................1055 LATCH.........................................................................................1056 REMOVAL...................................................................................1056 INSTALLATION..............................................................................1056 LATCH STRIKER.................................................................................1056 REMOVAL...................................................................................1056 INSTALLATION..............................................................................1056 LOCK CYLINDER.................................................................................1056 REMOVAL...................................................................................1056 INSTALLATION..............................................................................1056 TRIM PANEL....................................................................................1057 REMOVAL...................................................................................1057 INSTALLATION..............................................................................1058 WINDOW REGULATOR - POWER......................................................................1058 REMOVAL...................................................................................1058 INSTALLATION..............................................................................1059 WINDOW REGULATOR - MANUAL.....................................................................1060 REMOVAL...................................................................................1060 INSTALLATION..............................................................................1061 DOORS - REAR......................................................................................1062 CHECK.........................................................................................1062 REMOVAL...................................................................................1062 INSTALLATION..............................................................................1062 DOOR..........................................................................................1063 REMOVAL...................................................................................1063 DISASSEMBLY...............................................................................1064 RIGHT DOOR ...........................................................................1064 LEFT DOOR ............................................................................1065 ASSEMBLY..................................................................................1066 RIGHT DOOR ...........................................................................1066 LEFT DOOR ............................................................................1067 INSTALLATION..............................................................................1068 ADJUSTMENTS...............................................................................1068 ADJUSTMENT............................................................................1068 DOOR GLASS....................................................................................1069 REMOVAL...................................................................................1069 INSTALLATION..............................................................................1069 EXTERIOR HANDLE...............................................................................1070 REMOVAL...................................................................................1070 INSTALLATION..............................................................................1071 HINGE.........................................................................................1072 REMOVAL...................................................................................1072 INSTALLATION..............................................................................1072 INSIDE HANDLE ACTUATOR........................................................................1072 REMOVAL...................................................................................1072 INSTALLATION..............................................................................1072 LATCH.........................................................................................1072 REMOVAL...................................................................................1072 INSTALLATION..............................................................................1073 TRIM PANEL....................................................................................1073 REMOVAL...................................................................................1073 INSTALLATION..............................................................................1073 DOORS - SLIDING...................................................................................1074 EXTERIOR HANDLE...............................................................................1074 REMOVAL...................................................................................1074 INSTALLATION..............................................................................1074 INSIDE HANDLE ACTUATOR........................................................................1075 REMOVAL...................................................................................1075 INSTALLATION..............................................................................1075 UPPER ROLLER ARM..............................................................................1075 REMOVAL...................................................................................1075 INSTALLATION..............................................................................1075 CENTER ROLLER ARM.............................................................................1075 REMOVAL...................................................................................1075 INSTALLATION..............................................................................1076 LOWER ROLLER ARM..............................................................................1076 REMOVAL...................................................................................1076 INSTALLATION..............................................................................1076 CENTER TRACK..................................................................................1076 REMOVAL...................................................................................1076 INSTALLATION..............................................................................1077 LATCH / LOCK CONTROL..........................................................................1077 REMOVAL...................................................................................1077 INSTALLATION..............................................................................1078 REAR LATCH....................................................................................1078 REMOVAL...................................................................................1078 INSTALLATION..............................................................................1078 REAR LATCH STRIKER............................................................................1079 REMOVAL...................................................................................1079 INSTALLATION..............................................................................1079 SLIDING DOOR..................................................................................1079 REMOVAL...................................................................................1079 DISASSEMBLY...............................................................................1080 ASSEMBLY..................................................................................1081 INSTALLATION..............................................................................1082 ADJUSTMENTS...............................................................................1082 ADJUSTMENT............................................................................1082 Gaps and Ridge Adjustment.........................................................1082 Flush Adjustment..................................................................1083 Door Stop Bumper Adjust...........................................................1083 STABILIZER....................................................................................1083 REMOVAL...................................................................................1083 INSTALLATION..............................................................................1083 TRIM PANEL....................................................................................1084 REMOVAL...................................................................................1084 Upper.................................................................................1084 Lower.................................................................................1084 INSTALLATION..............................................................................1084 Upper.................................................................................1084 Lower.................................................................................1084 DOOR GLASS....................................................................................1084 REMOVAL...................................................................................1084 INSTALLATION..............................................................................1084 EXTERIOR..........................................................................................1085 FUEL FILL DOOR................................................................................1085 REMOVAL...................................................................................1085 INSTALLATION..............................................................................1085 GRILLE........................................................................................1085 REMOVAL...................................................................................1085 INSTALLATION..............................................................................1085 LICENSE PLATE BRACKET.........................................................................1085 REMOVAL...................................................................................1085 INSTALLATION..............................................................................1085 RADIATOR CROSSMEMBER..........................................................................1085 REMOVAL...................................................................................1085 INSTALLATION..............................................................................1086 SIDE VIEW MIRROR..............................................................................1086 REMOVAL...................................................................................1086 Driver's Side.........................................................................1086 Passenger Side........................................................................1086 INSTALLATION..............................................................................1086 Driver's Side.........................................................................1086 Passenger Side........................................................................1087 SIDE VIEW MIRROR - GLASS......................................................................1087 REMOVAL...................................................................................1087 INSTALLATION..............................................................................1087 HOOD..............................................................................................1088 HINGE.........................................................................................1088 REMOVAL...................................................................................1088 INSTALLATION..............................................................................1088 HOOD..........................................................................................1088 REMOVAL...................................................................................1088 INSTALLATION..............................................................................1088 ADJUSTMENTS...............................................................................1089 ADJUSTMENT............................................................................1089 LATCH.........................................................................................1089 REMOVAL...................................................................................1089 INSTALLATION..............................................................................1089 LATCH RELEASE CABLE...........................................................................1089 REMOVAL...................................................................................1089 INSTALLATION..............................................................................1089 LATCH RELEASE HANDLE..........................................................................1090 REMOVAL...................................................................................1090 INSTALLATION..............................................................................1090 PROP ROD......................................................................................1090 REMOVAL...................................................................................1090 INSTALLATION..............................................................................1090 SAFETY LATCH..................................................................................1090 REMOVAL...................................................................................1090 INSTALLATION..............................................................................1090 INSTRUMENT PANEL..................................................................................1091 CLUSTER BEZEL.................................................................................1091 REMOVAL...................................................................................1091 INSTALLATION..............................................................................1092 ACCESSORY SWITCH BEZEL........................................................................1092 REMOVAL...................................................................................1092 INSTALLATION..............................................................................1092 INSTRUMENT PANEL CENTER BEZEL.................................................................1093 REMOVAL...................................................................................1093 INSTALLATION..............................................................................1093 ASH RECEIVER..................................................................................1093 REMOVAL...................................................................................1093 INSTALLATION..............................................................................1093 CUP HOLDER....................................................................................1093 REMOVAL...................................................................................1093 INSTALLATION..............................................................................1094 GLOVE BOX.....................................................................................1094 REMOVAL...................................................................................1094 INSTALLATION..............................................................................1094 INSTRUMENT PANEL ASSEMBLY.....................................................................1095 REMOVAL...................................................................................1095 INSTALLATION..............................................................................1099 TOP COVER - CLUSTER...........................................................................1100 REMOVAL...................................................................................1100 INSTALLATION..............................................................................1100 TOP COVER - TRAY..............................................................................1101 REMOVAL...................................................................................1101 INSTALLATION..............................................................................1102 TOP COVER.....................................................................................1102 REMOVAL...................................................................................1102 INSTALLATION..............................................................................1103 STEERING COLUMN OPENING COVER.................................................................1104 REMOVAL...................................................................................1104 INSTALLATION..............................................................................1104 INTERIOR..........................................................................................1105 INTERIOR......................................................................................1105 CAUTION...................................................................................1105 A-PILLAR TRIM.................................................................................1105 REMOVAL...................................................................................1105 INSTALLATION..............................................................................1106 ASSIST HANDLE.................................................................................1106 REMOVAL...................................................................................1106 INSTALLATION..............................................................................1106 B-PILLAR TRIM.................................................................................1106 REMOVAL...................................................................................1106 INSTALLATION..............................................................................1107 BULKHEAD TRIM PANEL...........................................................................1107 REMOVAL...................................................................................1107 INSTALLATION..............................................................................1107 CARPETS AND FLOOR MATS........................................................................1107 REMOVAL...................................................................................1107 Cargo/Passenger Van - Front...........................................................1107 Passenger Van - Rear..................................................................1107 Cargo Van - Rear......................................................................1108 INSTALLATION..............................................................................1108 Cargo/Passenger Van - Front...........................................................1108 Passenger Van - Rear..................................................................1108 Cargo Van - Rear......................................................................1108 COWL TRIM.....................................................................................1108 REMOVAL...................................................................................1108 INSTALLATION..............................................................................1108 D-PILLAR TRIM.................................................................................1108 REMOVAL...................................................................................1108 INSTALLATION..............................................................................1108 HEADLINER.....................................................................................1108 REMOVAL...................................................................................1108 Cab Section...........................................................................1108 Number 2 Section......................................................................1108 Number 3 Section......................................................................1108 Number 4 Section......................................................................1109 INSTALLATION..............................................................................1109 Cab Section...........................................................................1109 Number 2 Section......................................................................1109 Number 3 Section......................................................................1109 Number 4 Section......................................................................1109 QUARTER TRIM PANEL............................................................................1109 REMOVAL...................................................................................1109 Passenger Van.........................................................................1109 Cargo Van.............................................................................1110 INSTALLATION..............................................................................1110 Passenger Van.........................................................................1110 Cargo Van.............................................................................1110 REAR VIEW MIRROR..............................................................................1110 REMOVAL...................................................................................1110 INSTALLATION..............................................................................1110 INSTALLATION..........................................................................1110 INSTALLATION - REAR VIEW MIRROR SUPPORT BRACKET.......................................1110 STEPWELL SCUFF PADS...........................................................................1110 REMOVAL...................................................................................1110 INSTALLATION..............................................................................1111 SUN VISOR.....................................................................................1111 REMOVAL...................................................................................1111 INSTALLATION..............................................................................1111 PAINT.............................................................................................1112 PAINT.........................................................................................1112 SPECIFICATIONS - PAINT CODES..............................................................1112 BASECOAT/CLEARCOAT FINISH.....................................................................1112 DESCRIPTION...............................................................................1112 PAINT TOUCH-UP................................................................................1112 DESCRIPTION...............................................................................1112 STANDARD PROCEDURE - PAINT TOUCH-UP.......................................................1113 FINESSE SANDING/BUFFING & POLISH..............................................................1113 DESCRIPTION...............................................................................1113 SEATS.............................................................................................1114 ARMREST.......................................................................................1114 REMOVAL...................................................................................1114 INSTALLATION..............................................................................1114 HEADREST......................................................................................1114 REMOVAL...................................................................................1114 INSTALLATION..............................................................................1114 SEAT - FRONT..................................................................................1115 REMOVAL...................................................................................1115 INSTALLATION0 - 6 VA (Continued)......................................................1115 SEAT BACK - FRONT.............................................................................1115 REMOVAL...................................................................................1115 INSTALLATION..............................................................................1115 SEAT CUSHION - FRONT..........................................................................1116 REMOVAL...................................................................................1116 INSTALLATION..............................................................................1116 SEAT ADJUSTERS - FRONT........................................................................1116 REMOVAL...................................................................................1116 INSTALLATION..............................................................................1116 SEAT - REAR...................................................................................1117 REMOVAL...................................................................................1117 INSTALLATION..............................................................................1117 REAR SEAT BACK SHIELD.........................................................................1117 REMOVAL...................................................................................1117 INSTALLATION..............................................................................1117 SEAT BACK CUSHION/COVER - REAR................................................................1118 REMOVAL...................................................................................1118 INSTALLATION..............................................................................1118 SEAT CUSHION/COVER - REAR.....................................................................1118 REMOVAL...................................................................................1118 INSTALLATION..............................................................................1118 STATIONARY GLASS..................................................................................1119 BACKLITE - BULKHEAD TRIM PANEL................................................................1119 REMOVAL...................................................................................1119 INSTALLATION..............................................................................1119 QUARTER WINDOW................................................................................1119 REMOVAL...................................................................................1119 INSTALLATION..............................................................................1119 WINDSHIELD....................................................................................1120 WARNING...................................................................................1120 WINDSHIELD SAFETY PRECAUTIONS.........................................................1120 REMOVAL...................................................................................1120 INSTALLATION..............................................................................1121 Windshield Preparation - Installing A Previously Installed Windshield.................1122 Windshield Preparation - Installing A New Windshield..................................1123 Windshield Opening Preparation........................................................1123 Windshield Installation...............................................................1123 WEATHERSTRIP/SEALS................................................................................1125 FRONT DOOR INNER BELT WEATHERSTRIP............................................................1125 REMOVAL...................................................................................1125 INSTALLATION..............................................................................1125 FRONT DOOR OUTER BELT WEATHERSTRIP............................................................1125 REMOVAL...................................................................................1125 INSTALLATION..............................................................................1125 DOOR OPENING SEALS............................................................................1125 REMOVAL...................................................................................1125 INSTALLATION..............................................................................1125 BODY STRUCTURE....................................................................................1126 GAP AND FLUSH.................................................................................1126 SPECIFICATIONS............................................................................1126 OPENING DIMENSIONS............................................................................1128 SPECIFICATIONS............................................................................1128 24-HEATING & AIR CONDITIONING.........................................................................1129 HEATING & AIR CONDITIONING........................................................................1129 DESCRIPTION...................................................................................1129 DESCRIPTION - COOLING SYSTEM REQUIREMENTS.................................................1129 DESCRIPTION - HEATER AND AIR CONDITIONER..................................................1129 OPERATION - HEATER AND AIR CONDITIONER........................................................1130 DIAGNOSIS AND TESTING.........................................................................1131 DIAGNOSIS AND TESTING - FUNCTION TEST.....................................................1131 DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..............................................1131 DIAGNOSIS AND TESTING - HEATER PERFORMANCE................................................1132 MAXIMUM HEATER OUTPUT.................................................................1132 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW................................1132 POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT......................................1132 TEMPERATURE CONTROL...................................................................1132 SPECIFICATIONS................................................................................1133 A/C SYSTEM................................................................................1133 CONTROLS - FRONT..................................................................................1136 A/C COMPRESSOR CLUTCH.........................................................................1136 DESCRIPTION...............................................................................1136 OPERATION.................................................................................1136 STANDARD PROCEDURE........................................................................1137 STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP........................................1137 STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN.......................................1137 REMOVAL...................................................................................1137 INSPECTION - COMPRESSOR CLUTCH/COIL.......................................................1138 INSTALLATION..............................................................................1139 A/C COMPRESSOR CLUTCH COIL....................................................................1140 DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL............................................1140 A/C HEATER CONTROL............................................................................1140 DESCRIPTION...............................................................................1140 OPERATION.................................................................................1140 REMOVAL...................................................................................1140 INSTALLATION..............................................................................1141 A/C PRESSURE TRANSDUCER.......................................................................1141 DESCRIPTION...............................................................................1141 OPERATION.................................................................................1141 DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................1141 REMOVAL...................................................................................1142 INSTALLATION..............................................................................1142 AIR OUTLET TEMPERATURE SENSOR.................................................................1142 DESCRIPTION...............................................................................1142 OPERATION.................................................................................1143 REMOVAL...................................................................................1143 INSTALLATION..............................................................................1143 AMBIENT TEMPERATURE SENSOR....................................................................1143 DESCRIPTION...............................................................................1143 OPERATION.................................................................................1143 REMOVAL...................................................................................1143 INSTALLATION..............................................................................1144 BLOWER MOTOR RESISTOR BLOCK...................................................................1144 DESCRIPTION...............................................................................1144 OPERATION.................................................................................1144 DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR BLOCK.......................................1144 REMOVAL...................................................................................1144 INSTALLATION..............................................................................1145 BLOWER MOTOR SWITCH...........................................................................1145 DESCRIPTION...............................................................................1145 OPERATION.................................................................................1145 DIAGNOSIS AND TESTING - BLOWER MOTOR SWITCH...............................................1145 REMOVAL...................................................................................1145 EVAPORATOR TEMPERATURE SENSOR.................................................................1145 DESCRIPTION...............................................................................1145 OPERATION.................................................................................1146 REMOVAL...................................................................................1146 INSTALLATION..............................................................................1146 IN-CAR TEMPERATURE SENSOR.....................................................................1147 DESCRIPTION...............................................................................1147 OPERATION.................................................................................1147 DIAGNOSIS AND TESTING.....................................................................1147 REMOVAL...................................................................................1147 MODE DOOR CABLES..............................................................................1147 REMOVAL...................................................................................1147 INSTALLATION..............................................................................1147 RECIRCULATION DOOR ACTUATOR...................................................................1148 DESCRIPTION...............................................................................1148 OPERATION.................................................................................1148 REMOVAL...................................................................................1149 INSTALLATION..............................................................................1149 CONTROLS - REAR...................................................................................1150 BLOWER MOTOR SWITCH...........................................................................1150 DESCRIPTION...............................................................................1150 OPERATION.................................................................................1150 DIAGNOSIS AND TESTING.....................................................................1151 REMOVAL...................................................................................1151 INSTALLATION..............................................................................1151 BLOWER MOTOR RELAY............................................................................1151 DESCRIPTION...............................................................................1151 OPERATION.................................................................................1151 DIAGNOSIS AND TESTING.....................................................................1152 REMOVAL...................................................................................1152 INSTALLATION..............................................................................1152 CONTROL MODULE................................................................................1152 DESCRIPTION...............................................................................1152 OPERATION.................................................................................1152 DIAGNOSIS AND TESTING.....................................................................1152 REMOVAL...................................................................................1152 INSTALLATION..............................................................................1153 EVAPORATOR TEMPERATURE SENSOR.................................................................1153 DESCRIPTION...............................................................................1153 OPERATION.................................................................................1154 DIAGNOSIS AND TESTING.....................................................................1154 REMOVAL...................................................................................1154 INSTALLATION..............................................................................1154 SOLENOID VALVE................................................................................1155 DESCRIPTION...............................................................................1155 OPERATION.................................................................................1155 DIAGNOSIS AND TESTING.....................................................................1155 REMOVAL...................................................................................1155 INSTALLATION..............................................................................1156 TEMPERATURE CONTROL...........................................................................1157 DESCRIPTION...............................................................................1157 OPERATION.................................................................................1157 DIAGNOSIS AND TESTING.....................................................................1157 REMOVAL...................................................................................1157 INSTALLATION..............................................................................1157 TEMPERATURE SENSOR............................................................................1158 DESCRIPTION...............................................................................1158 OPERATION.................................................................................1158 DIAGNOSIS AND TESTING.....................................................................1158 REMOVAL...................................................................................1158 INSTALLATION..............................................................................1158 DISTRIBUTION - FRONT..............................................................................1159 AIR FILTER....................................................................................1159 REMOVAL...................................................................................1159 INSTALLATION..............................................................................1159 AIR OUTLETS...................................................................................1159 REMOVAL...................................................................................1159 INSTALLATION..............................................................................1160 BLOWER MOTOR..................................................................................1160 REMOVAL...................................................................................1160 INSTALLATION..............................................................................1161 DEFROSTER DUCTS...............................................................................1161 REMOVAL...................................................................................1161 INSTALLATION..............................................................................1161 FLOOR DISTRIBUTION DUCTS......................................................................1161 REMOVAL...................................................................................1161 INSTALLATION..............................................................................1162 HVAC HOUSING..................................................................................1162 REMOVAL...................................................................................1162 DISASSEMBLY...............................................................................1164 ASSEMBLY..................................................................................1164 INSTALLATION..............................................................................1164 INSTRUMENT PANEL DUCTS........................................................................1165 REMOVAL...................................................................................1165 INSTALLATION..............................................................................1166 DISTRIBUTION - REAR...............................................................................1167 AIR FILTER....................................................................................1167 REMOVAL...................................................................................1167 INSTALLATION..............................................................................1167 BLOWER MOTOR..................................................................................1167 REMOVAL...................................................................................1167 INSTALLATION..............................................................................1168 REAR A/C HOUSING..............................................................................1168 REMOVAL...................................................................................1168 INSTALLATION..............................................................................1169 PLUMBING..........................................................................................1171 PLUMBING......................................................................................1172 DESCRIPTION - REFRIGERANT LINE............................................................1172 OPERATION - REFRIGERANT LINE..............................................................1172 WARNING...................................................................................1172 CAUTION...................................................................................1173 CAUTION...............................................................................1173 REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS.............................................1173 DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS..........................................1174 SYSTEM EMPTY..........................................................................1174 SYSTEM LOW............................................................................1174 STANDARD PROCEDURE........................................................................1174 STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT.............................1174 MANIFOLD GAUGE SET CONNECTIONS....................................................1175 STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................1175 STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE......................................1175 STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE........................................1176 PARTIAL CHARGE METHOD.............................................................1176 SPECIFICATIONS............................................................................1177 CHARGE CAPACITY.......................................................................1177 A/C COMPRESSOR................................................................................1177 DESCRIPTION...............................................................................1177 OPERATION.................................................................................1177 DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................1177 REMOVAL...................................................................................1178 INSTALLATION..............................................................................1179 A/C CONDENSER.................................................................................1180 DESCRIPTION...............................................................................1180 OPERATION.................................................................................1180 REMOVAL...................................................................................1180 INSTALLATION..............................................................................1180 A/C DISCHARGE LINE............................................................................1181 REMOVAL...................................................................................1181 INSTALLATION..............................................................................1182 A/C EVAPORATOR................................................................................1182 DESCRIPTION...............................................................................1182 OPERATION.................................................................................1182 REMOVAL...................................................................................1183 INSTALLATION..............................................................................1183 A/C EXPANSION VALVE...........................................................................1183 DESCRIPTION...............................................................................1183 OPERATION.................................................................................1183 DIAGNOSIS AND TESTING - A/C EXPANSION VALVE...............................................1184 REMOVAL...................................................................................1184 INSTALLATION..............................................................................1184 ELECTRIC COOLANT PUMP.........................................................................1185 DESCRIPTION...............................................................................1185 OPERATION.................................................................................1185 REMOVAL...................................................................................1185 INSTALLATION..............................................................................1185 HEATER CORE...................................................................................1185 DESCRIPTION...............................................................................1185 OPERATION.................................................................................1185 REMOVAL...................................................................................1186 INSTALLATION..............................................................................1186 LIQUID LINE...................................................................................1186 REMOVAL...................................................................................1186 INSTALLATION..............................................................................1187 REAR EVAPORATOR...............................................................................1188 REMOVAL...................................................................................1188 INSTALLATION..............................................................................1189 REAR EXPANSION VALVE..........................................................................1190 REMOVAL...................................................................................1190 INSTALLATION..............................................................................1191 RECEIVER/DRIER................................................................................1192 DESCRIPTION...............................................................................1192 OPERATION.................................................................................1192 REMOVAL...................................................................................1192 INSTALLATION..............................................................................1192 REFRIGERANT...................................................................................1193 DESCRIPTION...............................................................................1193 OPERATION.................................................................................1193 REFRIGERANT OIL...............................................................................1193 DESCRIPTION...............................................................................1193 OPERATION.................................................................................1193 STANDARD PROCEDURE - REFRIGERANT OIL LEVEL................................................1193 SUCTION LINE..................................................................................1194 REMOVAL...................................................................................1194 INSTALLATION..............................................................................1194 WATER VALVE...................................................................................1195 REMOVAL...................................................................................1195 INSTALLATION..............................................................................1195 UNDERBODY LINES...............................................................................1196 REMOVAL...................................................................................1196 INSTALLATION..............................................................................1197 CABIN HEATER......................................................................................1200 CABIN HEATER..................................................................................1200 DESCRIPTION...............................................................................1200 OPERATION.................................................................................1200 DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA.................................1200 EXHAUST TUBE..................................................................................1201 REMOVAL...................................................................................1201 INSTALLATION..............................................................................1201 FUEL DOSING PUMP..............................................................................1202 DESCRIPTION...............................................................................1202 OPERATION.................................................................................1202 REMOVAL...................................................................................1202 INSTALLATION..............................................................................1202 FUEL LINE.....................................................................................1203 STANDARD PROCEDURE - CLEANING.............................................................1203 REMOVAL...................................................................................1203 INSTALLATION..............................................................................1204 HEATER UNIT...................................................................................1205 REMOVAL...................................................................................1205 REMOVAL...............................................................................1205 REMOVAL...............................................................................1205 INSTALLATION..............................................................................1206 INSTALLATION..........................................................................1206 INSTALLATION..........................................................................1206 INLET HOSE....................................................................................1206 REMOVAL...................................................................................1206 INSTALLATION..............................................................................1206 25-EMISSIONS CONTROL..................................................................................1209 EXHAUST GAS RECIRCULATION.........................................................................1209 VALVE.........................................................................................1209 DESCRIPTION...............................................................................1209 OPERATION.................................................................................1209 REMOVAL...................................................................................1210 INSTALLATION..............................................................................1210 INDEX.................................................................................................1211 COMMENTS..............................................................................................1231
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