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Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide
Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide - Image 2
Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide - Image 3

Dodge Sprinter VA Service Manual – 2.7L CDI Diesel Complete Workshop Repair Guide

Original price was: $34.95.Current price is: $19.95.

Comprehensive Dodge Sprinter VA service manual covering the 2.7L CDI diesel engine, NAG1 automatic transmission, suspension, brakes, wiring, and every major vehicle system. 1,232 pages of detailed procedures, specifications, and exploded diagrams for complete repair and maintenance.

SKU: DODGE-SPRINTER-VA-SM-HD-001 Category: Tags: , , , Vendor: Body Repair Docs
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Description

Dodge Sprinter VA Service Manual – Your Complete Repair Resource

This Dodge Sprinter VA Service Manual is a full workshop repair guide for the 2.7L CDI diesel-powered Sprinter van. Whether you are a professional technician or a dedicated owner maintaining your own vehicle, this manual delivers the procedures, specifications, and diagrams needed to service every major system on the vehicle. From routine lubrication schedules to complex engine and transmission overhauls, this Dodge Sprinter VA Service Manual covers it all in one comprehensive PDF document.

File Details

  • Manual Type: Service Manual
  • Brand: Dodge
  • Model: Sprinter VA
  • Engine: 2.7L CDI 5-Cylinder Diesel
  • Transmission: NAG1 Automatic
  • Language: English
  • Page Count: 1,232 pages
  • File Format: PDF
  • Model Year Reference: 2003 (per VIN decoding table)
  • Assembly Plant: Dusseldorf Plant, Germany (per VIN decoding)

Chapters Covered

The Dodge Sprinter VA Service Manual is organized into the following major groups and systems:

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Dodge Sprinter VA Service Manual – 2.7L CDI Diesel Complete Workshop Repair Guide” are as follows:

VA Powertrain
VA Body
VA Chassis
VA Transmission
VA Service Manualp. 1
FOREWORD
GROUP TAB LOCATORp. 1
in-INTRODUCTIONp. 3
VEHICLE IDENTIFICATION NUMBERp. 3
DESCRIPTIONp. 3
INTERNATIONAL SYMBOLSp. 4
DESCRIPTIONp. 4
FASTENER IDENTIFICATIONp. 4
DESCRIPTIONp. 4
FASTENER USAGEp. 7
DESCRIPTION – FASTENER USAGEp. 7
THREADED HOLE REPAIRp. 7
DESCRIPTION – THREADED HOLE REPAIRp. 7
METRIC SYSTEMp. 7
DESCRIPTIONp. 7
TORQUE REFERENCESp. 9
DESCRIPTIONp. 9
0-LUBRICATION & MAINTENANCEp. 11
FLUID TYPESp. 11
DESCRIPTIONp. 11
DESCRIPTION – FUEL REQUIREMENTS – DIESEL ENGINEp. 11
DESCRIPTIONp. 11
DESCRIPTION – ENGINE COOLANTp. 11
ETHYLENE-GLYCOL MIXTURESp. 11
PROPYLENE-GLYCOL MIXTURESp. 12
DESCRIPTION – HOAT COOLANTp. 12
COOLANT PERFORMANCEp. 12
COOLANT SELECTION AND ADDITIVESp. 13
DESCRIPTION – AXLEp. 13
REAR AXLEp. 13
DESCRIPTION – BRAKE FLUIDp. 13
BRAKE FLUIDp. 13
DESCRIPTION – POWER STEERING FLUIDp. 13
POWER STEERING FLUIDp. 13
DESCRIPTION – ENGINE OIL – DIESEL ENGINESp. 13
SAE VISCOSITY GRADEp. 13
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID – NAG1p. 14
FLUID ADDITIVESp. 14
OPERATION – AUTOMATIC TRANSMISSION FLUIDp. 14
FLUID CAPACITIESp. 14
SPECIFICATIONS – FLUID CAPACITIESp. 14
FLUID FILL/CHECK LOCATIONSp. 14
INSPECTION – FLUID FILL/CHECK LOCATIONSp. 14
PARTS & LUBRICANT RECOMMENDATIONp. 15
STANDARD PROCEDURE – PARTS & LUBRICANT RECOMMENDATIONSp. 15
HOISTINGp. 15
STANDARD PROCEDURE – HOISTINGp. 15
FLOOR JACKp. 15
HOISTp. 15
JUMP STARTINGp. 16
STANDARD PROCEDURE – JUMP STARTINGp. 16
TO JUMP START A DISABLED VEHICLE:p. 16
DISCONNECT CABLE CLAMPS AS FOLLOWS:p. 16
TOWINGp. 16
STANDARD PROCEDURE – TOWINGp. 16
If the Engine is Damagedp. 17
If the Transmission is Damagedp. 17
If the Front Axle is Damagedp. 17
If the Rear Axle is Damagedp. 17
SAFETY PRECAUTIONSp. 17
GROUND CLEARANCEp. 17
RAMP ANGLEp. 17
TOWING WHEN KEYS ARE NOT AVAILABLEp. 17
MAINTENANCE SCHEDULESp. 17
DESCRIPTIONp. 17
MAINTENANCE – WITHOUT ASSYST MAINTENANCE COMPUTERp. 17
MAINTENANCE – WITH ASSYST MAINTENANCE COMPUTERp. 18
REGULAR CHECK-UPSp. 18
SPECIAL MAINTENANCE REQUIREMENTSp. 18
ENGINE OIL CHANGE AND FILTER REPLACEMENTp. 18
SCOPE OF WORK FOR MAINTENANCE SERVICEp. 18
ADDITIONAL MAINTENANCE WORKp. 19
ADDITIONAL MAINTENANCE WORK AFTER YEARSp. 19
INTERNATIONAL SYMBOLSp. 19
DESCRIPTIONp. 19
2-SUSPENSIONp. 21
FRONTp. 21
FRONTp. 22
SPECIFICATIONS – TORQUE CHARTp. 22
SPECIAL TOOLSp. 22
FRONT SUSPENSIONp. 22
BUSHINGSp. 23
REMOVALp. 23
INSTALLATIONp. 23
HUB / BEARINGp. 24
DIAGNOSIS AND TESTING –p. 24
REMOVALp. 24
INSTALLATIONp. 25
KNUCKLEp. 25
REMOVALp. 25
INSTALLATIONp. 25
LOWER BALL JOINTp. 26
REMOVALp. 26
INSTALLATIONp. 26
LOWER CONTROL ARMp. 26
REMOVALp. 26
INSTALLATIONp. 26
SPRINGp. 27
REMOVALp. 27
INSTALLATIONp. 28
SPRING CLAMP PLATESp. 28
REMOVALp. 28
INSTALLATIONp. 28
SPRING STOP PLATESp. 29
REMOVALp. 29
INSTALLATIONp. 29
STABILIZER BARp. 29
DESCRIPTIONp. 29
OPERATIONp. 29
REMOVALp. 29
INSTALLATIONp. 29
STABILIZER LINKp. 29
REMOVALp. 29
INSTALLATIONp. 29
STRUTp. 30
REMOVALp. 30
INSTALLATIONp. 30
REARp. 31
REARp. 31
DESCRIPTIONp. 31
DIAGNOSIS AND TESTING – SPRING AND SHOCKp. 31
SPECIFICATIONS – TORQUE CHARTp. 32
SHOCKp. 33
DIAGNOSIS AND TESTING – SHOCKp. 33
REMOVALp. 33
INSTALLATIONp. 33
SPRINGp. 34
DESCRIPTIONp. 34
OPERATIONp. 34
REMOVALp. 34
REMOVAL – (SRW)p. 34
REMOVAL – (DRW)p. 34
INSTALLATIONp. 34
INSTALLATION – (SRW)p. 34
INSTALLATION – (DRW)p. 35
SPRING SHACKLEp. 35
REMOVALp. 35
INSTALLATIONp. 35
STABILIZER BARp. 35
REMOVALp. 35
INSTALLATIONp. 35
STABILIZER LINKp. 36
REMOVALp. 36
INSTALLATIONp. 36
WHEEL ALIGNMENTp. 37
WHEEL ALIGNMENTp. 37
DESCRIPTIONp. 37
DIAGNOSIS AND TESTING – PRE-ALIGNMENT INSPECTIONp. 37
STANDARD PROCEDURE – TOE ADJUSTMENTp. 39
SPECIFICATIONSp. 39
3-DIFFERENTIAL & DRIVELINEp. 41
PROPELLER SHAFTp. 41
PROPELLER SHAFTp. 41
DIAGNOSIS AND TESTINGp. 41
PROPELLER SHAFT VIBRATIONp. 41
PROPELLER SHAFT BALANCEp. 42
PROPELLER SHAFT RUNOUTp. 43
STANDARD PROCEDUREp. 43
PROPELLER SHAFT ANGLEp. 43
TWO/THREE-PIECE PROPELLER SHAFTp. 44
SPECIFICATIONSp. 45
SPECIAL TOOLSp. 45
PROPELLER SHAFTp. 46
REMOVALp. 46
INSTALLATIONp. 46
CENTER BEARINGp. 48
REMOVALp. 48
INSTALLATIONp. 49
REAR AXLEp. 50
REAR AXLEp. 50
DESCRIPTIONp. 50
OPERATIONp. 50
DIAGNOSIS AND TESTINGp. 50
GEAR NOISEp. 50
BEARING NOISEp. 50
LOW SPEED KNOCKp. 51
VIBRATIONp. 51
DRIVELINE SNAPp. 51
STANDARD PROCEDURE – DRAIN AND FILLp. 51
REMOVALp. 51
INSTALLATIONp. 52
SPECIFICATIONSp. 53
SPECIAL TOOLSp. 54
AXLE SHAFTSp. 55
REMOVALp. 55
INSTALLATIONp. 55
AXLE BEARINGS/SEALSp. 57
REMOVALp. 57
INSTALLATIONp. 57
AXLE SHAFTS – DUAL REAR WHEELSp. 59
REMOVALp. 59
INSTALLATIONp. 59
AXLE HUB BEARINGS/SEALSp. 60
REMOVALp. 60
INSTALLATIONp. 60
PINION SEALp. 62
REMOVALp. 62
INSTALLATIONp. 62
5-BRAKESp. 65
BRAKES – BASEp. 65
BRAKES – BASEp. 66
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEMp. 66
PRELIMINARY BRAKE CHECKp. 66
ROAD TESTINGp. 67
BRAKE NOISESp. 68
STANDARD PROCEDUREp. 68
STANDARD PROCEDURE – MANUAL BLEEDINGp. 68
STANDARD PROCEDURE – PRESSURE BLEEDINGp. 69
HYDRAULIC/MECHANICALp. 69
SPECIFICATIONSp. 69
SPECIFICATIONS – TORQUE CHARTp. 69
BASE BRAKEp. 70
SPECIAL TOOLSp. 71
BRAKESp. 71
BRAKE LINESp. 72
STANDARD PROCEDUREp. 72
STANDARD PROCEDURE – ISO FLARINGp. 72
STANDARD PROCEDURE – DOUBLE INVERTED FLARINGp. 72
BRAKE PADS/SHOESp. 73
REMOVALp. 73
REMOVAL – FRONT (SRW)p. 73
REMOVAL – FRONT (DRW)p. 73
REMOVAL – REAR (16” WHEELS) (SRW)p. 73
REMOVAL – REAR (15” WHEELS) (SRW)p. 73
REMOVAL – REAR (DRW)p. 74
INSTALLATIONp. 74
INSTALLATION – FRONT (SRW)p. 74
INSTALLATION – FRONT (DRW)p. 75
INSTALLATION – REAR (16” WHEELS) (SRW)p. 75
INSTALLATION – REAR (16” WHEELS) (SRW)p. 75
INSTALLATION – REAR (DRW)p. 75
DISC BRAKE CALIPERSp. 75
REMOVALp. 75
REMOVAL – FRONT (SRW)p. 75
REMOVAL – FRONT (DRW)p. 76
REMOVAL – REAR (SRW)p. 76
REMOVAL – REAR (DRW)p. 76
INSTALLATIONp. 76
INSTALLATION – FRONT (SRW)p. 76
INSTALLATION – FRONT (DRW)p. 77
INSTALLATION – REAR (SRW)p. 77
INSTALLATION – REAR (DRW)p. 77
DISC BRAKE CALIPER ADAPTERp. 77
REMOVALp. 77
REMOVAL – FRONTp. 77
REMOVAL – REARp. 77
INSTALLATIONp. 78
INSTALLATION – FRONTp. 78
INSTALLATION – REARp. 78
FLUIDp. 78
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATIONp. 78
STANDARD PROCEDURE – BRAKE FLUID LEVELp. 78
SPECIFICATIONSp. 78
BRAKE FLUIDp. 78
FLUID RESERVOIRp. 79
REMOVALp. 79
INSTALLATIONp. 79
ALB LEVERp. 79
REMOVALp. 79
INSTALLATIONp. 79
ALB CONTROLLERp. 79
REMOVALp. 79
INSTALLATIONp. 79
ADJUSTMENTSp. 80
ADJUSTMENTp. 80
MASTER CYLINDERp. 80
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTERp. 80
POWER BOOSTER VACUUM TESTp. 81
POWER BOOSTER CHECK VALVE TESTp. 81
STANDARD PROCEDURE – MASTER CYLINDER BLEEDINGp. 81
REMOVALp. 81
INSTALLATIONp. 82
PEDALp. 82
REMOVALp. 82
INSTALLATIONp. 83
POWER BRAKE BOOSTERp. 83
DESCRIPTIONp. 83
OPERATIONp. 83
REMOVALp. 83
INSTALLATIONp. 83
ROTORSp. 83
REMOVALp. 83
REMOVAL – FRONT (SRW)p. 83
REMOVAL – REAR (SRW)p. 84
REMOVAL – FRONT (DRW)p. 84
REMOVAL – REAR (DRW)p. 84
INSTALLATIONp. 85
INSTALLATION – FRONT (SRW)p. 85
INSTALLATION – REAR (SRW)p. 85
INSTALLATION – FRONT (DRW)p. 85
INSTALLATION – REAR (DRW)p. 85
SUPPORT PLATEp. 86
REMOVAL – REARp. 86
INSTALLATION – REARp. 86
PARKING BRAKEp. 86
SPECIFICATIONSp. 86
TORQUE CHARTp. 86
SPECIAL TOOLSp. 87
PARK BRAKEp. 87
CABLE TENSIONERp. 87
REMOVALp. 87
INSTALLATIONp. 87
CABLESp. 88
REMOVALp. 88
REMOVAL – FRONTp. 88
REMOVAL – REARp. 88
INSTALLATIONp. 88
INSTALLATION – FRONTp. 88
INSTALLATION – REARp. 89
ADJUSTMENTSp. 89
ADJUSTMENT – PARKING BRAKE CABLESp. 89
LEVERp. 90
REMOVALp. 90
INSTALLATIONp. 90
SHOESp. 90
REMOVALp. 90
REMOVAL – (SRW)p. 90
REMOVAL – (DRW)p. 90
CLEANING – REAR DRUM IN HAT BRAKEp. 91
INSTALLATIONp. 91
INSTALLATION – (SRW)p. 91
INSTALLATION – (DRW)p. 91
ADJUSTMENTSp. 91
ADJUSTMENTp. 91
BRAKES – ABSp. 93
BRAKES – ABSp. 93
SPECIFICATIONS – TORQUE CHARTp. 93
ELECTRICALp. 93
DESCRIPTIONp. 93
OPERATIONp. 93
FRONT WHEEL SPEED SENSORp. 94
REMOVALp. 94
INSTALLATIONp. 94
REAR WHEEL SPEED SENSORp. 94
REMOVALp. 94
INSTALLATIONp. 95
TONE WHEELp. 95
REMOVALp. 95
INSTALLATIONp. 95
HCU (HYDRAULIC CONTROL UNIT)p. 95
DESCRIPTIONp. 95
REMOVALp. 95
INSTALLATIONp. 96
7-COOLINGp. 97
COOLINGp. 97
OPERATION—COOLING SYSTEMp. 97
DIAGNOSIS AND TESTINGp. 97
DIAGNOSIS AND TESTING – PRELIMINARY CHECKSp. 97
ENGINE COOLING SYSTEM OVERHEATINGp. 97
DIAGNOSIS AND TESTING – COOLING SYSTEMp. 98
ACCESSORY DRIVEp. 101
BELT TENSIONERSp. 101
DESCRIPTIONp. 101
OPERATIONp. 101
DRIVE BELTSp. 101
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELTp. 101
VISUAL DIAGNOSISp. 101
NOISE DIAGNOSISp. 102
REMOVALp. 104
INSTALLATIONp. 104
ENGINEp. 105
COOLANTp. 105
DESCRIPTIONp. 105
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAKSp. 106
ULTRAVIOLET LIGHT METHODp. 106
PRESSURE TESTER METHODp. 106
INTERNAL LEAKAGE INSPECTIONp. 107
COMBUSTION LEAKAGE TEST – WITHOUT PRESSURE TESTERp. 107
STANDARD PROCEDUREp. 107
STANDARD PROCEDURE – ADDING ADDITIONAL COOLANTp. 107
STANDARD PROCEDURE – DRAINING COOLING SYSTEMp. 108
STANDARD PROCEDURE – REFILLING COOLING SYSTEMp. 108
COOLANT LEVEL SENSORp. 109
REMOVALp. 109
INSTALLATIONp. 109
RADIATOR FANp. 109
REMOVALp. 109
INSTALLATIONp. 109
ENGINE BLOCK HEATERp. 110
REMOVALp. 110
INSTALLATIONp. 110
ENGINE COOLANT TEMP SENSORp. 110
DESCRIPTIONp. 110
REMOVALp. 110
INSTALLATIONp. 111
ENGINE COOLANT THERMOSTATp. 111
REMOVALp. 111
INSTALLATIONp. 112
FAN DRIVE VISCOUS CLUTCHp. 112
REMOVALp. 112
INSTALLATIONp. 112
RADIATORp. 112
REMOVALp. 112
INSTALLATIONp. 113
RADIATOR PRESSURE CAPp. 114
DESCRIPTIONp. 114
OPERATIONp. 114
DIAGNOSIS AND TESTING – RADIATOR PRESSURE CAPp. 115
WATER PUMPp. 115
REMOVALp. 115
INSTALLATIONp. 116
8a-AUDIO/VIDEOp. 117
AUDIOp. 117
SPECIAL TOOLSp. 117
AUDIOp. 117
ANTENNA BODY & CABLEp. 117
REMOVALp. 117
INSTALLATIONp. 117
INSTRUMENT PANEL ANTENNA CABLEp. 117
REMOVALp. 117
INSTALLATIONp. 118
RADIOp. 118
REMOVALp. 118
INSTALLATIONp. 118
SPEAKERp. 118
REMOVALp. 118
INSTALLATIONp. 118
8b-CHIME/BUZZERp. 119
CHIME/BUZZERp. 119
DESCRIPTIONp. 119
OPERATIONp. 119
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEMp. 120
8e-ELECTRONIC CONTROL MODULESp. 121
CENTRAL TIMER MODULEp. 121
DESCRIPTIONp. 121
OPERATIONp. 122
DIAGNOSIS AND TESTING – CENTRAL TIMER MODULEp. 122
REMOVALp. 122
INSTALLATIONp. 122
CONTROLLER ANTILOCK BRAKEp. 123
DESCRIPTIONp. 123
REMOVALp. 123
INSTALLATIONp. 123
ENGINE CONTROL MODULEp. 123
DESCRIPTIONp. 123
REMOVALp. 124
INSTALLATIONp. 124
TRANSMISSION CONTROL MODULEp. 125
DESCRIPTIONp. 125
OPERATIONp. 125
TCM SIGNALSp. 126
BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)p. 126
SHIFT SCHEDULESp. 126
DOWNSHIFT SAFETYp. 127
ADAPTATIONp. 127
CONTROLLER MODES OF OPERATIONp. 128
STANDARD PROCEDURE – TCM ADAPTATIONp. 128
8f-ENGINE SYSTEMSp. 129
BATTERY SYSTEMp. 129
BATTERY SYSTEMp. 129
DESCRIPTIONp. 129
OPERATIONp. 130
DIAGNOSIS AND TESTING – BATTERY SYSTEMp. 130
MICRO 420 BATTERY TESTERp. 130
ABNORMAL BATTERY DISCHARGINGp. 133
CLEANINGp. 133
INSPECTIONp. 134
SPECIAL TOOLSp. 134
BATTERY SYSTEM SPECIAL TOOLSp. 134
BATTERYp. 134
DESCRIPTIONp. 134
OPERATIONp. 135
DIAGNOSIS AND TESTING – BATTERYp. 135
MICRO 420 BATTERY TESTERp. 135
STANDARD PROCEDUREp. 136
STANDARD PROCEDURE – BATTERY CHARGINGp. 136
CHARGING A COMPLETELY DISCHARGED BATTERYp. 137
CHARGING TIME REQUIREDp. 137
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TESTp. 138
STANDARD PROCEDURE – IGNITION-OFF DRAW TESTp. 138
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTERp. 139
BATTERY TESTINGp. 139
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVELp. 140
REMOVALp. 140
UNDER HOOD BATTERY REMOVALp. 140
AUXILIARY BATTERY REMOVALp. 141
INSTALLATIONp. 141
UNDER HOOD BATTERY INSTALLATIONp. 141
AUXILIARY BATTERY INSTALLATIONp. 141
BATTERY HOLDDOWNp. 142
DESCRIPTIONp. 142
REMOVALp. 142
INSTALLATIONp. 142
BATTERY CABLESp. 142
DESCRIPTIONp. 142
OPERATIONp. 142
DIAGNOSIS AND TESTING – BATTERY CABLESp. 142
REMOVALp. 144
INSTALLATIONp. 144
BATTERY TRAYp. 144
DESCRIPTIONp. 144
OPERATIONp. 144
REMOVALp. 144
INSTALLATIONp. 144
CHARGING SYSTEMp. 145
CHARGING SYSTEMp. 145
SPECIFICATIONSp. 145
TORQUE – 2.7L DIESELp. 145
SPECIAL TOOLSp. 145
GENERATORp. 146
DESCRIPTIONp. 146
OPERATIONp. 146
REMOVALp. 146
INSTALLATIONp. 146
GENERATOR DECOUPLER PULLEYp. 147
DESCRIPTIONp. 147
OPERATIONp. 147
DIAGNOSIS AND TESTING – GENERATOR DECOUPLERp. 147
REMOVALp. 148
INSTALLATIONp. 149
VOLTAGE REGULATORp. 151
DESCRIPTIONp. 151
STARTING SYSTEMp. 152
STARTING SYSTEMp. 152
DESCRIPTIONp. 152
OPERATIONp. 152
DIAGNOSIS AND TESTING – STARTING SYSTEMp. 153
INSPECTIONp. 154
TESTINGp. 154
SPECIFICATIONSp. 157
TORQUE – STARTER – DIESELp. 157
SPECIFICATIONS – STARTER MOTOR – DIESELp. 157
STARTER MOTORp. 157
DIAGNOSIS AND TESTING – STARTER MOTORp. 157
REMOVALp. 158
INSTALLATIONp. 159
STARTER MOTOR RELAYp. 159
DESCRIPTIONp. 159
REMOVALp. 159
INSTALLATIONp. 160
8g-HEATED SYSTEMSp. 161
HEATED SEATSp. 161
DESCRIPTIONp. 161
OPERATIONp. 162
DIAGNOSIS AND TESTING – HEATED SEATSp. 162
DRIVER HEATED SEAT SWITCHp. 162
DESCRIPTIONp. 162
OPERATIONp. 162
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCHp. 162
REMOVALp. 163
INSTALLATIONp. 163
HEATED SEAT ELEMENTp. 163
DESCRIPTIONp. 163
OPERATIONp. 163
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENTp. 163
HEATED SEAT RELAYp. 164
DESCRIPTIONp. 164
OPERATIONp. 164
DIAGNOSIS AND TESTING – HEATED SEAT RELAYp. 164
REMOVALp. 164
INSTALLATIONp. 164
HEATED SEAT SENSORp. 164
DESCRIPTIONp. 164
DIAGNOSIS AND TESTING – HEATED SEAT SENSORp. 164
PASSENGER HEATED SEAT SWITCHp. 165
DESCRIPTIONp. 165
OPERATIONp. 165
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCHp. 165
REMOVALp. 165
INSTALLATIONp. 165
8h-HORNp. 167
HORNp. 167
REMOVALp. 167
INSTALLATIONp. 167
HORN SWITCHp. 167
REMOVALp. 167
INSTALLATIONp. 167
8i-IGNITION CONTROLp. 169
IGNITION CONTROLp. 169
SPECIAL TOOLSp. 169
GLOW PLUGp. 169
REMOVALp. 169
INSTALLATIONp. 169
GLOW PLUG RELAYp. 170
DESCRIPTIONp. 170
OPERATIONp. 170
DIAGNOSIS AND TESTING – GLOW PLUG RELAYSp. 170
8j-INSTRUMENT CLUSTERp. 171
INSTRUMENT CLUSTERp. 172
DESCRIPTIONp. 172
OPERATIONp. 175
INPUT AND OUTPUT CIRCUITSp. 176
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTERp. 177
REMOVALp. 177
INSTALLATIONp. 179
ABS INDICATORp. 179
DESCRIPTIONp. 179
OPERATIONp. 179
AIRBAG INDICATORp. 180
DESCRIPTIONp. 180
OPERATIONp. 180
AMBIENT TEMPERATURE INDICATORp. 181
DESCRIPTIONp. 181
OPERATIONp. 181
BRAKE/PARK BRAKE INDICATORp. 181
DESCRIPTIONp. 181
OPERATIONp. 182
BRAKE WEAR INDICATORp. 182
DESCRIPTIONp. 182
OPERATIONp. 182
CHARGING INDICATORp. 183
DESCRIPTIONp. 183
OPERATIONp. 183
CLOCKp. 183
DESCRIPTIONp. 183
OPERATIONp. 184
COOLANT LOW INDICATORp. 184
DESCRIPTIONp. 184
OPERATIONp. 184
ENGINE TEMPERATURE GAUGEp. 185
DESCRIPTIONp. 185
OPERATIONp. 185
FUEL FILTER CLOGGED INDICATORp. 185
DESCRIPTIONp. 185
OPERATIONp. 185
FUEL GAUGEp. 186
DESCRIPTIONp. 186
OPERATIONp. 186
GEAR SELECTOR INDICATORp. 187
DESCRIPTIONp. 187
OPERATIONp. 187
HIGH BEAM INDICATORp. 187
DESCRIPTIONp. 187
OPERATIONp. 187
LOW FUEL INDICATORp. 188
DESCRIPTIONp. 188
OPERATIONp. 188
LOW OIL LEVEL INDICATORp. 188
DESCRIPTIONp. 188
OPERATIONp. 188
MAINTENANCE INDICATORp. 189
DESCRIPTIONp. 189
OPERATIONp. 189
MALFUNCTION INDICATOR LAMP (MIL)p. 190
DESCRIPTIONp. 190
OPERATIONp. 190
MULTI-FUNCTION INDICATORp. 190
DESCRIPTIONp. 190
OPERATIONp. 191
ODOMETERp. 191
DESCRIPTIONp. 191
OPERATIONp. 192
SEATBELT INDICATORp. 192
DESCRIPTIONp. 192
OPERATIONp. 192
SPEEDOMETERp. 193
DESCRIPTIONp. 193
OPERATIONp. 193
TACHOMETERp. 193
DESCRIPTIONp. 193
OPERATIONp. 194
TRACTION CONTROL INDICATORp. 194
DESCRIPTIONp. 194
OPERATIONp. 194
TRACTION CONTROL MALFUNCTION INDICATORp. 195
DESCRIPTIONp. 195
OPERATIONp. 195
TURN SIGNAL INDICATORp. 195
DESCRIPTIONp. 195
OPERATIONp. 195
WAIT-TO-START INDICATORp. 196
DESCRIPTIONp. 196
OPERATIONp. 196
WASHER FLUID INDICATORp. 197
DESCRIPTIONp. 197
OPERATIONp. 197
WATER-IN-FUEL INDICATORp. 197
DESCRIPTIONp. 197
OPERATIONp. 198
8l-LAMPSp. 199
LAMPS/LIGHTING – EXTERIORp. 199
LAMPS/LIGHTING – EXTERIORp. 200
DESCRIPTIONp. 200
OPERATIONp. 201
SPECIFICATIONS – LAMPS/LIGHTING – EXTERIORp. 203
BACKUP LAMP BULBp. 203
REMOVALp. 203
INSTALLATIONp. 204
BRAKE LAMP SWITCHp. 204
REMOVAL0 – 2 VA (Continued)p. 204
INSTALLATIONp. 204
BRAKE/PARK LAMP BULBp. 205
REMOVALp. 205
INSTALLATIONp. 205
CENTER HIGH MOUNTED STOP LAMP BULBp. 205
REMOVALp. 205
INSTALLATIONp. 205
CENTER HIGH MOUNTED STOP LAMP UNp. 206
REMOVALp. 206
INSTALLATIONp. 206
CLEARANCE LAMP BULBp. 206
REMOVALp. 206
INSTALLATIONp. 206
CLEARANCE LAMP UNITp. 206
REMOVALp. 206
INSTALLATIONp. 207
DAYTIME RUNNING LAMP RELAYp. 207
REMOVALp. 207
INSTALLATIONp. 207
FOG LAMP BULBp. 208
REMOVALp. 208
INSTALLATIONp. 208
FOG LAMP RELAYp. 208
REMOVALp. 208
INSTALLATIONp. 209
FOG LAMP SWITCHp. 209
REMOVALp. 209
INSTALLATIONp. 210
FRONT LAMP UNITp. 210
REMOVALp. 210
INSTALLATIONp. 210
ADJUSTMENTSp. 210
ADJUSTMENT – FRONT LAMP UNITp. 210
VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENTp. 210
FRONT LAMP UNIT ALIGNMENTp. 211
FRONT POSITION LAMP BULBp. 212
REMOVALp. 212
INSTALLATIONp. 212
FRONT TURN/PARK/SIDE MARKER LAMP BULBp. 212
REMOVALp. 212
INSTALLATIONp. 213
HEADLAMP LEVELING MOTORp. 213
REMOVALp. 213
INSTALLATIONp. 214
HEADLAMP LEVELING SWITCHp. 214
REMOVALp. 214
INSTALLATIONp. 215
HIGH BEAM HEADLAMP BULBp. 215
REMOVALp. 215
INSTALLATIONp. 215
LICENSE PLATE LAMP BULBp. 215
REMOVALp. 215
INSTALLATIONp. 216
LICENSE PLATE LAMP UNITp. 216
REMOVALp. 216
INSTALLATIONp. 216
LOW BEAM HEADLAMP BULBp. 216
REMOVALp. 216
INSTALLATIONp. 217
MULTI-FUNCTION SWITCHp. 217
REMOVALp. 217
INSTALLATIONp. 218
PARK BRAKE SWITCHp. 218
REMOVALp. 218
INSTALLATIONp. 218
REAR SIDE MARKER LAMP BULBp. 219
REMOVALp. 219
INSTALLATIONp. 219
REAR TURN LAMP BULBp. 219
REMOVALp. 219
INSTALLATIONp. 220
REPEATER LAMP BULBp. 220
REMOVALp. 220
INSTALLATIONp. 220
REPEATER LAMP UNITp. 220
REMOVALp. 220
INSTALLATIONp. 221
TAIL LAMP UNITp. 221
REMOVALp. 221
INSTALLATIONp. 221
TURN SIGNAL RELAYp. 222
REMOVALp. 222
INSTALLATIONp. 222
LAMPS/LIGHTING – INTERIORp. 223
LAMPS/LIGHTING – INTERIORp. 223
DESCRIPTIONp. 223
OPERATIONp. 224
INTERIOR LIGHTING CIRCUITp. 224
EXTERIOR LIGHTING CIRCUITp. 224
SPECIFICATIONS – INTERIOR LIGHTINGp. 224
ASH RECEIVER/CIGAR LIGHTER LAMP UNITp. 225
REMOVALp. 225
INSTALLATIONp. 225
CARGO/DOME LAMP BULBp. 225
REMOVALp. 225
INSTALLATIONp. 225
CARGO/DOME LAMP UNITp. 226
REMOVALp. 226
INSTALLATIONp. 226
CARGO LAMP SWITCHp. 226
REMOVALp. 226
REMOVAL – INSTRUMENT PANELp. 226
REMOVAL – BULKHEADp. 226
REMOVAL – REAR PILLARp. 226
INSTALLATIONp. 227
INSTALLATION – INSTRUMENT PANELp. 227
INSTALLATION – BULKHEADp. 227
INSTALLATION – REAR PILLARp. 227
DOME/READING LAMP BULBp. 227
REMOVALp. 227
INSTALLATIONp. 227
DOME/READING LAMP UNITp. 228
REMOVALp. 228
INSTALLATIONp. 228
DOME LAMP/INTRUSION SENSOR BULBp. 228
REMOVALp. 228
INSTALLATIONp. 228
DOME LAMP/INTRUSION SENSORp. 229
REMOVALp. 229
INSTALLATIONp. 229
DOOR JAMB SWITCHp. 229
REMOVALp. 229
INSTALLATIONp. 229
ENTRY/EXIT LAMP BULBp. 229
REMOVALp. 229
INSTALLATIONp. 230
ENTRY/EXIT LAMP UNITp. 230
REMOVALp. 230
INSTALLATIONp. 230
TIME DELAY RELAYp. 230
REMOVALp. 230
INSTALLATIONp. 231
8n-POWER SYSTEMSp. 233
POWER LOCKSp. 233
POWER LOCKSp. 233
DESCRIPTIONp. 233
CENTRAL LOCKINGp. 233
REMOTE KEYLESS ENTRYp. 233
AUTO DOOR LOCKSp. 233
ACCIDENT RESPONSEp. 233
DOOR LOCK MOTORp. 233
REMOVALp. 233
INSTALLATIONp. 233
REMOTE KEYLESS ENTRY TRANSMITTERp. 234
DESCRIPTIONp. 234
MASTER LOCK SWITCHp. 234
DESCRIPTIONp. 234
DIAGNOSIS AND TESTING – MASTER LOCK SWITCHp. 234
REMOVALp. 234
INSTALLATIONp. 234
POWER MIRRORSp. 235
POWER MIRRORSp. 235
DESCRIPTIONp. 235
POWER MIRROR SWITCHp. 235
DIAGNOSIS AND TESTING – POWER MIRROR SWITCHp. 235
REMOVALp. 235
INSTALLATIONp. 236
POWER WINDOWSp. 237
POWER WINDOWSp. 237
DESCRIPTIONp. 237
OPERATIONp. 237
WINDOW SWITCHp. 237
WINDOW MOTORp. 237
WINDOW MOTORp. 237
REMOVALp. 237
POWER WINDOW SWITCHp. 237
DIAGNOSIS AND TESTING – POWER WINDOW SWITCHp. 237
REMOVALp. 238
INSTALLATIONp. 238
8o-RESTRAINTSp. 239
RESTRAINTSp. 240
DESCRIPTIONp. 240
ACTIVE RESTRAINTSp. 241
PASSIVE RESTRAINTSp. 241
OPERATIONp. 242
ACTIVE RESTRAINTSp. 242
PASSIVE RESTRAINTSp. 242
WARNINGp. 243
WARNINGS – RESTRAINT SYSTEMp. 243
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEMp. 243
STANDARD PROCEDUREp. 244
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTSp. 244
SUPPLEMENTAL RESTRAINT STORAGEp. 244
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENTp. 244
CLEANUP PROCEDUREp. 244
STANDARD PROCEDURE – VERIFICATION TESTp. 245
AIRBAG CONTROL MODULEp. 246
DESCRIPTIONp. 246
OPERATIONp. 247
REMOVALp. 248
INSTALLATIONp. 249
CLOCKSPRINGp. 250
DESCRIPTIONp. 250
OPERATIONp. 251
STANDARD PROCEDURE – CLOCKSPRING CENTERINGp. 251
REMOVALp. 252
INSTALLATIONp. 253
DRIVER AIRBAGp. 254
DESCRIPTIONp. 254
OPERATIONp. 255
REMOVALp. 255
INSTALLATIONp. 256
FRONT SEAT BELT & RETRACTORp. 257
REMOVALp. 257
INSTALLATIONp. 259
FRONT SEAT BELT BUCKLEp. 260
REMOVALp. 260
INSTALLATIONp. 261
PASSENGER AIRBAGp. 261
DESCRIPTIONp. 261
OPERATIONp. 262
REMOVALp. 262
INSTALLATIONp. 264
PASSENGER AIRBAG BRACKETp. 265
REMOVALp. 265
INSTALLATIONp. 265
REAR SEAT BELT & RETRACTORp. 265
REMOVALp. 265
INSTALLATIONp. 267
REAR SEAT BELT BUCKLEp. 267
REMOVALp. 267
REMOVAL – INBOARDp. 267
REMOVAL – OUTBOARDp. 268
INSTALLATIONp. 268
INSTALLATION – INBOARDp. 268
INSTALLATION – OUTBOARDp. 269
SEAT BELT SWITCHp. 269
DESCRIPTIONp. 269
OPERATIONp. 269
SEAT BELT TENSIONERp. 269
DESCRIPTIONp. 269
OPERATIONp. 270
SEAT BELT TURNING LOOP ADJUSTERp. 271
REMOVALp. 271
INSTALLATIONp. 272
8p-SPEED CONTROLp. 273
SPEED CONTROLp. 273
DESCRIPTIONp. 273
OPERATIONp. 273
SPECIFICATIONSp. 274
TORQUEp. 274
CABLEp. 275
DESCRIPTIONp. 275
SERVOp. 275
DESCRIPTIONp. 275
SWITCHp. 275
REMOVALp. 275
INSTALLATIONp. 275
8q-VEHICLE THEFT SECURITYp. 277
VEHICLE THEFT SECURITYp. 277
DESCRIPTIONp. 277
OPERATIONp. 277
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITYp. 277
INTRUSION SENSORp. 278
REMOVALp. 278
INSTALLATIONp. 278
SECURITY SYSTEM MODULEp. 278
REMOVALp. 278
INSTALLATIONp. 278
SENTRY KEY REMOTE ENTRY MODULEp. 278
DESCRIPTIONp. 278
SENTRY KEY IMMOBILIZERp. 279
REMOTE KEYLESS ENTRY (RKE)p. 279
OPERATIONp. 279
SENTRY KEY IMMOBILIZERp. 279
REMOTE KEYLESS ENTRYp. 279
REMOVALp. 279
SENTRY KEY REMOTE ENTRY MODULEp. 279
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RINGp. 280
INSTALLATIONp. 280
SENTRY KEY REMOTE ENTRY MODULEp. 280
SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RINGp. 280
SIRENp. 280
REMOVALp. 280
INSTALLATIONp. 280
TRANSPONDER KEYp. 281
DESCRIPTIONp. 281
OPERATIONp. 281
8r-WIPERS/WASHERSp. 283
WIPERS/WASHERSp. 283
DESCRIPTIONp. 283
OPERATING MODESp. 285
OPERATIONp. 285
DIAGNOSIS AND TESTING – WIPER & WASHER SYSTEMp. 287
CLEANING – WIPER & WASHER SYSTEMp. 287
WIPER SYSTEMp. 287
WASHER SYSTEMp. 287
INSPECTION – WIPER & WASHER SYSTEMp. 288
WIPER SYSTEMp. 288
WASHER SYSTEMp. 288
CHECK VALVEp. 289
DESCRIPTIONp. 289
OPERATIONp. 289
REMOVALp. 289
INSTALLATIONp. 289
WASHER FLUID LEVEL SWITCHp. 289
DESCRIPTIONp. 289
OPERATIONp. 290
WASHER HOSES/TUBESp. 290
DESCRIPTIONp. 290
OPERATIONp. 291
WASHER NOZZLEp. 291
DESCRIPTIONp. 291
OPERATIONp. 291
REMOVALp. 291
INSTALLATIONp. 291
WASHER PUMP/MOTORp. 291
DESCRIPTIONp. 291
OPERATIONp. 292
REMOVALp. 292
INSTALLATIONp. 292
WASHER RESERVOIRp. 293
DESCRIPTIONp. 293
OPERATIONp. 293
REMOVALp. 293
INSTALLATIONp. 294
WIPER ARMp. 295
DESCRIPTIONp. 295
OPERATIONp. 296
REMOVALp. 296
INSTALLATIONp. 296
WIPER BLADEp. 297
DESCRIPTIONp. 297
OPERATIONp. 297
REMOVALp. 298
INSTALLATIONp. 298
WIPER LINKAGEp. 299
DESCRIPTIONp. 299
OPERATIONp. 299
REMOVALp. 299
INSTALLATIONp. 300
WIPER MOTORp. 301
DESCRIPTIONp. 301
OPERATIONp. 301
REMOVALp. 301
INSTALLATIONp. 301
WIPER RELAYp. 302
DESCRIPTIONp. 302
OPERATIONp. 303
REMOVALp. 304
INSTALLATIONp. 304
8w-WIRINGp. 305
8W-01 WIRING DIAGRAM INFORMATIONp. 307
WIRING DIAGRAM INFORMATIONp. 307
DESCRIPTIONp. 307
DESCRIPTION – HOW TO USE WIRING DIAGRAMSp. 307
SYMBOLSp. 307
TERMINOLOGYp. 311
DESCRIPTION – CIRCUIT INFORMATIONp. 311
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATIONp. 311
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATIONp. 311
IDENTIFICATIONp. 311
LOCATIONSp. 312
WARNINGp. 312
WARNINGS – GENERALp. 312
DIAGNOSIS AND TESTING – WIRING HARNESSp. 312
TROUBLESHOOTING TOOLSp. 312
INTERMITTENT AND POOR CONNECTIONSp. 313
TROUBLESHOOTING WIRING PROBLEMSp. 313
STANDARD PROCEDUREp. 313
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICESp. 313
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIALp. 313
STANDARD PROCEDURE – TESTING FOR CONTINUITYp. 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUNDp. 314
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADSp. 314
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROPp. 314
CONNECTORp. 314
REMOVALp. 314
INSTALLATIONp. 315
DIODEp. 315
REMOVALp. 315
INSTALLATIONp. 315
TERMINALp. 315
REMOVALp. 315
INSTALLATIONp. 316
WIREp. 316
STANDARD PROCEDURE – WIRE SPLICINGp. 316
8W-02 COMPONENT INDEXp. 317
8W-10 POWER DISTRIBUTIONp. 319
8W-11 FUSE BLOCKp. 353
8W-15 GROUND DISTRIBUTIONp. 393
8W-18 BUS COMMUNICATIONSp. 421
8W-20 CHARGING SYSTEMp. 427
8W-21 STARTING SYSTEMp. 433
8W-30 FUEL/IGNITION SYSTEMp. 435
8W-31 TRANSMISSION CONTROL SYSTEMp. 453
8W-33 VEHICLE SPEED CONTROLp. 463
8W-35 ANTILOCK BRAKESp. 467
8W-39 VEHICLE THEFT SECURITY SYSTEMp. 475
8W-40 INSTRUMENT CLUSTERp. 489
8W-41 HORN/CIGAR LIGHTERp. 497
8W-42 AIR CONDITIONER/HEATERp. 501
8W-43 AIRBAG SYSTEMp. 525
8W-44 INTERIOR LIGHTINGp. 529
8W-45 CENTRAL TIMER MODULEp. 541
8W-47 AUDIO SYSTEMp. 549
8W-48 REAR WINDOW DEFOGGERp. 555
8W-50 FRONT LIGHTINGp. 561
8W-51 REAR LIGHTINGp. 577
8W-52 TURN SIGNALSp. 587
8W-53 WIPERSp. 593
8W-54 TRAILER TOWp. 597
8W-55 NAVIGATION/TELECOMMUNICATIONSp. 601
8W-60 POWER WINDOWSp. 605
8W-61 POWER DOOR LOCKSp. 609
8W-62 POWER MIRRORSp. 617
8W-63 POWER SEATSp. 621
8W-70 SPLICE INFORMATIONp. 625
8W-80 CONNECTOR PIN-OUTSp. 627
8W-91 CONNECTOR/GROUND/SPLICE LOCATIONp. 695
CONNECTOR/GROUND/SPLICE LOCATIONp. 695
DESCRIPTIONp. 695
8W-97 POWER DISTRIBUTIONp. 733
POWER DISTRIBUTIONp. 733
DESCRIPTIONp. 733
OPERATIONp. 733
CIGAR LIGHTER OUTLETp. 733
DESCRIPTIONp. 733
OPERATIONp. 734
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLETp. 734
REMOVALp. 734
CIRCUIT BREAKERp. 734
DESCRIPTIONp. 734
OPERATIONp. 734
DIAGNOSIS AND TESTING – CIRCUIT BREAKERp. 734
FUSE BLOCK #1p. 734
DESCRIPTIONp. 734
OPERATIONp. 734
REMOVALp. 735
INSTALLATIONp. 735
FUSE BLOCK #2p. 735
DESCRIPTIONp. 735
OPERATIONp. 735
POWER DISTRIBUTION CENTERp. 735
DESCRIPTIONp. 735
OPERATIONp. 735
POWER OUTLETp. 735
DESCRIPTIONp. 735
OPERATIONp. 736
DIAGNOSIS AND TESTING – POWER OUTLETp. 736
REMOVALp. 736
INSTALLATIONp. 736
RELAYp. 736
DESCRIPTIONp. 736
OPERATIONp. 737
DIAGNOSIS AND TESTING – RELAYp. 737
DIAGNOSIS AND TESTING – RELAY CIRCUIT TESTp. 737
REMOVALp. 737
INSTALLATIONp. 737
9-ENGINEp. 739
ENGINEp. 740
DESCRIPTIONp. 740
STANDARD PROCEDUREp. 741
STANDARD PROCEDURE – COMPRESSION TESTING ENGINEp. 741
STANDARD PROCEDURE – CYLINDER LEAK DOWN TESTp. 741
INSPECTINGp. 741
STANDARD PROCEDURE – DETERMINING CYLINDER PRESSURE LOSSp. 742
REMOVALp. 742
REMOVAL – ENGINE COVERp. 742
REMOVALp. 742
INSTALLATIONp. 745
INSTALLATION – ENGINE COVERp. 745
INSTALLATIONp. 745
SPECIFICATIONS – TORQUE SPECIFICATIONSp. 746
SPECIAL TOOLSp. 752
AIR CLEANER ELEMENTp. 758
REMOVALp. 758
INSTALLATIONp. 758
AIR CLEANER HOUSINGp. 758
REMOVALp. 758
INSTALLATIONp. 758
CYLINDER HEADp. 759
STANDARD PROCEDUREp. 759
STANDARD PROCEDURE – CYLINDER HEAD BOLT INSPECTIONp. 759
STANDARD PROCEDURE – MEASURE CYLINDER HEAD SURFACEp. 759
REMOVALp. 760
REMOVAL – CYLINDER HEADp. 760
REMOVAL – CYLINDER HEAD FRONT COVERp. 761
REMOVAL – CYLINDER HEAD GUIDE RAILp. 762
INSTALLATIONp. 763
INSTALLATION – CYLINDER HEADp. 763
CYLINDER HEAD BOLT TORQUE SEQUENCEp. 763
INSTALLATION – CYLINDER HEAD FRONT COVERp. 764
INSTALLATION – CYLINDER HEAD GUIDE RAILp. 764
CAMSHAFT(S)p. 765
STANDARD PROCEDURE – CHECKING CAMSHAFT POSITIONp. 765
REMOVALp. 766
INSTALLATIONp. 767
CYLINDER HEAD COVER(S)p. 768
REMOVALp. 768
INSTALLATIONp. 768
VALVE SPRINGSp. 769
REMOVALp. 769
REMOVAL – VALVE SPRINGSp. 769
REMOVAL – VALVESp. 769
INSTALLATIONp. 770
INSTALLATION – VALVE SPRINGSp. 770
INSTALLATION – VALVESp. 771
ENGINE BLOCKp. 772
STANDARD PROCEDUREp. 772
STANDARD PROCEDURE – REPLACING ENGINE CORE AND OIL GALLERY PLUGSp. 772
STANDARD PROCEDURE – MEASURING CYLINDER BORESp. 772
CRANKSHAFTp. 773
STANDARD PROCEDURE – MEASURE CRANKSHAFT AND BLOCK JOURNALSp. 773
ASSIGN CRANKSHAFT BEARING SHELLSp. 773
REMOVALp. 773
INSTALLATIONp. 774
CRANKSHAFT OIL SEAL – REARp. 775
REMOVALp. 775
INSTALLATIONp. 775
CRANKSHAFT OIL SEAL – FRONTp. 776
REMOVALp. 776
INSTALLATIONp. 776
FLYWHEELp. 777
REMOVALp. 777
INSTALLATIONp. 777
INSTALLATIONp. 777
INSTALLATIONp. 777
PISTON & CONNECTING RODp. 778
DESCRIPTIONp. 778
STANDARD PROCEDUREp. 778
STANDARD PROCEDURE – CHECKING AND REPAIRING CONNECTING RODSp. 778
CONNECTING ROD SPECIFICATIONSp. 780
STANDARD PROCEDURE – MEASURING PISTON PROTRUSIONp. 780
REMOVALp. 780
INSTALLATIONp. 781
PISTON RINGSp. 784
STANDARD PROCEDURE – PISTON RING FITTINGp. 784
VIBRATION DAMPERp. 785
REMOVALp. 785
INSTALLATIONp. 786
VACUUM PUMPp. 786
DESCRIPTIONp. 786
OPERATIONp. 786
REMOVALp. 786
INSTALLATIONp. 787
LEFT MOUNTp. 787
REMOVALp. 787
INSTALLATIONp. 787
RIGHT MOUNTp. 787
REMOVALp. 787
INSTALLATIONp. 787
OILp. 788
REMOVAL – OIL SEPARATORp. 788
INSTALLATION – OIL SEPARATORp. 788
OIL COOLER & LINESp. 788
REMOVALp. 788
INSTALLATIONp. 788
OIL FILTERp. 789
REMOVALp. 789
INSTALLATIONp. 789
OIL JETp. 789
DESCRIPTIONp. 789
REMOVALp. 789
INSTALLATIONp. 789
OIL PANp. 790
REMOVALp. 790
INSTALLATIONp. 790
OIL PUMPp. 791
REMOVALp. 791
REMOVALp. 791
REMOVAL- OIL PUMP CHAINp. 791
INSTALLATIONp. 792
INSTALLATIONp. 792
INSTALLATION – OIL PUMP CHAINp. 792
OIL TEMPERATURE SENSORp. 794
DESCRIPTIONp. 794
OPERATIONp. 794
REMOVALp. 795
INSTALLATIONp. 795
INTAKE MANIFOLDp. 795
REMOVALp. 795
INSTALLATIONp. 796
EXHAUST MANIFOLDp. 797
REMOVALp. 797
INSTALLATIONp. 797
TIMING CHAIN COVERp. 797
REMOVALp. 797
INSTALLATIONp. 798
TIMING BELT/CHAIN AND SPROCKETSp. 799
REMOVALp. 799
REMOVAL – TENSIONING AND SLIDE RAILSp. 799
REMOVAL – INTERMEDIATE GEARp. 799
REMOVAL – TIMING CHAIN TENSIONING RAILp. 801
REMOVAL – TIMING CHAINp. 801
INSTALLATIONp. 804
INSTALLATION – TENSIONING AND SLIDE RAILp. 804
INSTALLATION – INTERMEDIATE GEARp. 804
INSTALLATION – TIMING CHAIN TENSIONING RAILp. 804
ADJUSTMENTSp. 805
INSTALLATION – TIMING CHAINp. 805
TIMING CHAIN TENSIONERp. 808
REMOVALp. 808
INSTALLATIONp. 809
11-EXHAUST SYSTEMp. 811
EXHAUST SYSTEMp. 811
DESCRIPTION – 2.7L DIESELp. 811
DIAGNOSIS AND TESTING – DIESEL ENGINEp. 812
CATALYTIC CONVERTERp. 813
REMOVALp. 813
INSTALLATIONp. 813
EXHAUST PIPEp. 813
REMOVALp. 813
INSTALLATIONp. 813
TAILPIPEp. 813
REMOVALp. 813
INSTALLATIONp. 813
TURBOCHARGER SYSTEMp. 813
DESCRIPTIONp. 813
OPERATIONp. 814
CHARGE AIR COOLER AND PLUMBINGp. 814
DESCRIPTIONp. 814
OPERATIONp. 814
DIAGNOSIS AND TESTING – CHARGE AIR COOLER SYSTEM – LEAKSp. 814
REMOVALp. 815
CLEANINGp. 815
INSPECTIONp. 815
INSTALLATIONp. 815
TURBOCHARGERp. 816
DESCRIPTIONp. 816
OPERATIONp. 816
REMOVALp. 817
REMOVALp. 817
REMOVAL – VACUUM TRANSDUCERp. 817
INSTALLATIONp. 818
INSTALLATIONp. 818
INSTALLATION – VACUUM TRANSDUCERp. 818
13-FRAME & BUMPERSp. 819
BUMPERSp. 819
SPECIFICATIONS – TORQUEp. 819
FRONT BUMPER – STEPSp. 820
REMOVALp. 820
INSTALLATIONp. 820
FRONT FASCIAp. 820
REMOVALp. 820
INSTALLATIONp. 820
REAR BUMPER – STEPp. 821
REMOVALp. 821
INSTALLATIONp. 821
REAR FASCIAp. 821
REMOVALp. 821
INSTALLATIONp. 821
FRAMEp. 822
SPECIFICATIONSp. 822
SPECIFICATIONS – FRAME DIMENSIONSp. 822
VEHICLE PREPARATIONp. 822
SPECIFICATIONS – TORQUEp. 824
ENGINE CRADLE CROSSMEMBERp. 824
REMOVALp. 824
INSTALLATIONp. 826
REAR CROSSMEMBER – TRANSMISSIONp. 827
REMOVALp. 827
INSTALLATIONp. 827
TRAILER HITCHp. 827
REMOVALp. 827
INSTALLATIONp. 828
14-FUEL SYSTEMp. 829
FUEL SYSTEMp. 829
WARNINGp. 829
WARNING – HIGH FUEL SYSTEM PRESSUREp. 829
WARNINGp. 829
DIAGNOSIS AND TESTINGp. 829
DIAGNOSIS AND TESTING – HIGH PRESSURE FUEL LINESp. 829
DIAGNOSIS AND TESTING – AIR IN FUEL SYSTEMp. 830
STANDARD PROCEDUREp. 830
STANDARD PROCEDURES – CLEANING FUEL SYSTEM COMPONENTSp. 830
STANDARD PROCEDURE – DISCONNECTING AND CONNECTING FUEL LINESp. 830
STANDARD PROCEDURES – DRAINING WATER FROM FUEL FILTERp. 830
STANDARD PROCEDURE – LOW PRESSURE FUEL PUMP TESTp. 831
FUEL DELIVERYp. 832
FUEL DELIVERYp. 832
SPECIFICATIONSp. 832
TORQUEp. 832
SPECIAL TOOLSp. 833
FUEL SYSTEMp. 833
FUEL DRAIN TUBESp. 833
DIAGNOSIS AND TESTING – FUEL SUPPLY RESTRICTIONSp. 833
LOW-PRESSURE LINES0 – 4 VA (Continued)p. 833
HIGH-PRESSURE LINESp. 833
FUEL FILTERp. 833
DESCRIPTIONp. 833
OPERATIONp. 833
REMOVALp. 833
INSTALLATIONp. 834
FUEL LINESp. 834
REMOVAL – HIGH PRESSURE LINESp. 834
INSTALLATION – HIGH PRESSURE LINESp. 835
FUEL PUMPp. 835
DESCRIPTIONp. 835
DESCRIPTION – HIGH PRESSURE PUMPp. 835
DESCRIPTION – LOW PRESSURE PUMPp. 835
OPERATIONp. 835
OPERATIONp. 835
LOW PRESSURE SIDEp. 835
HIGH PRESSURE SIDEp. 836
OPERATION – LOW PRESSURE PUMPp. 836
REMOVALp. 836
REMOVAL – HIGH PRESSURE PUMPp. 836
REMOVAL – LOW PRESSURE PUMPp. 837
INSTALLATIONp. 838
INSTALLATION – HIGH PRESSURE PUMPp. 838
INSTALLATION – LOW PRESSURE PUMPp. 839
FUEL RAILp. 839
DESCRIPTIONp. 839
OPERATIONp. 839
REMOVALp. 839
INSTALLATIONp. 839
FUEL TANKp. 840
DESCRIPTIONp. 840
REMOVALp. 840
INSTALLATIONp. 841
FUEL TANK MODULEp. 841
DESCRIPTIONp. 841
REMOVALp. 841
INSTALLATIONp. 842
FUEL LEVEL SENDING UNIT / SENSORp. 843
DESCRIPTIONp. 843
REMOVALp. 843
INSTALLATIONp. 843
HI PRESSURE FUEL SHUTOFF SOLp. 844
DESCRIPTIONp. 844
OPERATIONp. 844
WATER IN FUEL SENSORp. 844
DESCRIPTIONp. 844
OPERATIONp. 844
FUEL INJECTIONp. 845
ACCELERATOR PEDAL POSITION SENSORp. 845
DESCRIPTIONp. 845
BOOST PRESSURE SENSORp. 845
DESCRIPTIONp. 845
OPERATIONp. 846
DIAGNOSIS AND TESTING – BOOST PRESSURE SENSORp. 846
REMOVALp. 846
INSTALLATIONp. 846
CAMSHAFT POSITION SENSORp. 847
DESCRIPTIONp. 847
OPERATIONp. 847
REMOVALp. 847
INSTALLATIONp. 847
CRANKSHAFT POSITION SENSORp. 848
DESCRIPTIONp. 848
OPERATIONp. 848
REMOVALp. 848
INSTALLATIONp. 848
FUEL INJECTORp. 848
DESCRIPTIONp. 848
FUEL INJECTORp. 848
OPERATIONp. 848
Injector closed (with high pressure applied)p. 849
Injector opens (start of injection)p. 849
Injector opens fullyp. 850
Injector closes (end of injection)p. 850
STANDARD PROCEDUREp. 850
STANDARD PROCEDURE – INJECTOR CLASSIFICATIONp. 850
INJECTOR CLASSIFICATION PROCEDUREp. 850
STANDARD PROCEDURE – CLEANING FUEL INJECTORSp. 850
REMOVALp. 851
INSTALLATIONp. 851
FUEL PRESSURE SENSORp. 853
DESCRIPTIONp. 853
DESCRIPTIONp. 853
DESCRIPTIONp. 853
OPERATIONp. 853
OPERATIONp. 853
OPERATIONp. 853
REMOVALp. 854
REMOVALp. 854
REMOVALp. 854
INSTALLATIONp. 854
INSTALLATIONp. 854
INSTALLATIONp. 855
FUEL PRESSURE SOLENOIDp. 855
DESCRIPTIONp. 855
OPERATIONp. 855
REMOVALp. 856
INSTALLATIONp. 856
FUEL TEMPERATURE SENSORp. 857
DESCRIPTIONp. 857
OPERATIONp. 857
REMOVALp. 857
INSTALLATIONp. 857
INLET AIR TEMPERATURE SENSORp. 857
DESCRIPTIONp. 857
OPERATIONp. 857
REMOVALp. 858
INSTALLATIONp. 858
MANIFOLD AIR FLOW (MAF) SENSORp. 858
DESCRIPTIONp. 858
OPERATIONp. 858
REMOVALp. 859
INSTALLATIONp. 859
19-STEERINGp. 861
STEERINGp. 861
DESCRIPTIONp. 861
OPERATIONp. 861
DIAGNOSIS AND TESTING – POWER STEERING SYSTEMp. 862
COLUMNp. 865
COLUMNp. 865
SPECIFICATIONS – TORQUE CHARTp. 865
INTERMEDIATE SHAFTp. 865
REMOVALp. 865
INSTALLATIONp. 865
KEY/LOCK CYLINDERp. 866
REMOVALp. 866
INSTALLATIONp. 867
STEERING WHEELp. 867
REMOVALp. 867
INSTALLATIONp. 867
GEARp. 868
GEARp. 868
DESCRIPTIONp. 868
REMOVALp. 868
INSTALLATIONp. 868
SPECIFICATIONS – TORQUE CHARTp. 869
LINKAGEp. 870
LINKAGEp. 870
DIAGNOSIS AND TESTING – OUTER TIE ROD ENDp. 870
SPECIFICATIONS – TORQUE CHARTp. 870
SPECIAL TOOLSp. 871
FRONT SUSPENSIONp. 871
TIE ROD ENDp. 871
REMOVALp. 871
INSTALLATIONp. 871
PUMPp. 872
PUMPp. 872
DESCRIPTIONp. 872
OPERATIONp. 872
DIAGNOSIS AND TESTING – PUMP LEAKAGEp. 872
STANDARD PROCEDUREp. 872
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATIONp. 872
STANDARD PROCEDURE – FLUSHING POWER STEERING SYSTEMp. 873
REMOVALp. 873
INSTALLATIONp. 873
SPECIFICATIONS – TORQUE CHARTp. 874
FLUIDp. 874
STANDARD PROCEDUREp. 874
POWER STEERING PUMP FILL AND BLEED PROCEDUREp. 874
FLUID COOLER TUBEp. 874
REMOVALp. 874
INSTALLATIONp. 874
HOSESp. 875
REMOVALp. 875
REMOVAL – PRESSURE HOSEp. 875
REMOVAL – RETURN LINE FROM PUMP TO COOLER TUBEp. 875
REMOVAL – RETURN HOSE FROM GEAR TO COOLER TUBEp. 875
INSTALLATIONp. 875
INSTALLATION – PRESSURE HOSEp. 875
INSTALLATION – RETURN LINE FROM PUMP TO COOLER TUBEp. 875
INSTALLATION – RETURN HOSE FROM GEAR TO COOLER TUBEp. 875
21-TRANSMISSIONp. 877
AUTOMATIC TRANSMISSION – NAG1p. 877
AUTOMATIC TRANSMISSION – NAG1p. 878
DESCRIPTIONp. 878
TRANSMISSION IDENTIFICATIONp. 878
TRANSMISSION GEAR RATIOSp. 878
TRANSMISSION HOUSINGp. 878
MECHANICAL SECTIONp. 879
ELECTROHYDRAULIC CONTROL UNITp. 879
SHIFT GROUPSp. 880
OPERATIONp. 880
EMERGENCY RUNNING FUNCTIONp. 880
CLUTCH APPLICATIONp. 880
FIRST GEAR POWERFLOWp. 881
SECOND GEAR POWERFLOWp. 883
THIRD GEAR POWERFLOWp. 885
FOURTH GEAR POWERFLOWp. 887
FIFTH GEAR POWERFLOWp. 889
REVERSE GEAR POWERFLOWp. 891
SHIFT GROUPS/ SHIFT SEQUENCEp. 893
DIAGNOSIS AND TESTINGp. 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSIONp. 899
DIAGNOSIS AND TESTING – PRELIMINARYp. 899
VEHICLE IS DRIVABLEp. 899
VEHICLE IS DISABLEDp. 899
DIAGNOSIS AND TESTING – ROAD TESTINGp. 899
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSIONp. 900
STANDARD PROCEDURE – ALUMINUM THREAD REPAIRp. 903
REMOVALp. 903
DISASSEMBLYp. 906
ASSEMBLYp. 910
INSTALLATIONp. 917
SCHEMATICS AND DIAGRAMSp. 923
SPECIFICATIONS – NAG1 AUTOMATIC TRANSMISSIONp. 944
SPECIAL TOOLS – NAG1 AUTOMATIC TRANSMISSIONp. 945
DRIVING CLUTCHESp. 948
DESCRIPTIONp. 948
OPERATIONp. 948
DRIVING CLUTCH K1p. 950
DISASSEMBLYp. 950
ASSEMBLYp. 951
DRIVING CLUTCH K2p. 952
DISASSEMBLYp. 952
ASSEMBLYp. 954
DRIVING CLUTCH K3p. 956
DISASSEMBLYp. 956
ASSEMBLYp. 956
ELECTROHYDRAULIC UNITp. 958
DESCRIPTIONp. 958
ELECTRICAL CONTROL UNITp. 958
HYDRAULIC CONTROL UNITp. 958
OPERATIONp. 963
ELECTRICAL CONTROL UNITp. 963
HYDRAULIC CONTROL UNITp. 964
REMOVALp. 968
DISASSEMBLYp. 968
ASSEMBLYp. 971
INSTALLATIONp. 976
FLUID AND FILTERp. 977
DESCRIPTIONp. 977
OPERATIONp. 977
DIAGNOSIS AND TESTINGp. 978
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVELp. 978
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUIDp. 978
DIAGNOSIS AND TESTING – FLUID CONTAMINATIONp. 978
STANDARD PROCEDUREp. 978
STANDARD PROCEDURE – CHECK OIL LEVELp. 978
STANDARD PROCEDURE – TRANSMISSION FILLp. 979
STANDARD PROCEDURE – FLUID/FILTER SERVICEp. 980
FREEWHEELING CLUTCHp. 981
DESCRIPTIONp. 981
OPERATIONp. 981
DISASSEMBLYp. 982
ASSEMBLYp. 983
GEARSHIFT CABLEp. 985
DIAGNOSIS AND TESTING – GEARSHIFT CABLEp. 985
REMOVALp. 985
INSTALLATIONp. 985
HOLDING CLUTCHESp. 987
DESCRIPTIONp. 987
OPERATIONp. 988
HOLDING CLUTCH B1p. 988
DISASSEMBLYp. 988
ASSEMBLYp. 989
HOLDING CLUTCH B2p. 991
DISASSEMBLYp. 991
ASSEMBLYp. 992
INPUT SPEED SENSORSp. 995
DESCRIPTIONp. 995
OPERATIONp. 995
OIL PUMPp. 996
DESCRIPTIONp. 996
OPERATIONp. 996
DISASSEMBLYp. 996
ASSEMBLYp. 997
OUTPUT SHAFT BEARINGp. 998
REMOVALp. 998
INSTALLATIONp. 998
OUTPUT SHAFT SEALp. 1001
REMOVALp. 1001
INSTALLATIONp. 1001
PARK LOCK CABLEp. 1001
REMOVALp. 1001
INSTALLATIONp. 1002
PISTONSp. 1004
DESCRIPTIONp. 1004
OPERATIONp. 1004
PRESSUREp. 1005
PRESSURE ON A CONFINED FLUIDp. 1005
FORCE MULTIPLICATIONp. 1005
PISTON TRAVELp. 1005
PLANETARY GEARTRAINp. 1006
DESCRIPTIONp. 1006
OPERATIONp. 1006
DISASSEMBLYp. 1007
ASSEMBLYp. 1007
SHIFT MECHANISMp. 1009
DESCRIPTIONp. 1009
OPERATIONp. 1009
REMOVALp. 1010
INSTALLATIONp. 1011
SOLENOIDp. 1012
DESCRIPTIONp. 1012
UPSHIFT/DOWNSHIFT SOLENOID VALVESp. 1013
MODULATING PRESSURE CONTROL SOLENOID VALVEp. 1013
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVEp. 1013
SHIFT PRESSURE CONTROL SOLENOID VALVEp. 1014
OPERATIONp. 1014
UPSHIFT/DOWNSHIFT SOLENOID VALVESp. 1015
MODULATING PRESSURE CONTROL SOLENOID VALVEp. 1015
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVEp. 1015
SHIFT PRESSURE CONTROL SOLENOID VALVEp. 1015
TEMPERATURE SENSOR/PARK-NEUTRAL CONTACTp. 1015
DESCRIPTIONp. 1015
DESCRIPTION – PARK/NEUTRAL CONTACTp. 1015
DESCRIPTION – TRANSMISSION TEMPERATURE SENSORp. 1016
OPERATIONp. 1016
OPERATION – PARK/NEUTRAL CONTACTp. 1016
OPERATION – TRANSMISSION TEMPERATURE SENSORp. 1017
TORQUE CONVERTERp. 1017
DESCRIPTIONp. 1017
IMPELLERp. 1018
TURBINEp. 1018
STATORp. 1018
TORQUE CONVERTER CLUTCH (TCC)p. 1019
OPERATIONp. 1019
TURBINEp. 1020
STATORp. 1021
TORQUE CONVERTER CLUTCH (TCC)p. 1022
REMOVALp. 1022
INSTALLATIONp. 1022
TORQUE CONVERTER HUB SEALp. 1023
REMOVALp. 1023
INSTALLATIONp. 1023
22-TIRES/WHEELSp. 1025
TIRES/WHEELSp. 1025
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUTp. 1025
METHOD 1 (RELOCATE WHEEL ON HUB)p. 1026
METHOD 2 (RELOCATE TIRE ON WHEEL)p. 1026
STANDARD PROCEDUREp. 1026
STANDARD PROCEDURE – MATCH MOUNTINGp. 1026
STANDARD PROCEDURE – TIRE AND WHEEL BALANCEp. 1027
STANDARD PROCEDURE – TIRE ROTATIONp. 1029
SPECIFICATIONSp. 1029
TORQUE CHARTp. 1029
TIRESp. 1030
DESCRIPTIONp. 1030
DESCRIPTION – TIRESp. 1030
TIRE IDENTIFICATIONp. 1030
TIRE CHAINSp. 1030
DESCRIPTION – RADIAL – PLY TIRESp. 1030
DESCRIPTION – TIRE PRESSURE FOR HIGH SPEEDSp. 1030
DESCRIPTION – REPLACEMENT TIRESp. 1031
DESCRIPTION – TIRE INFLATION PRESSURESp. 1031
DIAGNOSIS AND TESTINGp. 1032
DIAGNOSIS AND TESTING – PRESSURE GAUGESp. 1032
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATIONp. 1032
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORSp. 1032
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNSp. 1032
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEADp. 1032
STANDARD PROCEDURE – REPAIRING LEAKSp. 1034
CLEANINGp. 1034
SPECIFICATIONSp. 1034
TIRESp. 1034
SPARE TIRE CARRIERp. 1034
REMOVALp. 1034
INSTALLATIONp. 1034
WHEELSp. 1035
DESCRIPTIONp. 1035
OPERATIONp. 1035
DIAGNOSIS AND TESTINGp. 1035
WHEEL INSPECTIONp. 1035
STANDARD PROCEDUREp. 1035
STANDARD PROCEDURE – WHEEL REPLACEMENTp. 1035
STANDARD PROCEDURE – DUAL REAR WHEEL INSTALLATIONp. 1036
REMOVALp. 1037
INSTALLATIONp. 1037
23-BODYp. 1039
BODYp. 1039
WARNINGp. 1039
SAFETY PRECAUTIONS AND WARNINGSp. 1039
DIAGNOSIS AND TESTINGp. 1039
DIAGNOSIS AND TESTING – WATER LEAKSp. 1039
VISUAL INSPECTION BEFORE WATER LEAK TESTSp. 1040
WATER LEAK TESTSp. 1040
WATER LEAK DETECTIONp. 1040
DIAGNOSIS AND TESTING – WIND NOISEp. 1040
VISUAL INSPECTION BEFORE TESTSp. 1040
STANDARD PROCEDUREp. 1041
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIRp. 1041
Rigid Plastics:p. 1041
Semi-Rigid Plastics:p. 1041
Flexible Plastics:p. 1041
Repair Procedure:p. 1041
Adhesion Promoter/Surface Modifier:p. 1041
SAFETY PRECAUTION AND WARNINGSp. 1041
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPESp. 1042
PANEL SECTIONINGp. 1044
PANEL REINFORCEMENTp. 1044
VISUAL INSPECTIONp. 1045
PANEL SURFACE PREPARATIONp. 1045
PATCHING PANELSp. 1045
PANEL PATCH FABRICATIONSp. 1045
PANEL PATCH INSTALLATIONp. 1046
PATCHED PANEL SURFACINGp. 1048
STANDARD PROCEDURE – BUZZ, SQUEAK & RATTLEp. 1048
SPECIFICATIONSp. 1050
DOOR – FRONTp. 1051
CHECKp. 1051
REMOVALp. 1051
INSTALLATIONp. 1051
DOORp. 1052
REMOVALp. 1052
INSTALLATIONp. 1052
ADJUSTMENTSp. 1053
ADJUSTMENTp. 1053
DOOR GLASSp. 1053
REMOVALp. 1053
INSTALLATIONp. 1053
EXTERIOR HANDLEp. 1054
REMOVALp. 1054
INSTALLATIONp. 1054
HINGEp. 1055
REMOVALp. 1055
INSTALLATIONp. 1055
LATCHp. 1056
REMOVALp. 1056
INSTALLATIONp. 1056
LATCH STRIKERp. 1056
REMOVALp. 1056
INSTALLATIONp. 1056
LOCK CYLINDERp. 1056
REMOVALp. 1056
INSTALLATIONp. 1056
TRIM PANELp. 1057
REMOVALp. 1057
INSTALLATIONp. 1058
WINDOW REGULATOR – POWERp. 1058
REMOVALp. 1058
INSTALLATIONp. 1059
WINDOW REGULATOR – MANUALp. 1060
REMOVALp. 1060
INSTALLATIONp. 1061
DOORS – REARp. 1062
CHECKp. 1062
REMOVALp. 1062
INSTALLATIONp. 1062
DOORp. 1063
REMOVALp. 1063
DISASSEMBLYp. 1064
RIGHT DOORp. 1064
LEFT DOORp. 1065
ASSEMBLYp. 1066
RIGHT DOORp. 1066
LEFT DOORp. 1067
INSTALLATIONp. 1068
ADJUSTMENTSp. 1068
ADJUSTMENTp. 1068
DOOR GLASSp. 1069
REMOVALp. 1069
INSTALLATIONp. 1069
EXTERIOR HANDLEp. 1070
REMOVALp. 1070
INSTALLATIONp. 1071
HINGEp. 1072
REMOVALp. 1072
INSTALLATIONp. 1072
INSIDE HANDLE ACTUATORp. 1072
REMOVALp. 1072
INSTALLATIONp. 1072
LATCHp. 1072
REMOVALp. 1072
INSTALLATIONp. 1073
TRIM PANELp. 1073
REMOVALp. 1073
INSTALLATIONp. 1073
DOORS – SLIDINGp. 1074
EXTERIOR HANDLEp. 1074
REMOVALp. 1074
INSTALLATIONp. 1074
INSIDE HANDLE ACTUATORp. 1075
REMOVALp. 1075
INSTALLATIONp. 1075
UPPER ROLLER ARMp. 1075
REMOVALp. 1075
INSTALLATIONp. 1075
CENTER ROLLER ARMp. 1075
REMOVALp. 1075
INSTALLATIONp. 1076
LOWER ROLLER ARMp. 1076
REMOVALp. 1076
INSTALLATIONp. 1076
CENTER TRACKp. 1076
REMOVALp. 1076
INSTALLATIONp. 1077
LATCH / LOCK CONTROLp. 1077
REMOVALp. 1077
INSTALLATIONp. 1078
REAR LATCHp. 1078
REMOVALp. 1078
INSTALLATIONp. 1078
REAR LATCH STRIKERp. 1079
REMOVALp. 1079
INSTALLATIONp. 1079
SLIDING DOORp. 1079
REMOVALp. 1079
DISASSEMBLYp. 1080
ASSEMBLYp. 1081
INSTALLATIONp. 1082
ADJUSTMENTSp. 1082
ADJUSTMENTp. 1082
Gaps and Ridge Adjustmentp. 1082
Flush Adjustmentp. 1083
Door Stop Bumper Adjustp. 1083
STABILIZERp. 1083
REMOVALp. 1083
INSTALLATIONp. 1083
TRIM PANELp. 1084
REMOVALp. 1084
Upperp. 1084
Lowerp. 1084
INSTALLATIONp. 1084
Upperp. 1084
Lowerp. 1084
DOOR GLASSp. 1084
REMOVALp. 1084
INSTALLATIONp. 1084
EXTERIORp. 1085
FUEL FILL DOORp. 1085
REMOVALp. 1085
INSTALLATIONp. 1085
GRILLEp. 1085
REMOVALp. 1085
INSTALLATIONp. 1085
LICENSE PLATE BRACKETp. 1085
REMOVALp. 1085
INSTALLATIONp. 1085
RADIATOR CROSSMEMBERp. 1085
REMOVALp. 1085
INSTALLATIONp. 1086
SIDE VIEW MIRRORp. 1086
REMOVALp. 1086
Driver's Sidep. 1086
Passenger Sidep. 1086
INSTALLATIONp. 1086
Driver's Sidep. 1086
Passenger Sidep. 1087
SIDE VIEW MIRROR – GLASSp. 1087
REMOVALp. 1087
INSTALLATIONp. 1087
HOODp. 1088
HINGEp. 1088
REMOVALp. 1088
INSTALLATIONp. 1088
HOODp. 1088
REMOVALp. 1088
INSTALLATIONp. 1088
ADJUSTMENTSp. 1089
ADJUSTMENTp. 1089
LATCHp. 1089
REMOVALp. 1089
INSTALLATIONp. 1089
LATCH RELEASE CABLEp. 1089
REMOVALp. 1089
INSTALLATIONp. 1089
LATCH RELEASE HANDLEp. 1090
REMOVALp. 1090
INSTALLATIONp. 1090
PROP RODp. 1090
REMOVALp. 1090
INSTALLATIONp. 1090
SAFETY LATCHp. 1090
REMOVALp. 1090
INSTALLATIONp. 1090
INSTRUMENT PANELp. 1091
CLUSTER BEZELp. 1091
REMOVALp. 1091
INSTALLATIONp. 1092
ACCESSORY SWITCH BEZELp. 1092
REMOVALp. 1092
INSTALLATIONp. 1092
INSTRUMENT PANEL CENTER BEZELp. 1093
REMOVALp. 1093
INSTALLATIONp. 1093
ASH RECEIVERp. 1093
REMOVALp. 1093
INSTALLATIONp. 1093
CUP HOLDERp. 1093
REMOVALp. 1093
INSTALLATIONp. 1094
GLOVE BOXp. 1094
REMOVALp. 1094
INSTALLATIONp. 1094
INSTRUMENT PANEL ASSEMBLYp. 1095
REMOVALp. 1095
INSTALLATIONp. 1099
TOP COVER – CLUSTERp. 1100
REMOVALp. 1100
INSTALLATIONp. 1100
TOP COVER – TRAYp. 1101
REMOVALp. 1101
INSTALLATIONp. 1102
TOP COVERp. 1102
REMOVALp. 1102
INSTALLATIONp. 1103
STEERING COLUMN OPENING COVERp. 1104
REMOVALp. 1104
INSTALLATIONp. 1104
INTERIORp. 1105
INTERIORp. 1105
CAUTIONp. 1105
A-PILLAR TRIMp. 1105
REMOVALp. 1105
INSTALLATIONp. 1106
ASSIST HANDLEp. 1106
REMOVALp. 1106
INSTALLATIONp. 1106
B-PILLAR TRIMp. 1106
REMOVALp. 1106
INSTALLATIONp. 1107
BULKHEAD TRIM PANELp. 1107
REMOVALp. 1107
INSTALLATIONp. 1107
CARPETS AND FLOOR MATSp. 1107
REMOVALp. 1107
Cargo/Passenger Van – Frontp. 1107
Passenger Van – Rearp. 1107
Cargo Van – Rearp. 1108
INSTALLATIONp. 1108
Cargo/Passenger Van – Frontp. 1108
Passenger Van – Rearp. 1108
Cargo Van – Rearp. 1108
COWL TRIMp. 1108
REMOVALp. 1108
INSTALLATIONp. 1108
D-PILLAR TRIMp. 1108
REMOVALp. 1108
INSTALLATIONp. 1108
HEADLINERp. 1108
REMOVALp. 1108
Cab Sectionp. 1108
Number 2 Sectionp. 1108
Number 3 Sectionp. 1108
Number 4 Sectionp. 1109
INSTALLATIONp. 1109
Cab Sectionp. 1109
Number 2 Sectionp. 1109
Number 3 Sectionp. 1109
Number 4 Sectionp. 1109
QUARTER TRIM PANELp. 1109
REMOVALp. 1109
Passenger Vanp. 1109
Cargo Vanp. 1110
INSTALLATIONp. 1110
Passenger Vanp. 1110
Cargo Vanp. 1110
REAR VIEW MIRRORp. 1110
REMOVALp. 1110
INSTALLATIONp. 1110
INSTALLATIONp. 1110
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKETp. 1110
STEPWELL SCUFF PADSp. 1110
REMOVALp. 1110
INSTALLATIONp. 1111
SUN VISORp. 1111
REMOVALp. 1111
INSTALLATIONp. 1111
PAINTp. 1112
PAINTp. 1112
SPECIFICATIONS – PAINT CODESp. 1112
BASECOAT/CLEARCOAT FINISHp. 1112
DESCRIPTIONp. 1112
PAINT TOUCH-UPp. 1112
DESCRIPTIONp. 1112
STANDARD PROCEDURE – PAINT TOUCH-UPp. 1113
FINESSE SANDING/BUFFING & POLISHp. 1113
DESCRIPTIONp. 1113
SEATSp. 1114
ARMRESTp. 1114
REMOVALp. 1114
INSTALLATIONp. 1114
HEADRESTp. 1114
REMOVALp. 1114
INSTALLATIONp. 1114
SEAT – FRONTp. 1115
REMOVALp. 1115
INSTALLATION0 – 6 VA (Continued)p. 1115
SEAT BACK – FRONTp. 1115
REMOVALp. 1115
INSTALLATIONp. 1115
SEAT CUSHION – FRONTp. 1116
REMOVALp. 1116
INSTALLATIONp. 1116
SEAT ADJUSTERS – FRONTp. 1116
REMOVALp. 1116
INSTALLATIONp. 1116
SEAT – REARp. 1117
REMOVALp. 1117
INSTALLATIONp. 1117
REAR SEAT BACK SHIELDp. 1117
REMOVALp. 1117
INSTALLATIONp. 1117
SEAT BACK CUSHION/COVER – REARp. 1118
REMOVALp. 1118
INSTALLATIONp. 1118
SEAT CUSHION/COVER – REARp. 1118
REMOVALp. 1118
INSTALLATIONp. 1118
STATIONARY GLASSp. 1119
BACKLITE – BULKHEAD TRIM PANELp. 1119
REMOVALp. 1119
INSTALLATIONp. 1119
QUARTER WINDOWp. 1119
REMOVALp. 1119
INSTALLATIONp. 1119
WINDSHIELDp. 1120
WARNINGp. 1120
WINDSHIELD SAFETY PRECAUTIONSp. 1120
REMOVALp. 1120
INSTALLATIONp. 1121
Windshield Preparation – Installing A Previously Installed Windshieldp. 1122
Windshield Preparation – Installing A New Windshieldp. 1123
Windshield Opening Preparationp. 1123
Windshield Installationp. 1123
WEATHERSTRIP/SEALSp. 1125
FRONT DOOR INNER BELT WEATHERSTRIPp. 1125
REMOVALp. 1125
INSTALLATIONp. 1125
FRONT DOOR OUTER BELT WEATHERSTRIPp. 1125
REMOVALp. 1125
INSTALLATIONp. 1125
DOOR OPENING SEALSp. 1125
REMOVALp. 1125
INSTALLATIONp. 1125
BODY STRUCTUREp. 1126
GAP AND FLUSHp. 1126
SPECIFICATIONSp. 1126
OPENING DIMENSIONSp. 1128
SPECIFICATIONSp. 1128
24-HEATING & AIR CONDITIONINGp. 1129
HEATING & AIR CONDITIONINGp. 1129
DESCRIPTIONp. 1129
DESCRIPTION – COOLING SYSTEM REQUIREMENTSp. 1129
DESCRIPTION – HEATER AND AIR CONDITIONERp. 1129
OPERATION – HEATER AND AIR CONDITIONERp. 1130
DIAGNOSIS AND TESTINGp. 1131
DIAGNOSIS AND TESTING – FUNCTION TESTp. 1131
DIAGNOSIS AND TESTING – A/C PERFORMANCE TESTp. 1131
DIAGNOSIS AND TESTING – HEATER PERFORMANCEp. 1132
MAXIMUM HEATER OUTPUTp. 1132
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOWp. 1132
POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEATp. 1132
TEMPERATURE CONTROLp. 1132
SPECIFICATIONSp. 1133
A/C SYSTEMp. 1133
CONTROLS – FRONTp. 1136
A/C COMPRESSOR CLUTCHp. 1136
DESCRIPTIONp. 1136
OPERATIONp. 1136
STANDARD PROCEDUREp. 1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH AIR GAPp. 1137
STANDARD PROCEDURE – COMPRESSOR CLUTCH BREAK-INp. 1137
REMOVALp. 1137
INSPECTION – COMPRESSOR CLUTCH/COILp. 1138
INSTALLATIONp. 1139
A/C COMPRESSOR CLUTCH COILp. 1140
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH COILp. 1140
A/C HEATER CONTROLp. 1140
DESCRIPTIONp. 1140
OPERATIONp. 1140
REMOVALp. 1140
INSTALLATIONp. 1141
A/C PRESSURE TRANSDUCERp. 1141
DESCRIPTIONp. 1141
OPERATIONp. 1141
DIAGNOSIS AND TESTING – A/C PRESSURE TRANSDUCERp. 1141
REMOVALp. 1142
INSTALLATIONp. 1142
AIR OUTLET TEMPERATURE SENSORp. 1142
DESCRIPTIONp. 1142
OPERATIONp. 1143
REMOVALp. 1143
INSTALLATIONp. 1143
AMBIENT TEMPERATURE SENSORp. 1143
DESCRIPTIONp. 1143
OPERATIONp. 1143
REMOVALp. 1143
INSTALLATIONp. 1144
BLOWER MOTOR RESISTOR BLOCKp. 1144
DESCRIPTIONp. 1144
OPERATIONp. 1144
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR BLOCKp. 1144
REMOVALp. 1144
INSTALLATIONp. 1145
BLOWER MOTOR SWITCHp. 1145
DESCRIPTIONp. 1145
OPERATIONp. 1145
DIAGNOSIS AND TESTING – BLOWER MOTOR SWITCHp. 1145
REMOVALp. 1145
EVAPORATOR TEMPERATURE SENSORp. 1145
DESCRIPTIONp. 1145
OPERATIONp. 1146
REMOVALp. 1146
INSTALLATIONp. 1146
IN-CAR TEMPERATURE SENSORp. 1147
DESCRIPTIONp. 1147
OPERATIONp. 1147
DIAGNOSIS AND TESTINGp. 1147
REMOVALp. 1147
MODE DOOR CABLESp. 1147
REMOVALp. 1147
INSTALLATIONp. 1147
RECIRCULATION DOOR ACTUATORp. 1148
DESCRIPTIONp. 1148
OPERATIONp. 1148
REMOVALp. 1149
INSTALLATIONp. 1149
CONTROLS – REARp. 1150
BLOWER MOTOR SWITCHp. 1150
DESCRIPTIONp. 1150
OPERATIONp. 1150
DIAGNOSIS AND TESTINGp. 1151
REMOVALp. 1151
INSTALLATIONp. 1151
BLOWER MOTOR RELAYp. 1151
DESCRIPTIONp. 1151
OPERATIONp. 1151
DIAGNOSIS AND TESTINGp. 1152
REMOVALp. 1152
INSTALLATIONp. 1152
CONTROL MODULEp. 1152
DESCRIPTIONp. 1152
OPERATIONp. 1152
DIAGNOSIS AND TESTINGp. 1152
REMOVALp. 1152
INSTALLATIONp. 1153
EVAPORATOR TEMPERATURE SENSORp. 1153
DESCRIPTIONp. 1153
OPERATIONp. 1154
DIAGNOSIS AND TESTINGp. 1154
REMOVALp. 1154
INSTALLATIONp. 1154
SOLENOID VALVEp. 1155
DESCRIPTIONp. 1155
OPERATIONp. 1155
DIAGNOSIS AND TESTINGp. 1155
REMOVALp. 1155
INSTALLATIONp. 1156
TEMPERATURE CONTROLp. 1157
DESCRIPTIONp. 1157
OPERATIONp. 1157
DIAGNOSIS AND TESTINGp. 1157
REMOVALp. 1157
INSTALLATIONp. 1157
TEMPERATURE SENSORp. 1158
DESCRIPTIONp. 1158
OPERATIONp. 1158
DIAGNOSIS AND TESTINGp. 1158
REMOVALp. 1158
INSTALLATIONp. 1158
DISTRIBUTION – FRONTp. 1159
AIR FILTERp. 1159
REMOVALp. 1159
INSTALLATIONp. 1159
AIR OUTLETSp. 1159
REMOVALp. 1159
INSTALLATIONp. 1160
BLOWER MOTORp. 1160
REMOVALp. 1160
INSTALLATIONp. 1161
DEFROSTER DUCTSp. 1161
REMOVALp. 1161
INSTALLATIONp. 1161
FLOOR DISTRIBUTION DUCTSp. 1161
REMOVALp. 1161
INSTALLATIONp. 1162
HVAC HOUSINGp. 1162
REMOVALp. 1162
DISASSEMBLYp. 1164
ASSEMBLYp. 1164
INSTALLATIONp. 1164
INSTRUMENT PANEL DUCTSp. 1165
REMOVALp. 1165
INSTALLATIONp. 1166
DISTRIBUTION – REARp. 1167
AIR FILTERp. 1167
REMOVALp. 1167
INSTALLATIONp. 1167
BLOWER MOTORp. 1167
REMOVALp. 1167
INSTALLATIONp. 1168
REAR A/C HOUSINGp. 1168
REMOVALp. 1168
INSTALLATIONp. 1169
PLUMBINGp. 1171
PLUMBINGp. 1172
DESCRIPTION – REFRIGERANT LINEp. 1172
OPERATION – REFRIGERANT LINEp. 1172
WARNINGp. 1172
CAUTIONp. 1173
CAUTIONp. 1173
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONSp. 1173
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKSp. 1174
SYSTEM EMPTYp. 1174
SYSTEM LOWp. 1174
STANDARD PROCEDUREp. 1174
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENTp. 1174
MANIFOLD GAUGE SET CONNECTIONSp. 1175
STANDARD PROCEDURE – REFRIGERANT RECOVERYp. 1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATEp. 1175
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGEp. 1176
PARTIAL CHARGE METHODp. 1176
SPECIFICATIONSp. 1177
CHARGE CAPACITYp. 1177
A/C COMPRESSORp. 1177
DESCRIPTIONp. 1177
OPERATIONp. 1177
DIAGNOSIS AND TESTING – COMPRESSOR NOISEp. 1177
REMOVALp. 1178
INSTALLATIONp. 1179
A/C CONDENSERp. 1180
DESCRIPTIONp. 1180
OPERATIONp. 1180
REMOVALp. 1180
INSTALLATIONp. 1180
A/C DISCHARGE LINEp. 1181
REMOVALp. 1181
INSTALLATIONp. 1182
A/C EVAPORATORp. 1182
DESCRIPTIONp. 1182
OPERATIONp. 1182
REMOVALp. 1183
INSTALLATIONp. 1183
A/C EXPANSION VALVEp. 1183
DESCRIPTIONp. 1183
OPERATIONp. 1183
DIAGNOSIS AND TESTING – A/C EXPANSION VALVEp. 1184
REMOVALp. 1184
INSTALLATIONp. 1184
ELECTRIC COOLANT PUMPp. 1185
DESCRIPTIONp. 1185
OPERATIONp. 1185
REMOVALp. 1185
INSTALLATIONp. 1185
HEATER COREp. 1185
DESCRIPTIONp. 1185
OPERATIONp. 1185
REMOVALp. 1186
INSTALLATIONp. 1186
LIQUID LINEp. 1186
REMOVALp. 1186
INSTALLATIONp. 1187
REAR EVAPORATORp. 1188
REMOVALp. 1188
INSTALLATIONp. 1189
REAR EXPANSION VALVEp. 1190
REMOVALp. 1190
INSTALLATIONp. 1191
RECEIVER/DRIERp. 1192
DESCRIPTIONp. 1192
OPERATIONp. 1192
REMOVALp. 1192
INSTALLATIONp. 1192
REFRIGERANTp. 1193
DESCRIPTIONp. 1193
OPERATIONp. 1193
REFRIGERANT OILp. 1193
DESCRIPTIONp. 1193
OPERATIONp. 1193
STANDARD PROCEDURE – REFRIGERANT OIL LEVELp. 1193
SUCTION LINEp. 1194
REMOVALp. 1194
INSTALLATIONp. 1194
WATER VALVEp. 1195
REMOVALp. 1195
INSTALLATIONp. 1195
UNDERBODY LINESp. 1196
REMOVALp. 1196
INSTALLATIONp. 1197
CABIN HEATERp. 1200
CABIN HEATERp. 1200
DESCRIPTIONp. 1200
OPERATIONp. 1200
DIAGNOSIS AND TESTING – DIESEL SUPPLEMENTAL HEATER – DCHAp. 1200
EXHAUST TUBEp. 1201
REMOVALp. 1201
INSTALLATIONp. 1201
FUEL DOSING PUMPp. 1202
DESCRIPTIONp. 1202
OPERATIONp. 1202
REMOVALp. 1202
INSTALLATIONp. 1202
FUEL LINEp. 1203
STANDARD PROCEDURE – CLEANINGp. 1203
REMOVALp. 1203
INSTALLATIONp. 1204
HEATER UNITp. 1205
REMOVALp. 1205
REMOVALp. 1205
REMOVALp. 1205
INSTALLATIONp. 1206
INSTALLATIONp. 1206
INSTALLATIONp. 1206
INLET HOSEp. 1206
REMOVALp. 1206
INSTALLATIONp. 1206
25-EMISSIONS CONTROLp. 1209
EXHAUST GAS RECIRCULATIONp. 1209
VALVEp. 1209
DESCRIPTIONp. 1209
OPERATIONp. 1209
REMOVALp. 1210
INSTALLATIONp. 1210
INDEXp. 1211
COMMENTSp. 1231

  • 0 Lubrication & Maintenance
  • 2 Suspension
  • 3 Differential & Driveline
  • 5 Brakes
  • 7 Cooling
  • 8A Audio/Video
  • 8B Chime/Buzzer
  • 8E Electronic Control Modules
  • 8F Engine Systems
  • 8G Heated Systems
  • 8H Horn
  • 8I Ignition Control
  • 8J Instrument Cluster
  • 8L Lamps
  • 8N Power Systems
  • 😯 Restraints
  • 8P Speed Control
  • 8Q Vehicle Theft Security
  • 8R Wipers/Washers
  • 8W Wiring
  • 9 Engine
  • 11 Exhaust System
  • 13 Frame & Bumpers
  • 14 Fuel System
  • 19 Steering
  • 21 Transmission
  • 22 Tires/Wheels
  • 23 Body
  • 24 Heating & Air Conditioning
  • 25 Emissions Control

Within these groups, the manual provides detailed sub-sections covering every serviceable component. The Engine section alone includes complete procedures for cylinder head removal and installation, camshaft service, crankshaft and bearing measurement, piston and connecting rod assembly, timing chain service, turbocharger system, and the common rail diesel injection system. The Transmission section covers the NAG1 automatic transmission with full disassembly, assembly, and electrohydraulic unit service. Suspension, brakes, steering, and the extensive wiring diagrams are all present with the same level of technical depth.

What This Manual Enables You to Do

With this Dodge Sprinter VA Service Manual in hand, you can confidently tackle:

  • Engine Repair: Cylinder head inspection and resurfacing, valve spring replacement, camshaft position checking, crankshaft measurement, piston ring fitting, timing chain replacement, and complete engine removal and installation.
  • Fuel System Service: High-pressure fuel line diagnosis, fuel injector cleaning and classification, fuel rail service, fuel pressure solenoid replacement, and water-in-fuel sensor testing.
  • Transmission Overhaul: NAG1 transmission removal, disassembly, assembly, clutch pack measurement and adjustment, electrohydraulic unit service, and torque converter replacement.
  • Brake System Repair: Front and rear brake pad replacement, disc brake caliper service, rotor removal and installation, master cylinder bleeding, and parking brake adjustment.
  • Suspension Work: Front strut replacement, lower ball joint service, control arm bushing replacement, stabilizer bar link service, spring clamp plate installation, and rear leaf spring and shock absorber replacement.
  • Electrical Diagnosis: Complete wiring diagrams, connector pin-outs, ground distribution, splice locations, and component location illustrations.
  • Routine Maintenance: Fluid type specifications, capacities, maintenance schedules with and without the ASSYST system, and all torque specifications.

IMAGES PREVIEW

Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide — PDF page 24 preview
Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide — PDF page 23 preview
Dodge Sprinter VA Service Manual - 2.7L CDI Diesel Complete Workshop Repair Guide — PDF page 27 preview

Why the Dodge Sprinter VA Service Manual Matters

Working on a modern diesel van without the correct procedures and specifications is risky. The 2.7L CDI engine and NAG1 transmission are sophisticated systems with precise tolerances and specific service requirements. This Dodge Sprinter VA Service Manual provides the exact torque values, clearances, tightening sequences, and diagnostic steps that the manufacturer specifies. Whether you are replacing a timing chain, servicing the turbocharger, overhauling the transmission, or diagnosing an electrical fault, having the correct information prevents costly mistakes and ensures the job is done right the first time.

Instant PDF Delivery

The Dodge Sprinter VA Service Manual is delivered as an instant PDF download after payment. There is no shipping, no waiting, and no physical book to handle. The PDF format works on any device – laptop, tablet, or smartphone – and you can print the pages you need for the workshop. Keep it on your computer for quick reference or print the entire manual for a complete workshop set. With 1,232 pages of detailed technical content, this is the most comprehensive resource available for the Dodge Sprinter VA with the 2.7L CDI diesel engine.

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