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Description
Sprinter 2006 VA Service Manual – PDF DOWNLOAD
FILE DETAILS:
Sprinter 2006 VA Service Manual – PDF DOWNLOAD
Language : English
Pages : 1458
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Sprinter 2006 VA Service Manual – PDF DOWNLOAD
MAIN WELCOME PAGE................................................................................ 0 INSTRUCTIONS..................................................................................... 0 VA Powertrain.................................................................................... 0 VA Body.......................................................................................... 0 VA Chassis....................................................................................... 0 VA Transmission.................................................................................. 0 VA Service Manual................................................................................ 1 FOREWORD..................................................................................... 0 GROUP TAB LOCATOR............................................................................ 1 in-INTRODUCTION.............................................................................. 3 VEHICLE IDENTIFICATION NUMBER............................................................ 3 DESCRIPTION.......................................................................... 3 INTERNATIONAL SYMBOLS.................................................................... 4 DESCRIPTION.......................................................................... 4 FASTENER IDENTIFICATION.................................................................. 5 DESCRIPTION.......................................................................... 5 FASTENER USAGE........................................................................... 8 DESCRIPTION - FASTENER USAGE......................................................... 8 THREADED HOLE REPAIR..................................................................... 8 DESCRIPTION - THREADED HOLE REPAIR................................................... 8 METRIC SYSTEM............................................................................ 8 DESCRIPTION.......................................................................... 8 TORQUE REFERENCES........................................................................ 11 DESCRIPTION.......................................................................... 11 0-LUBRICATION & MAINTENANCE.................................................................. 13 FLUID TYPES.............................................................................. 13 DESCRIPTION.......................................................................... 13 PARTS AND LUBRICANT RECOMMENDATIONS.............................................. 13 AUTOMATIC TRANSMISSION FLUID - NAG1.............................................. 13 FLUID ADDITIVES.............................................................. 13 AXLE FLUID....................................................................... 14 BRAKE FLUID...................................................................... 14 HOAT COOLANT..................................................................... 14 COOLANT PERFORMANCE.......................................................... 14 ENGINE OIL - DIESEL ENGINES...................................................... 15 SAE VISCOSITY GRADE.......................................................... 15 FUEL REQUIREMENTS - DIESEL ENGINE................................................ 16 DIESEL FUELS FOR USE AT VERY LOW TEMPERATURE................................. 16 POWER STEERING FLUID............................................................. 17 OPERATION - AUTOMATIC TRANSMISSION FLUID............................................. 17 FLUID CAPACITIES......................................................................... 17 SPECIFICATIONS - FLUID CAPACITIES.................................................... 17 FLUID FILL / CHECK LOCATIONS............................................................. 17 INSPECTION - FLUID FILL / CHECK LOCATIONS............................................ 17 HOISTING................................................................................. 17 STANDARD PROCEDURE - HOISTING........................................................ 17 FLOOR JACK....................................................................... 17 HOIST............................................................................ 18 JUMP STARTING............................................................................ 18 STANDARD PROCEDURE - JUMP STARTING................................................... 18 TO JUMP START A DISABLED VEHICLE:................................................ 18 DISCONNECT CABLE CLAMPS AS FOLLOWS:.............................................. 19 TOWING................................................................................... 19 STANDARD PROCEDURE - TOWING.......................................................... 19 If the Engine is Damaged......................................................... 19 If the Transmission is Damaged................................................... 19 If the Front Axle is Damaged..................................................... 19 If the Rear Axle is Damaged...................................................... 19 SAFETY PRECAUTIONS............................................................... 19 GROUND CLEARANCE................................................................. 19 RAMP ANGLE....................................................................... 20 TOWING WHEN KEYS ARE NOT AVAILABLE............................................... 20 MAINTENANCE SCHEDULES.................................................................... 20 DESCRIPTION.......................................................................... 20 MAINTENANCE - WITHOUT ASSYST MAINTENANCE COMPUTER................................ 20 MAINTENANCE - WITH ASSYST MAINTENANCE COMPUTER................................... 20 REGULAR CHECK - UPS.............................................................. 20 SPECIAL MAINTENANCE REQUIREMENTS................................................. 20 ENGINE OIL CHANGE AND FILTER REPLACEMENT......................................... 20 SCOPE OF WORK FOR MAINTENANCE SERVICE............................................ 21 ADDITIONAL MAINTENANCE WORK...................................................... 21 ADDITIONAL MAINTENANCE WORK AFTER YEARS.......................................... 21 INTERNATIONAL SYMBOLS.................................................................... 21 DESCRIPTION.......................................................................... 21 2-SUSPENSION................................................................................. 23 FRONT.................................................................................... 23 FRONT................................................................................ 23 SPECIFICATIONS - TORQUE CHART.................................................... 23 SPECIAL TOOLS.................................................................... 24 FRONT SUSPENSION............................................................. 24 BUSHINGS............................................................................. 25 REMOVAL.......................................................................... 25 INSTALLATION..................................................................... 25 HUB / BEARING........................................................................ 26 DIAGNOSIS AND TESTING -.......................................................... 26 REMOVAL.......................................................................... 26 INSTALLATION..................................................................... 27 KNUCKLE.............................................................................. 27 REMOVAL.......................................................................... 27 INSTALLATION..................................................................... 28 LOWER BALL JOINT..................................................................... 28 REMOVAL.......................................................................... 28 INSTALLATION..................................................................... 28 LOWER CONTROL ARM.................................................................... 28 REMOVAL.......................................................................... 28 INSTALLATION..................................................................... 29 SPRING............................................................................... 29 REMOVAL.......................................................................... 29 INSTALLATION..................................................................... 30 SPRING CLAMP PLATES.................................................................. 30 REMOVAL.......................................................................... 30 INSTALLATION..................................................................... 31 SPRING STOP PLATES................................................................... 31 REMOVAL.......................................................................... 31 INSTALLATION..................................................................... 31 STABILIZER BAR....................................................................... 31 DESCRIPTION...................................................................... 31 OPERATION........................................................................ 31 REMOVAL.......................................................................... 31 INSTALLATION..................................................................... 31 STABILIZER LINK...................................................................... 32 REMOVAL.......................................................................... 32 INSTALLATION..................................................................... 32 STRUT................................................................................ 32 REMOVAL.......................................................................... 32 INSTALLATION..................................................................... 32 REAR..................................................................................... 33 REAR................................................................................. 33 DESCRIPTION...................................................................... 33 DIAGNOSIS AND TESTING - SPRING AND SHOCK......................................... 33 SPECIFICATIONS - TORQUE CHART.................................................... 34 SHOCK................................................................................ 35 DIAGNOSIS AND TESTING - SHOCK.................................................... 35 REMOVAL.......................................................................... 35 INSTALLATION..................................................................... 35 SPRING............................................................................... 36 DESCRIPTION...................................................................... 36 OPERATION........................................................................ 36 REMOVAL.......................................................................... 36 REMOVAL - (SRW).............................................................. 36 REMOVAL - (DRW).............................................................. 36 INSTALLATION..................................................................... 36 INSTALLATION - (SRW)......................................................... 36 INSTALLATION - (DRW)......................................................... 37 SPRING SHACKLE....................................................................... 37 REMOVAL.......................................................................... 37 INSTALLATION..................................................................... 37 STABILIZER BAR....................................................................... 37 REMOVAL.......................................................................... 37 INSTALLATION..................................................................... 37 STABILIZER LINK...................................................................... 38 REMOVAL.......................................................................... 38 INSTALLATION..................................................................... 38 WHEEL ALIGNMENT.......................................................................... 39 WHEEL ALIGNMENT...................................................................... 39 DESCRIPTION...................................................................... 39 DIAGNOSIS AND TESTING - PRE - ALIGNMENT INSPECTION............................... 39 STANDARD PROCEDURE - TOE ADJUSTMENT.............................................. 40 SPECIFICATIONS................................................................... 41 3-DIFFERENTIAL & DRIVELINE................................................................... 43 PROPELLER SHAFT.......................................................................... 43 PROPELLER SHAFT...................................................................... 43 DIAGNOSIS AND TESTING............................................................ 43 PROPELLER SHAFT.............................................................. 43 PROPELLER SHAFT VIBRATION................................................ 43 PROPELLER SHAFT BALANCE.................................................. 44 PROPELLER SHAFT RUNOUT................................................... 45 STANDARD PROCEDURE............................................................... 46 PROPELLER SHAFT ANGLE........................................................ 46 TWO / THREE - PIECE PROPELLER SHAFT.......................................... 47 SPECIFICATIONS................................................................... 48 SPECIAL TOOLS.................................................................... 48 PROPELLER SHAFT...................................................................... 49 REMOVAL.......................................................................... 49 INSTALLATION..................................................................... 51 CENTER BEARING....................................................................... 51 REMOVAL.......................................................................... 51 INSTALLATION..................................................................... 52 REAR AXLE................................................................................ 54 REAR AXLE............................................................................ 54 DIAGNOSIS AND TESTING............................................................ 54 GEAR NOISE................................................................... 54 BEARING NOISE................................................................ 54 LOW SPEED KNOCK.............................................................. 55 VIBRATION.................................................................... 55 DRIVELINE SNAP............................................................... 55 STANDARD PROCEDURE - DRAIN AND FILL.............................................. 55 REMOVAL.......................................................................... 56 INSTALLATION..................................................................... 58 SPECIFICATIONS................................................................... 60 SPECIAL TOOLS.................................................................... 61 SHAFT - AXLE SINGLE REAR WHEEL....................................................... 65 REMOVAL-SINGLE REAR WHEEL........................................................ 65 INSTALLATION - SINGLE REAR WHEEL................................................. 66 BEARING / SEAL - AXLE................................................................ 66 REMOVAL.......................................................................... 66 INSTALLATION..................................................................... 68 SHAFT - AXLE DUAL REAR WHEELS........................................................ 69 REMOVAL - DUAL REAR WHEEL........................................................ 69 INSTALLATION - DUAL REAR WHEEL................................................... 70 BEARING / SEAL - AXLE HUB............................................................ 70 REMOVAL.......................................................................... 70 INSTALLATION..................................................................... 71 DIFFERENTIAL......................................................................... 73 REMOVAL.......................................................................... 73 DISASSEMBLY...................................................................... 74 DISASSEMBLY - SINGLE REAR WHEEL.............................................. 74 DISASSEMBLY - DUAL REAR WHEEL................................................ 75 ASSEMBLY......................................................................... 76 ASSEMBLY - SINGLE REAR WHEEL................................................. 76 ASSEMBLY - DUAL REAR WHEEL................................................... 78 INSTALLATION..................................................................... 79 BEARINGS - DIFFERENTIAL CASE......................................................... 80 REMOVAL.......................................................................... 80 INSTALLATION..................................................................... 80 SEAL - PINION........................................................................ 81 REMOVAL.......................................................................... 81 INSTALLATION..................................................................... 82 GEAR - PINION / RING................................................................. 83 REMOVAL.......................................................................... 83 INSTALLATION..................................................................... 84 5-BRAKES..................................................................................... 87 BRAKES - BASE............................................................................ 87 BRAKES - BASE........................................................................ 88 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM........................................ 88 PRELIMINARY BRAKE CHECK...................................................... 88 ROAD TESTING................................................................. 88 BRAKE NOISES................................................................. 90 STANDARD PROCEDURE............................................................... 90 STANDARD PROCEDURE - MANUAL BLEEDING......................................... 90 STANDARD PROCEDURE - PRESSURE BLEEDING....................................... 91 HYDRAULIC / MECHANICAL............................................................... 91 SPECIFICATIONS................................................................... 91 SPECIFICATIONS - TORQUE CHART................................................ 91 BASE BRAKE................................................................... 92 SPECIAL TOOLS.................................................................... 93 BRAKES....................................................................... 93 BRAKE LINES.......................................................................... 94 STANDARD PROCEDURE............................................................... 94 STANDARD PROCEDURE - ISO FLARING............................................. 94 STANDARD PROCEDURE - DOUBLE INVERTED FLARING................................. 94 BRAKE PADS / SHOES................................................................... 94 REMOVAL.......................................................................... 94 REMOVAL - FRONT (SRW)........................................................ 94 REMOVAL - FRONT (DRW)........................................................ 95 REMOVAL - REAR (16” WHEELS) (SRW)............................................ 95 REMOVAL - REAR (15” WHEELS) (SRW)............................................ 96 REMOVAL - REAR (DRW)......................................................... 96 INSTALLATION..................................................................... 97 INSTALLATION - FRONT (SRW)................................................... 97 INSTALLATION - FRONT (DRW)................................................... 97 INSTALLATION - REAR (16” WHEELS) (SRW)....................................... 97 INSTALLATION - REAR (16” WHEELS) (SRW)....................................... 97 INSTALLATION - REAR (DRW).................................................... 97 DISC BRAKE CALIPERS.................................................................. 97 REMOVAL.......................................................................... 97 REMOVAL - FRONT (SRW)........................................................ 97 REMOVAL - FRONT (DRW)........................................................ 98 REMOVAL - REAR (SRW)......................................................... 98 REMOVAL - REAR (DRW)......................................................... 99 INSTALLATION..................................................................... 99 INSTALLATION - FRONT (SRW)................................................... 99 INSTALLATION - FRONT (DRW)................................................... 99 INSTALLATION - REAR (SRW).................................................... 100 INSTALLATION - REAR (DRW).................................................... 100 DISC BRAKE CALIPER ADAPTER........................................................... 100 REMOVAL.......................................................................... 100 REMOVAL - FRONT.............................................................. 100 REMOVAL - REAR............................................................... 100 INSTALLATION..................................................................... 100 INSTALLATION - FRONT......................................................... 100 INSTALLATION - REAR.......................................................... 100 FLUID................................................................................ 101 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION................................ 101 STANDARD PROCEDURE - BRAKE FLUID LEVEL........................................... 101 SPECIFICATIONS................................................................... 101 BRAKE FLUID.................................................................. 101 FLUID RESERVOIR...................................................................... 101 REMOVAL.......................................................................... 101 INSTALLATION..................................................................... 101 ALB LEVER............................................................................ 102 REMOVAL.......................................................................... 102 INSTALLATION..................................................................... 102 ALB CONTROLLER....................................................................... 102 REMOVAL.......................................................................... 102 INSTALLATION..................................................................... 102 ADJUSTMENTS...................................................................... 102 ADJUSTMENT................................................................... 102 MASTER CYLINDER...................................................................... 103 DIAGNOSIS AND TESTING - MASTER CYLINDER / POWER BOOSTER.......................... 103 POWER BOOSTER VACUUM TEST.................................................... 103 POWER BOOSTER CHECK VALVE TEST............................................... 103 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING.................................... 104 REMOVAL.......................................................................... 104 INSTALLATION..................................................................... 105 PEDAL................................................................................ 105 REMOVAL.......................................................................... 105 INSTALLATION..................................................................... 105 POWER BRAKE BOOSTER.................................................................. 105 DESCRIPTION...................................................................... 105 OPERATION........................................................................ 105 REMOVAL.......................................................................... 106 INSTALLATION..................................................................... 106 ROTORS............................................................................... 106 REMOVAL.......................................................................... 106 REMOVAL - FRONT (SRW)........................................................ 106 REMOVAL - REAR (SRW)......................................................... 106 REMOVAL - FRONT (DRW)........................................................ 107 REMOVAL - REAR (DRW)......................................................... 107 INSTALLATION..................................................................... 108 INSTALLATION - FRONT (SRW)................................................... 108 INSTALLATION - REAR (SRW).................................................... 108 INSTALLATION - FRONT (DRW)................................................... 108 INSTALLATION - REAR (DRW).................................................... 108 SUPPORT PLATE........................................................................ 109 REMOVAL - REAR................................................................... 109 INSTALLATION - REAR.............................................................. 109 PARKING BRAKE........................................................................ 109 SPECIFICATIONS................................................................... 109 TORQUE CHART................................................................. 109 SPECIAL TOOLS.................................................................... 110 PARK BRAKE................................................................... 110 CABLE TENSIONER...................................................................... 110 REMOVAL.......................................................................... 110 INSTALLATION..................................................................... 110 CABLES............................................................................... 110 REMOVAL.......................................................................... 110 REMOVAL - FRONT.............................................................. 110 REMOVAL - REAR............................................................... 111 INSTALLATION..................................................................... 111 INSTALLATION - FRONT......................................................... 111 INSTALLATION - REAR.......................................................... 112 ADJUSTMENTS...................................................................... 112 ADJUSTMENT - PARKING BRAKE CABLES............................................ 112 LEVER................................................................................ 112 REMOVAL.......................................................................... 112 INSTALLATION..................................................................... 113 SHOES................................................................................ 113 REMOVAL.......................................................................... 113 REMOVAL - (SRW).............................................................. 113 REMOVAL - (DRW).............................................................. 113 CLEANING - REAR DRUM IN HAT BRAKE................................................ 114 INSTALLATION..................................................................... 114 INSTALLATION - (SRW)......................................................... 114 INSTALLATION - (DRW)......................................................... 114 ADJUSTMENTS...................................................................... 114 ADJUSTMENT................................................................... 114 BRAKES - ABS............................................................................. 116 BRAKES - ABS......................................................................... 116 SPECIFICATIONS - TORQUE CHART.................................................... 116 ELECTRICAL........................................................................... 116 DESCRIPTION...................................................................... 116 OPERATION........................................................................ 116 FRONT WHEEL SPEED SENSOR............................................................. 117 REMOVAL.......................................................................... 117 INSTALLATION..................................................................... 117 REAR WHEEL SPEED SENSOR.............................................................. 117 REMOVAL.......................................................................... 117 INSTALLATION..................................................................... 118 TONE WHEEL........................................................................... 118 REMOVAL.......................................................................... 118 INSTALLATION..................................................................... 118 STEERING ANGLE SENSOR................................................................ 118 DESCRIPTION...................................................................... 118 REMOVAL.......................................................................... 119 INSTALLATION..................................................................... 119 LATERAL ACCELERATION SENSOR.......................................................... 119 DESCRIPTION...................................................................... 119 REMOVAL.......................................................................... 119 INSTALLATION..................................................................... 120 YAW RATE SENSOR...................................................................... 121 DESCRIPTION...................................................................... 121 REMOVAL.......................................................................... 121 INSTALLATION..................................................................... 122 HCU (HYDRAULIC CONTROL UNIT)......................................................... 122 DESCRIPTION...................................................................... 122 REMOVAL.......................................................................... 122 INSTALLATION..................................................................... 123 7-COOLING.................................................................................... 125 COOLING.................................................................................. 125 OPERATION - COOLING SYSTEM........................................................... 125 DIAGNOSIS AND TESTING................................................................ 125 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS....................................... 125 ENGINE COOLING SYSTEM OVERHEATING............................................ 125 COOLING SYSTEM................................................................... 126 ACCESSORY DRIVE.......................................................................... 129 BELT TENSIONERS...................................................................... 129 DESCRIPTION...................................................................... 129 OPERATION........................................................................ 129 DRIVE BELTS.......................................................................... 129 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT..................................... 129 VISUAL DIAGNOSIS............................................................. 129 NOISE DIAGNOSIS.............................................................. 130 REMOVAL.......................................................................... 132 REMOVAL...................................................................... 132 REMOVAL...................................................................... 132 INSTALLATION..................................................................... 132 INSTALLATION................................................................. 132 INSTALLATION................................................................. 132 ENGINE................................................................................... 133 COOLANT.............................................................................. 133 DESCRIPTION...................................................................... 133 DIAGNOSIS AND TESTING............................................................ 134 COOLING SYSTEM LEAKS......................................................... 134 ULTRAVIOLET LIGHT METHOD................................................. 134 PRESSURE TESTER METHOD................................................... 134 INTERNAL LEAKAGE INSPECTION.............................................. 135 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER........................ 135 STANDARD PROCEDURE............................................................... 136 ADDING ADDITIONAL COOLANT.................................................... 136 DRAINING COOLING SYSTEM...................................................... 136 REFILLING COOLING SYSTEM..................................................... 137 COOLANT LEVEL SENSOR................................................................. 137 REMOVAL.......................................................................... 137 INSTALLATION..................................................................... 138 RADIATOR FAN......................................................................... 138 REMOVAL.......................................................................... 138 INSTALLATION..................................................................... 138 ENGINE BLOCK HEATER.................................................................. 138 REMOVAL.......................................................................... 138 INSTALLATION..................................................................... 139 ENGINE COOLANT TEMP SENSOR........................................................... 139 DESCRIPTION...................................................................... 139 REMOVAL.......................................................................... 139 INSTALLATION..................................................................... 139 ENGINE COOLANT THERMOSTAT............................................................ 140 REMOVAL.......................................................................... 140 INSTALLATION..................................................................... 140 FAN DRIVE VISCOUS CLUTCH............................................................. 141 REMOVAL.......................................................................... 141 INSTALLATION..................................................................... 141 RADIATOR............................................................................. 141 REMOVAL.......................................................................... 141 INSTALLATION..................................................................... 143 RADIATOR PRESSURE CAP................................................................ 143 DESCRIPTION...................................................................... 143 OPERATION........................................................................ 144 DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP.................................... 144 WATER PUMP........................................................................... 144 REMOVAL.......................................................................... 144 INSTALLATION..................................................................... 146 8a-AUDIO / VIDEO............................................................................. 147 AUDIO.................................................................................... 147 SPECIAL TOOLS........................................................................ 147 AUDIO............................................................................ 147 ANTENNA BODY & CABLE..................................................................... 147 REMOVAL.............................................................................. 147 INSTALLATION......................................................................... 147 INSTRUMENT PANEL ANTENNA CABLE........................................................... 148 REMOVAL.............................................................................. 148 INSTALLATION......................................................................... 148 RADIO.................................................................................... 148 REMOVAL.............................................................................. 148 INSTALLATION......................................................................... 148 SPEAKER.................................................................................. 148 REMOVAL.............................................................................. 148 INSTALLATION......................................................................... 149 8b-CHIME / BUZZER............................................................................ 151 CHIME / BUZZER........................................................................... 151 DESCRIPTION.......................................................................... 151 OPERATION............................................................................ 151 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM......................................... 152 8e-ELECTRONIC CONTROL MODULES................................................................ 153 CENTRAL TIMER MODULE..................................................................... 153 DESCRIPTION.......................................................................... 153 OPERATION............................................................................ 153 DIAGNOSIS AND TESTING - CENTRAL TIMER MODULE......................................... 154 REMOVAL.............................................................................. 154 INSTALLATION......................................................................... 155 CONTROLLER ANTILOCK BRAKE................................................................ 155 DESCRIPTION.......................................................................... 155 REMOVAL.............................................................................. 155 INSTALLATION......................................................................... 155 ENGINE CONTROL MODULE.................................................................... 155 DESCRIPTION.......................................................................... 155 REMOVAL.............................................................................. 158 INSTALLATION......................................................................... 158 TRANSMISSION CONTROL MODULE.............................................................. 158 DESCRIPTION.......................................................................... 158 OPERATION............................................................................ 159 TCM SIGNALS...................................................................... 159 BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)........................................ 160 SHIFT SCHEDULES.................................................................. 160 DOWNSHIFT SAFETY................................................................. 160 ADAPTATION....................................................................... 160 CONTROLLER MODES OF OPERATION.................................................... 161 STANDARD PROCEDURE - TCM ADAPTATION.................................................. 162 8f-ENGINE SYSTEMS............................................................................ 163 BATTERY SYSTEM........................................................................... 163 BATTERY SYSTEM....................................................................... 163 DESCRIPTION...................................................................... 163 OPERATION........................................................................ 164 DIAGNOSIS AND TESTING - BATTERY SYSTEM........................................... 164 MICRO 420 BATTERY TESTER..................................................... 164 ABNORMAL BATTERY DISCHARGING................................................. 166 CLEANING......................................................................... 167 INSPECTION....................................................................... 168 SPECIAL TOOLS.................................................................... 168 BATTERY SYSTEM SPECIAL TOOLS................................................. 168 BATTERY.............................................................................. 168 DESCRIPTION...................................................................... 168 OPERATION........................................................................ 169 DIAGNOSIS AND TESTING - BATTERY.................................................. 169 MICRO 420 BATTERY TESTER..................................................... 169 STANDARD PROCEDURE............................................................... 170 STANDARD PROCEDURE - BATTERY CHARGING........................................ 170 CHARGING A COMPLETELY DISCHARGED BATTERY................................. 170 CHARGING TIME REQUIRED................................................... 171 STANDARD PROCEDURE - OPEN - CIRCUIT VOLTAGE TEST............................. 171 STANDARD PROCEDURE - IGNITION - OFF DRAW TEST................................ 172 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER.......................... 173 BATTERY TESTING.......................................................... 173 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL...................... 174 REMOVAL.......................................................................... 174 UNDER HOOD BATTERY REMOVAL................................................... 174 AUXILIARY BATTERY REMOVAL.................................................... 175 INSTALLATION..................................................................... 175 UNDER HOOD BATTERY INSTALLATION.............................................. 175 AUXILIARY BATTERY INSTALLATION............................................... 175 BATTERY HOLDDOWN..................................................................... 175 DESCRIPTION...................................................................... 175 REMOVAL.......................................................................... 175 INSTALLATION..................................................................... 176 BATTERY CABLES....................................................................... 176 DESCRIPTION...................................................................... 176 OPERATION........................................................................ 176 DIAGNOSIS AND TESTING - BATTERY CABLES........................................... 176 REMOVAL.......................................................................... 178 INSTALLATION..................................................................... 178 BATTERY TRAY......................................................................... 178 DESCRIPTION...................................................................... 178 OPERATION........................................................................ 178 REMOVAL.......................................................................... 178 INSTALLATION..................................................................... 178 CHARGING SYSTEM.......................................................................... 179 CHARGING SYSTEM...................................................................... 179 SPECIFICATIONS................................................................... 179 TORQUE – 2.7L DIESEL......................................................... 179 SPECIAL TOOLS.................................................................... 180 GENERATOR............................................................................ 180 DESCRIPTION...................................................................... 180 OPERATION........................................................................ 180 REMOVAL.......................................................................... 180 INSTALLATION..................................................................... 181 GENERATOR DECOUPLER PULLEY........................................................... 181 DESCRIPTION...................................................................... 181 OPERATION........................................................................ 181 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER...................................... 182 REMOVAL.......................................................................... 182 INSTALLATION..................................................................... 184 VOLTAGE REGULATOR.................................................................... 186 DESCRIPTION...................................................................... 186 REMOVAL.......................................................................... 186 INSTALLATION..................................................................... 188 STARTING SYSTEM.......................................................................... 190 STARTING SYSTEM...................................................................... 190 DESCRIPTION...................................................................... 190 OPERATION........................................................................ 190 DIAGNOSIS AND TESTING - STARTING SYSTEM.......................................... 191 INSPECTION................................................................... 192 TESTING...................................................................... 192 SPECIFICATIONS................................................................... 195 TORQUE - STARTER - DIESEL.................................................... 195 SPECIFICATIONS - STARTER MOTOR - DIESEL...................................... 195 STARTER MOTOR........................................................................ 195 DIAGNOSIS AND TESTING - STARTER MOTOR............................................ 195 REMOVAL.......................................................................... 196 INSTALLATION..................................................................... 197 STARTER MOTOR RELAY.................................................................. 197 DESCRIPTION...................................................................... 197 REMOVAL.......................................................................... 197 INSTALLATION..................................................................... 198 8g-HEATED SYSTEMS............................................................................ 199 HEATED GLASS............................................................................. 199 HEATED GLASS......................................................................... 199 DESCRIPTION...................................................................... 199 OPERATION........................................................................ 199 DIAGNOSIS AND TESTING............................................................ 200 ELECTRIC BACKLIGHT (EBL) SYSTEM.............................................. 200 REAR WINDOW DEFOGGER RELAY........................................................... 201 DESCRIPTION...................................................................... 201 OPERATION........................................................................ 201 REMOVAL.......................................................................... 202 INSTALLATION..................................................................... 202 REAR WINDOW DEFOGGER SWITCH.......................................................... 202 DESCRIPTION...................................................................... 202 OPERATION........................................................................ 202 DIAGNOSIS AND TESTING............................................................ 203 REAR WINDOW DEFOGGER SWITCH.................................................. 203 REMOVAL.......................................................................... 204 INSTALLATION..................................................................... 204 REAR WINDOW DEFOGGER GRID............................................................ 205 STANDARD PROCEDURE............................................................... 205 GRID LINE AND TERMINAL REPAIR................................................ 205 HEATED MIRRORS........................................................................... 207 HEATED MIRRORS....................................................................... 207 DESCRIPTION...................................................................... 207 OPERATION........................................................................ 207 HEATED SEATS............................................................................. 208 HEATED SEATS......................................................................... 208 DESCRIPTION...................................................................... 208 OPERATION........................................................................ 208 DIAGNOSIS AND TESTING - HEATED SEATS............................................. 209 DRIVER HEATED SEAT SWITCH............................................................ 209 DESCRIPTION...................................................................... 209 OPERATION........................................................................ 209 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH................................ 209 REMOVAL.......................................................................... 209 INSTALLATION..................................................................... 210 HEATED SEAT ELEMENT.................................................................. 210 DESCRIPTION...................................................................... 210 OPERATION........................................................................ 210 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT...................................... 210 HEATED SEAT RELAY.................................................................... 210 DESCRIPTION...................................................................... 210 OPERATION........................................................................ 211 DIAGNOSIS AND TESTING - HEATED SEAT RELAY........................................ 211 REMOVAL.......................................................................... 211 INSTALLATION..................................................................... 211 HEATED SEAT SENSOR................................................................... 211 DESCRIPTION...................................................................... 211 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR....................................... 211 PASSENGER HEATED SEAT SWITCH......................................................... 211 DESCRIPTION...................................................................... 211 OPERATION........................................................................ 211 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH............................. 212 REMOVAL.......................................................................... 212 INSTALLATION..................................................................... 212 8h-HORN...................................................................................... 213 HORN..................................................................................... 213 REMOVAL.............................................................................. 213 INSTALLATION......................................................................... 213 HORN SWITCH.............................................................................. 213 REMOVAL.............................................................................. 213 INSTALLATION......................................................................... 213 8i-IGNITION CONTROL.......................................................................... 215 IGNITION CONTROL......................................................................... 215 OPERATION - GLOW PLUG................................................................ 215 Pre - Glowing.................................................................... 215 Glow Output Stage................................................................ 215 After Glow....................................................................... 215 SPECIAL TOOLS........................................................................ 215 GLOW PLUG................................................................................ 215 REMOVAL.............................................................................. 215 INSTALLATION......................................................................... 215 GLOW PLUG RELAY.......................................................................... 215 DESCRIPTION.......................................................................... 215 OPERATION............................................................................ 216 DIAGNOSIS AND TESTING - GLOW PLUG RELAYS............................................. 216 8j-INSTRUMENT CLUSTER........................................................................ 217 INSTRUMENT CLUSTER....................................................................... 218 DESCRIPTION.......................................................................... 218 OPERATION............................................................................ 221 INPUT AND OUTPUT CIRCUITS........................................................ 222 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER........................................... 223 STANDARD PROCEDURE................................................................... 223 CLUSTER PROGRAMMING.............................................................. 223 REMOVAL.............................................................................. 224 INSTALLATION......................................................................... 225 ABS INDICATOR............................................................................ 225 DESCRIPTION.......................................................................... 225 OPERATION............................................................................ 226 ADR INDICATOR............................................................................ 226 DESCRIPTION.......................................................................... 226 OPERATION............................................................................ 226 AIRBAG INDICATOR......................................................................... 227 DESCRIPTION.......................................................................... 227 OPERATION............................................................................ 227 AMBIENT TEMPERATURE INDICATOR............................................................ 227 DESCRIPTION.......................................................................... 227 OPERATION............................................................................ 228 BRAKE INDICATOR.......................................................................... 228 DESCRIPTION.......................................................................... 228 OPERATION............................................................................ 228 BRAKE WEAR INDICATOR..................................................................... 229 DESCRIPTION.......................................................................... 229 OPERATION............................................................................ 229 CHARGING INDICATOR....................................................................... 230 DESCRIPTION.......................................................................... 230 OPERATION............................................................................ 230 CLOCK.................................................................................... 230 DESCRIPTION.......................................................................... 230 OPERATION............................................................................ 230 COOLANT LOW INDICATOR.................................................................... 231 DESCRIPTION.......................................................................... 231 OPERATION............................................................................ 231 ENGINE TEMPERATURE GAUGE................................................................. 231 DESCRIPTION.......................................................................... 231 OPERATION............................................................................ 232 ESP INDICATOR............................................................................ 232 DESCRIPTION.......................................................................... 232 OPERATION............................................................................ 232 FUEL FILTER CLOGGED INDICATOR............................................................ 233 DESCRIPTION.......................................................................... 233 OPERATION............................................................................ 233 FUEL GAUGE............................................................................... 233 DESCRIPTION.......................................................................... 233 OPERATION............................................................................ 234 GEAR SELECTOR INDICATOR.................................................................. 234 DESCRIPTION.......................................................................... 234 OPERATION............................................................................ 234 HIGH BEAM INDICATOR...................................................................... 235 DESCRIPTION.......................................................................... 235 OPERATION............................................................................ 235 LOW FUEL INDICATOR....................................................................... 235 DESCRIPTION.......................................................................... 235 OPERATION............................................................................ 235 LOW OIL LEVEL INDICATOR.................................................................. 236 DESCRIPTION.......................................................................... 236 OPERATION............................................................................ 236 MAINTENANCE INDICATOR.................................................................... 236 DESCRIPTION.......................................................................... 236 OPERATION............................................................................ 237 MALFUNCTION INDICATOR LAMP (MIL)......................................................... 237 DESCRIPTION.......................................................................... 237 OPERATION............................................................................ 237 MULTI - FUNCTION INDICATOR............................................................... 238 DESCRIPTION.......................................................................... 238 OPERATION............................................................................ 238 ODOMETER................................................................................. 238 DESCRIPTION.......................................................................... 238 OPERATION............................................................................ 239 PARK BRAKE INDICATOR..................................................................... 239 DESCRIPTION.......................................................................... 239 OPERATION............................................................................ 240 SEATBELT INDICATOR....................................................................... 240 DESCRIPTION.......................................................................... 240 OPERATION............................................................................ 240 SPEEDOMETER.............................................................................. 241 DESCRIPTION.......................................................................... 241 OPERATION............................................................................ 241 TACHOMETER............................................................................... 241 DESCRIPTION.......................................................................... 241 OPERATION............................................................................ 241 TRACTION CONTROL INDICATOR............................................................... 242 DESCRIPTION.......................................................................... 242 OPERATION............................................................................ 242 TRACTION CONTROL MALFUNCTION INDICATOR................................................... 243 DESCRIPTION.......................................................................... 243 OPERATION............................................................................ 243 TURN SIGNAL INDICATOR.................................................................... 243 DESCRIPTION.......................................................................... 243 OPERATION............................................................................ 243 WAIT - TO - START INDICATOR.............................................................. 244 DESCRIPTION.......................................................................... 244 OPERATION............................................................................ 244 WASHER FLUID INDICATOR................................................................... 245 DESCRIPTION.......................................................................... 245 OPERATION............................................................................ 245 WATER - IN - FUEL INDICATOR.............................................................. 245 DESCRIPTION.......................................................................... 245 OPERATION............................................................................ 245 8l-LAMPS..................................................................................... 247 LAMPS / LIGHTING - EXTERIOR.............................................................. 247 LAMPS / LIGHTING - EXTERIOR.......................................................... 248 DESCRIPTION...................................................................... 248 OPERATION........................................................................ 249 SPECIFICATIONS - LAMPS / LIGHTING - EXTERIOR..................................... 251 BACKUP LAMP BULB..................................................................... 251 REMOVAL.......................................................................... 251 INSTALLATION..................................................................... 252 BRAKE LAMP SWITCH.................................................................... 252 REMOVAL.......................................................................... 252 INSTALLATION..................................................................... 253 ADJUSTMENTS...................................................................... 253 ADJUSTMENT................................................................... 253 BRAKE / PARK LAMP BULB............................................................... 253 REMOVAL.......................................................................... 253 INSTALLATION..................................................................... 254 CENTER HIGH MOUNTED STOP LAMP BULB................................................... 254 REMOVAL.......................................................................... 254 INSTALLATION..................................................................... 254 CENTER HIGH MOUNTED STOP LAMP UN..................................................... 254 REMOVAL.......................................................................... 254 INSTALLATION..................................................................... 255 CLEARANCE LAMP BULB.................................................................. 255 REMOVAL.......................................................................... 255 INSTALLATION..................................................................... 255 CLEARANCE LAMP UNIT.................................................................. 255 REMOVAL.......................................................................... 255 INSTALLATION..................................................................... 255 DAYTIME RUNNING LAMP RELAY........................................................... 256 REMOVAL.......................................................................... 256 INSTALLATION..................................................................... 256 FOG LAMP BULB........................................................................ 256 REMOVAL.......................................................................... 256 INSTALLATION..................................................................... 257 FOG LAMP RELAY....................................................................... 257 REMOVAL.......................................................................... 257 INSTALLATION..................................................................... 258 FOG LAMP SWITCH...................................................................... 258 REMOVAL.......................................................................... 258 INSTALLATION..................................................................... 259 FRONT LAMP UNIT...................................................................... 259 REMOVAL.......................................................................... 259 INSTALLATION..................................................................... 259 ADJUSTMENTS...................................................................... 260 ADJUSTMENT - FRONT LAMP UNIT................................................. 260 VEHICLE PREPARATION FOR FRONT LAMP UNIT ALIGNMENT........................ 260 FRONT LAMP UNIT ALIGNMENT................................................ 260 FRONT POSITION LAMP BULB............................................................. 260 REMOVAL.......................................................................... 260 INSTALLATION..................................................................... 261 FRONT TURN / PARK / SIDE MARKER LAMP BULB............................................ 261 REMOVAL.......................................................................... 261 INSTALLATION..................................................................... 262 HEADLAMP LEVELING MOTOR.............................................................. 262 REMOVAL.......................................................................... 262 INSTALLATION..................................................................... 263 HEADLAMP LEVELING SWITCH............................................................. 263 REMOVAL.......................................................................... 263 INSTALLATION..................................................................... 264 HIGH BEAM HEADLAMP BULB.............................................................. 264 REMOVAL.......................................................................... 264 INSTALLATION..................................................................... 265 LICENSE PLATE LAMP BULB.............................................................. 265 REMOVAL.......................................................................... 265 INSTALLATION..................................................................... 265 LICENSE PLATE LAMP UNIT.............................................................. 265 REMOVAL.......................................................................... 265 INSTALLATION..................................................................... 265 LOW BEAM HEADLAMP BULB............................................................... 266 REMOVAL.......................................................................... 266 INSTALLATION..................................................................... 266 MULTI - FUNCTION SWITCH.............................................................. 267 REMOVAL.......................................................................... 267 INSTALLATION..................................................................... 267 PARK BRAKE SWITCH.................................................................... 267 REMOVAL.......................................................................... 267 INSTALLATION..................................................................... 268 REAR SIDE MARKER LAMP BULB........................................................... 268 REMOVAL.......................................................................... 268 INSTALLATION..................................................................... 268 REAR TURN LAMP BULB.................................................................. 269 REMOVAL.......................................................................... 269 INSTALLATION..................................................................... 269 REPEATER LAMP BULB................................................................... 269 REMOVAL.......................................................................... 269 INSTALLATION..................................................................... 270 REPEATER LAMP UNIT................................................................... 270 REMOVAL.......................................................................... 270 SMALL........................................................................ 270 LARGE........................................................................ 270 INSTALLATION..................................................................... 271 SMALL........................................................................ 271 LARGE........................................................................ 271 TAIL LAMP UNIT....................................................................... 271 REMOVAL.......................................................................... 271 INSTALLATION..................................................................... 272 TURN SIGNAL RELAY.................................................................... 272 REMOVAL.......................................................................... 272 INSTALLATION..................................................................... 272 LAMPS / LIGHTING - INTERIOR.............................................................. 274 LAMPS / LIGHTING - INTERIOR.......................................................... 274 DESCRIPTION...................................................................... 274 OPERATION........................................................................ 275 INTERIOR LIGHTING CIRCUIT.................................................... 275 EXTERIOR LIGHTING CIRCUIT.................................................... 275 SPECIFICATIONS - INTERIOR LIGHTING............................................... 275 ASH RECEIVER / CIGAR LIGHTER LAMP UNIT............................................... 276 REMOVAL.......................................................................... 276 INSTALLATION..................................................................... 276 CARGO / DOME LAMP BULB............................................................... 276 REMOVAL.......................................................................... 276 INSTALLATION..................................................................... 276 CARGO / DOME LAMP UNIT............................................................... 277 REMOVAL.......................................................................... 277 INSTALLATION..................................................................... 277 CARGO LAMP SWITCH.................................................................... 277 REMOVAL.......................................................................... 277 REMOVAL - INSTRUMENT PANEL................................................... 277 REMOVAL - BULKHEAD........................................................... 277 REMOVAL - REAR PILLAR........................................................ 277 INSTALLATION..................................................................... 278 INSTALLATION - INSTRUMENT PANEL.............................................. 278 INSTALLATION - BULKHEAD...................................................... 278 INSTALLATION - REAR PILLAR................................................... 278 DOME / READING LAMP BULB............................................................. 278 REMOVAL.......................................................................... 278 INSTALLATION..................................................................... 278 DOME / READING LAMP UNIT............................................................. 278 REMOVAL.......................................................................... 278 INSTALLATION..................................................................... 279 DOME LAMP / INTRUSION SENSOR BULB.................................................... 279 REMOVAL.......................................................................... 279 INSTALLATION..................................................................... 279 DOME LAMP / INTRUSION SENSOR......................................................... 279 REMOVAL.......................................................................... 279 INSTALLATION..................................................................... 280 DOOR JAMB SWITCH..................................................................... 280 REMOVAL.......................................................................... 280 INSTALLATION..................................................................... 280 ENTRY / EXIT LAMP BULB............................................................... 280 REMOVAL.......................................................................... 280 INSTALLATION..................................................................... 281 ENTRY / EXIT LAMP UNIT............................................................... 281 REMOVAL.......................................................................... 281 INSTALLATION..................................................................... 281 TIME DELAY RELAY..................................................................... 281 REMOVAL.......................................................................... 281 INSTALLATION..................................................................... 282 8n-POWER SYSTEMS............................................................................. 283 POWER LOCKS.............................................................................. 283 DOOR LOCK MOTOR...................................................................... 283 REMOVAL.......................................................................... 283 INSTALLATION..................................................................... 283 REMOTE KEYLESS ENTRY TRANSMITTER..................................................... 283 DESCRIPTION...................................................................... 283 MASTER LOCK SWITCH................................................................... 283 DESCRIPTION...................................................................... 283 DIAGNOSIS AND TESTING - MASTER LOCK SWITCH....................................... 283 REMOVAL.......................................................................... 284 INSTALLATION..................................................................... 284 POWER MIRRORS............................................................................ 285 POWER MIRRORS........................................................................ 285 DESCRIPTION...................................................................... 285 POWER MIRROR SWITCH.................................................................. 285 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH...................................... 285 REMOVAL.......................................................................... 285 INSTALLATION..................................................................... 286 POWER WINDOWS............................................................................ 287 POWER WINDOWS........................................................................ 287 DESCRIPTION...................................................................... 287 OPERATION........................................................................ 287 WINDOW SWITCH................................................................ 287 WINDOW MOTOR................................................................. 287 WINDOW MOTOR......................................................................... 287 REMOVAL.......................................................................... 287 POWER WINDOW SWITCH.................................................................. 287 DIAGNOSIS AND TESTING - POWER WINDOW SWITCH...................................... 287 REMOVAL.......................................................................... 287 INSTALLATION..................................................................... 288 8o-RESTRAINTS................................................................................ 289 RESTRAINTS............................................................................... 290 DESCRIPTION.......................................................................... 290 ACTIVE RESTRAINTS................................................................ 290 PASSIVE RESTRAINTS............................................................... 291 OPERATION............................................................................ 292 ACTIVE RESTRAINTS................................................................ 292 PASSIVE RESTRAINTS............................................................... 292 WARNINGS - RESTRAINT SYSTEM.......................................................... 293 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM................................ 293 STANDARD PROCEDURE................................................................... 294 STANDARD PROCEDURE - HANDLING NON - DEPLOYED SUPPLEMENTAL RESTRAINTS............. 294 SUPPLEMENTAL RESTRAINT STORAGE............................................... 294 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT........... 294 CLEANUP PROCEDURE............................................................ 294 STANDARD PROCEDURE - VERIFICATION TEST........................................... 295 AIRBAG CONTROL MODULE.................................................................... 296 DESCRIPTION.......................................................................... 296 OPERATION............................................................................ 296 REMOVAL.............................................................................. 298 INSTALLATION......................................................................... 299 CLOCKSPRING.............................................................................. 300 DESCRIPTION.......................................................................... 300 OPERATION............................................................................ 301 STANDARD PROCEDURE - CLOCKSPRING CENTERING........................................... 301 REMOVAL.............................................................................. 302 INSTALLATION......................................................................... 303 DRIVER AIRBAG............................................................................ 304 DESCRIPTION.......................................................................... 304 OPERATION............................................................................ 305 REMOVAL.............................................................................. 306 INSTALLATION......................................................................... 307 FRONT SEAT BELT & RETRACTOR.............................................................. 308 REMOVAL.............................................................................. 308 INSTALLATION......................................................................... 310 FRONT SEAT BELT BUCKLE................................................................... 311 REMOVAL.............................................................................. 311 INSTALLATION......................................................................... 311 PASSENGER AIRBAG......................................................................... 312 DESCRIPTION.......................................................................... 312 OPERATION............................................................................ 312 REMOVAL.............................................................................. 313 INSTALLATION......................................................................... 315 PASSENGER AIRBAG BRACKET................................................................. 315 REMOVAL.............................................................................. 315 INSTALLATION......................................................................... 316 REAR SEAT BELT & RETRACTOR............................................................... 316 REMOVAL.............................................................................. 316 INSTALLATION......................................................................... 318 REAR SEAT BELT BUCKLE.................................................................... 318 REMOVAL.............................................................................. 318 REMOVAL - INBOARD................................................................ 318 REMOVAL - OUTBOARD............................................................... 319 INSTALLATION......................................................................... 319 INSTALLATION - INBOARD........................................................... 319 INSTALLATION - OUTBOARD.......................................................... 319 SEAT BELT SWITCH......................................................................... 319 DESCRIPTION.......................................................................... 319 OPERATION............................................................................ 320 SEAT BELT TENSIONER...................................................................... 320 DESCRIPTION.......................................................................... 320 OPERATION............................................................................ 321 SEAT BELT TURNING LOOP ADJUSTER.......................................................... 321 REMOVAL.............................................................................. 321 INSTALLATION......................................................................... 323 SIDE CURTAIN AIRBAG...................................................................... 323 DESCRIPTION.......................................................................... 323 OPERATION............................................................................ 324 REMOVAL.............................................................................. 324 INSTALLATION......................................................................... 326 SIDE IMPACT SENSOR....................................................................... 327 DESCRIPTION.......................................................................... 327 OPERATION............................................................................ 327 REMOVAL.............................................................................. 328 INSTALLATION......................................................................... 328 8p-SPEED CONTROL............................................................................. 331 SPEED CONTROL............................................................................ 331 DESCRIPTION.......................................................................... 331 OPERATION............................................................................ 332 SPECIFICATIONS....................................................................... 332 TORQUE........................................................................... 332 CABLE.................................................................................... 332 DESCRIPTION.......................................................................... 332 SERVO.................................................................................... 332 DESCRIPTION.......................................................................... 332 SWITCH................................................................................... 333 REMOVAL.............................................................................. 333 INSTALLATION......................................................................... 333 8q-VEHICLE THEFT SECURITY.................................................................... 335 VEHICLE THEFT SECURITY................................................................... 335 DESCRIPTION.......................................................................... 335 OPERATION............................................................................ 335 DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY....................................... 335 INTRUSION SENSOR......................................................................... 335 REMOVAL.............................................................................. 335 INSTALLATION......................................................................... 336 SECURITY SYSTEM MODULE................................................................... 336 REMOVAL.............................................................................. 336 INSTALLATION......................................................................... 336 SENTRY KEY REMOTE ENTRY MODULE........................................................... 336 DESCRIPTION.......................................................................... 336 SENTRY KEY IMMOBILIZER........................................................... 336 REMOTE KEYLESS ENTRY (RKE)....................................................... 337 OPERATION............................................................................ 337 SENTRY KEY IMMOBILIZER........................................................... 337 REMOTE KEYLESS ENTRY............................................................. 337 REMOVAL.............................................................................. 337 SENTRY KEY REMOTE ENTRY MODULE................................................... 337 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING.................................. 338 INSTALLATION......................................................................... 338 SENTRY KEY REMOTE ENTRY MODULE................................................... 338 SENTRY KEY REMOTE ENTRY MODULE TRANSPONDER RING.................................. 338 SIREN.................................................................................... 338 REMOVAL.............................................................................. 338 INSTALLATION......................................................................... 338 TRANSPONDER KEY.......................................................................... 339 DESCRIPTION.......................................................................... 339 OPERATION............................................................................ 339 8r-WIPERS / WASHERS.......................................................................... 341 WIPERS/WASHERS........................................................................... 342 DESCRIPTION.......................................................................... 342 OPERATION............................................................................ 343 INTERMITTENT WIPE SYSTEM......................................................... 344 AUTOMATIC WIPE SYSTEM............................................................ 345 OPERATING MODES.................................................................. 345 DIAGNOSIS AND TESTING - WIPER & WASHER SYSTEM........................................ 346 INTERMITTENT WIPER SYSTEM........................................................ 346 AUTOMATIC WIPER SYSTEM........................................................... 347 CLEANING - WIPER & WASHER SYSTEM..................................................... 349 WIPER SYSTEM..................................................................... 349 WASHER SYSTEM.................................................................... 349 INSPECTION - WIPER & WASHER SYSTEM................................................... 350 WIPER SYSTEM..................................................................... 350 WASHER SYSTEM.................................................................... 350 CHECK VALVE.............................................................................. 351 DESCRIPTION.......................................................................... 351 OPERATION............................................................................ 351 REMOVAL.............................................................................. 351 INSTALLATION......................................................................... 351 RAIN SENSOR.............................................................................. 352 DESCRIPTION.......................................................................... 352 OPERATION............................................................................ 352 STANDARD PROCEDURE................................................................... 352 RAIN SENSOR BRACKET REPLACEMENT.................................................. 352 REMOVAL.............................................................................. 354 INSTALLATION......................................................................... 354 RAIN SENSOR CONTROL MODULE............................................................... 355 DESCRIPTION.......................................................................... 355 OPERATION............................................................................ 355 REMOVAL.............................................................................. 355 INSTALLATION......................................................................... 356 WASHER FLUID LEVEL SWITCH................................................................ 356 DESCRIPTION.......................................................................... 356 OPERATION............................................................................ 356 WASHER HOSES / TUBES..................................................................... 358 DESCRIPTION.......................................................................... 358 OPERATION............................................................................ 358 WASHER NOZZLE............................................................................ 358 DESCRIPTION.......................................................................... 358 OPERATION............................................................................ 359 REMOVAL.............................................................................. 359 INSTALLATION......................................................................... 359 WASHER PUMP / MOTOR...................................................................... 359 DESCRIPTION.......................................................................... 359 OPERATION............................................................................ 360 REMOVAL.............................................................................. 360 INSTALLATION......................................................................... 360 WASHER RESERVOIR......................................................................... 361 DESCRIPTION.......................................................................... 361 OPERATION............................................................................ 361 REMOVAL.............................................................................. 361 INSTALLATION......................................................................... 362 WIPER ARM................................................................................ 363 DESCRIPTION.......................................................................... 363 OPERATION............................................................................ 364 REMOVAL.............................................................................. 364 INSTALLATION......................................................................... 364 WIPER BLADE.............................................................................. 366 DESCRIPTION.......................................................................... 366 OPERATION............................................................................ 366 REMOVAL.............................................................................. 366 INSTALLATION......................................................................... 367 WIPER LINKAGE............................................................................ 368 DESCRIPTION.......................................................................... 368 OPERATION............................................................................ 368 REMOVAL.............................................................................. 368 INSTALLATION......................................................................... 371 WIPER MOTOR.............................................................................. 371 DESCRIPTION.......................................................................... 371 OPERATION............................................................................ 372 REMOVAL.............................................................................. 372 INSTALLATION......................................................................... 373 WIPER RELAY.............................................................................. 374 DESCRIPTION.......................................................................... 374 OPERATION............................................................................ 374 REMOVAL.............................................................................. 375 INSTALLATION......................................................................... 375 8w-WIRING.................................................................................... 377 8W-01 WIRING DIAGRAM INFORMATION......................................................... 379 WIRING DIAGRAM INFORMATION........................................................... 379 DESCRIPTION...................................................................... 379 HOW TO USE WIRING DIAGRAMS................................................... 379 SYMBOLS.................................................................. 379 TERMINOLOGY.............................................................. 383 CIRCUIT INFORMATION.......................................................... 383 SECTION IDENTIFICATION AND INFORMATION....................................... 383 CONNECTOR, GROUND, AND SPLICE INFORMATION.................................... 383 IDENTIFICATION........................................................... 383 LOCATIONS................................................................ 384 WARNINGS - GENERAL............................................................... 384 DIAGNOSIS AND TESTING............................................................ 384 WIRING HARNESS............................................................... 384 TROUBLESHOOTING TOOLS.................................................... 384 INTERMITTENT AND POOR CONNECTIONS........................................ 385 TROUBLESHOOTING WIRING PROBLEMS.......................................... 385 STANDARD PROCEDURE............................................................... 385 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.............................. 385 TESTING FOR VOLTAGE POTENTIAL................................................ 385 TESTING FOR CONTINUITY....................................................... 385 TESTING FOR A SHORT TO GROUND................................................ 386 TESTING COMPONENTS FOR A SHORT TO GROUND ON A FUSE POWERING SEVERAL LOADS.... 386 TESTING FOR A VOLTAGE DROP................................................... 386 CONNECTOR............................................................................ 387 REMOVAL.......................................................................... 387 INSTALLATION..................................................................... 387 DIODE................................................................................ 387 REMOVAL.......................................................................... 387 INSTALLATION..................................................................... 387 TERMINAL............................................................................. 388 REMOVAL.......................................................................... 388 INSTALLATION..................................................................... 388 WIRE................................................................................. 388 STANDARD PROCEDURE............................................................... 388 WIRE SPLICING................................................................ 388 8W-02 COMPONENT INDEX.................................................................... 389 8W-10 POWER DISTRIBUTION................................................................. 391 8W-11 FUSE BLOCK......................................................................... 425 8W-15 GROUND DISTRIBUTION................................................................ 465 8W-18 BUS COMMUNICATIONS................................................................. 497 8W-20 CHARGING SYSTEM.................................................................... 503 8W-21 STARTING SYSTEM.................................................................... 509 8W-30 FUEL/IGNITION SYSTEM............................................................... 511 8W-31 TRANSMISSION CONTROL SYSTEM........................................................ 537 8W-33 VEHICLE SPEED CONTROL.............................................................. 547 8W-35 ANTILOCK BRAKES.................................................................... 551 8W-39 VEHICLE THEFT SECURITY SYSTEM...................................................... 561 8W-40 INSTRUMENT CLUSTER................................................................. 575 8W-41 HORN/CIGAR LIGHTER................................................................. 583 8W-42 AIR CONDITIONING-HEATER............................................................ 587 8W-43 AIRBAG SYSTEM...................................................................... 613 8W-44 INTERIOR LIGHTING.................................................................. 617 8W-45 CENTRAL TIMER MODULE............................................................... 629 8W-47 AUDIO SYSTEM....................................................................... 637 8W-48 REAR WINDOW DEFOGGER............................................................... 643 8W-50 FRONT LIGHTING..................................................................... 647 8W-51 REAR LIGHTING...................................................................... 663 8W-52 TURN SIGNALS....................................................................... 673 8W-53 WIPERS............................................................................. 679 8W-54 TRAILER TOW........................................................................ 685 8W-55 NAVIGATION/TELECOMMUNICATIONS...................................................... 689 8W-60 POWER WINDOWS...................................................................... 693 8W-61 POWER DOOR LOCKS................................................................... 697 8W-62 POWER MIRRORS...................................................................... 705 8W-63 POWER SEATS........................................................................ 709 8W-70 SPLICE INFORMATION................................................................. 713 8W-80 CONNECTOR PIN-OUTS................................................................. 715 8W-91 CONNECTOR/GROUND/SPLICE LOCATION................................................... 801 CONNECTOR/GROUND/SPLICE LOCATION..................................................... 801 DESCRIPTION...................................................................... 801 8W-97 POWER DISTRIBUTION................................................................. 867 POWER DISTRIBUTION................................................................... 867 DESCRIPTION...................................................................... 867 OPERATION........................................................................ 867 CIGAR LIGHTER OUTLET................................................................. 867 DESCRIPTION...................................................................... 867 OPERATION........................................................................ 868 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..................................... 868 REMOVAL.......................................................................... 868 CIRCUIT BREAKER...................................................................... 868 DESCRIPTION...................................................................... 868 OPERATION........................................................................ 868 DIAGNOSIS AND TESTING - CIRCUIT BREAKER.......................................... 868 FUSE BLOCK #1........................................................................ 868 DESCRIPTION...................................................................... 868 OPERATION........................................................................ 869 REMOVAL.......................................................................... 869 INSTALLATION..................................................................... 869 FUSE BLOCK #2........................................................................ 869 DESCRIPTION...................................................................... 869 OPERATION........................................................................ 869 POWER DISTRIBUTION CENTER............................................................ 869 DESCRIPTION...................................................................... 869 OPERATION........................................................................ 869 POWER OUTLET......................................................................... 869 DESCRIPTION...................................................................... 869 OPERATION........................................................................ 870 DIAGNOSIS AND TESTING - POWER OUTLET............................................. 870 REMOVAL.......................................................................... 870 INSTALLATION..................................................................... 870 RELAY................................................................................ 870 DESCRIPTION...................................................................... 870 OPERATION........................................................................ 871 DIAGNOSIS AND TESTING - RELAY.................................................... 871 DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST................................... 871 REMOVAL.......................................................................... 871 INSTALLATION..................................................................... 871 9-ENGINE..................................................................................... 873 ENGINE................................................................................... 874 DESCRIPTION.......................................................................... 874 STANDARD PROCEDURE................................................................... 875 STANDARD PROCEDURE - COMPRESSION TESTING ENGINE.................................. 875 STANDARD PROCEDURE - CYLINDER LEAK DOWN TEST..................................... 875 INSPECTING................................................................... 875 STANDARD PROCEDURE - DETERMINING CYLINDER PRESSURE LOSS.......................... 876 REMOVAL.............................................................................. 876 REMOVAL - ENGINE COVER........................................................... 876 REMOVAL.......................................................................... 877 INSTALLATION......................................................................... 881 INSTALLATION - ENGINE COVER...................................................... 881 INSTALLATION..................................................................... 881 SPECIFICATIONS - TORQUE SPECIFICATIONS............................................... 883 SPECIAL TOOLS........................................................................ 889 AIR CLEANER ELEMENT...................................................................... 893 REMOVAL.............................................................................. 893 INSTALLATION......................................................................... 893 AIR CLEANER HOUSING...................................................................... 893 REMOVAL.............................................................................. 893 INSTALLATION......................................................................... 894 CYLINDER HEAD............................................................................ 894 DESCRIPTION.......................................................................... 894 STANDARD PROCEDURE................................................................... 894 STANDARD PROCEDURE - CYLINDER HEAD BOLT INSPECTION............................... 894 STANDARD PROCEDURE - MEASURE CYLINDER HEAD SURFACE............................... 894 REMOVAL.............................................................................. 895 REMOVAL - CYLINDER HEAD.......................................................... 895 REMOVAL - CYLINDER HEAD FRONT COVER.............................................. 897 REMOVAL - CYLINDER HEAD GUIDE RAIL............................................... 898 INSTALLATION......................................................................... 898 INSTALLATION - CYLINDER HEAD..................................................... 898 INSTALLATION - CYLINDER HEAD FRONT COVER......................................... 900 INSTALLATION - CYLINDER HEAD GUIDE RAIL.......................................... 900 CAMSHAFT(S).............................................................................. 900 STANDARD PROCEDURE................................................................... 900 STANDARD PROCEDURE - CHECKING CAMSHAFT POSITION.................................. 900 STANDARD PROCEDURE - INSPECTING TAPPET CLEARANCE................................. 902 REMOVAL.............................................................................. 902 INSTALLATION......................................................................... 904 CYLINDER HEAD COVER(S)................................................................... 905 REMOVAL.............................................................................. 905 INSTALLATION......................................................................... 906 VALVE STEM SEALS......................................................................... 906 DESCRIPTION.......................................................................... 906 VALVE SPRINGS............................................................................ 907 REMOVAL.............................................................................. 907 REMOVAL - VALVE SPRINGS.......................................................... 907 REMOVAL - VALVES................................................................. 908 INSTALLATION......................................................................... 908 INSTALLATION - VALVE SPRINGS..................................................... 908 INSTALLATION - VALVES............................................................ 909 ENGINE BLOCK............................................................................. 909 STANDARD PROCEDURE................................................................... 909 STANDARD PROCEDURE - REPLACING ENGINE CORE AND OIL GALLERY PLUGS................. 909 STANDARD PROCEDURE - MEASURING CYLINDER BORES.................................... 910 CRANKSHAFT............................................................................... 911 DESCRIPTION.......................................................................... 911 STANDARD PROCEDURE - MEASURE CRANKSHAFT AND BLOCK JOURNALS........................... 911 ASSIGN CRANKSHAFT BEARING SHELLS................................................. 912 REMOVAL.............................................................................. 912 INSTALLATION......................................................................... 912 CRANKSHAFT OIL SEAL - REAR............................................................... 913 REMOVAL.............................................................................. 913 INSTALLATION......................................................................... 914 CRANKSHAFT OIL SEAL - FRONT.............................................................. 914 REMOVAL.............................................................................. 914 INSTALLATION......................................................................... 915 FLYWHEEL................................................................................. 915 REMOVAL.............................................................................. 915 INSTALLATION......................................................................... 916 INSTALLATION..................................................................... 916 INSTALLATION - CRANKSHAFT LOCK................................................... 916 PISTON & CONNECTING ROD.................................................................. 917 DESCRIPTION.......................................................................... 917 STANDARD PROCEDURE................................................................... 918 STANDARD PROCEDURE - CHECKING AND REPAIRING CONNECTING RODS...................... 918 CONNECTING ROD SPECIFICATIONS................................................ 918 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION................................. 919 REMOVAL.............................................................................. 919 INSTALLATION......................................................................... 921 PISTON RINGS............................................................................. 924 STANDARD PROCEDURE - PISTON RING FITTING............................................. 924 VIBRATION DAMPER......................................................................... 925 REMOVAL.............................................................................. 925 INSTALLATION......................................................................... 926 VACUUM PUMP.............................................................................. 926 DESCRIPTION.......................................................................... 926 OPERATION............................................................................ 926 REMOVAL.............................................................................. 927 INSTALLATION......................................................................... 927 LEFT MOUNT............................................................................... 927 REMOVAL.............................................................................. 927 INSTALLATION......................................................................... 927 RIGHT MOUNT.............................................................................. 928 REMOVAL.............................................................................. 928 INSTALLATION......................................................................... 928 OIL...................................................................................... 928 REMOVAL - OIL SEPARATOR.............................................................. 928 INSTALLATION - OIL SEPARATOR......................................................... 928 OIL COOLER & LINES....................................................................... 928 REMOVAL.............................................................................. 928 INSTALLATION......................................................................... 929 OIL FILTER............................................................................... 929 REMOVAL.............................................................................. 929 INSTALLATION......................................................................... 929 OIL JET.................................................................................. 929 DESCRIPTION.......................................................................... 929 REMOVAL.............................................................................. 930 INSTALLATION......................................................................... 930 OIL PAN.................................................................................. 930 REMOVAL.............................................................................. 930 INSTALLATION......................................................................... 932 OIL PUMP................................................................................. 933 REMOVAL.............................................................................. 933 REMOVAL.......................................................................... 933 REMOVAL - OIL PUMP CHAIN......................................................... 933 INSTALLATION......................................................................... 934 INSTALLATION..................................................................... 934 INSTALLATION - OIL PUMP CHAIN.................................................... 934 OIL SENSOR............................................................................... 936 DESCRIPTION.......................................................................... 936 OPERATION............................................................................ 936 REMOVAL.............................................................................. 937 INSTALLATION......................................................................... 937 INTAKE MANIFOLD.......................................................................... 937 REMOVAL.............................................................................. 937 INSTALLATION......................................................................... 940 EXHAUST MANIFOLD......................................................................... 940 REMOVAL.............................................................................. 940 INSTALLATION......................................................................... 941 TIMING CHAIN COVER....................................................................... 942 REMOVAL.............................................................................. 942 INSTALLATION......................................................................... 943 TIMING CHAIN AND SPROCKETS............................................................... 944 REMOVAL.............................................................................. 944 REMOVAL - TENSIONING AND SLIDE RAILS............................................. 944 REMOVAL - INTERMEDIATE GEAR...................................................... 945 REMOVAL - TIMING CHAIN TENSIONING RAIL........................................... 946 REMOVAL - TIMING CHAIN........................................................... 946 INSTALLATION......................................................................... 948 INSTALLATION - TENSIONING AND SLIDE RAIL......................................... 948 INSTALLATION - INTERMEDIATE GEAR................................................. 949 INSTALLATION - TIMING CHAIN TENSIONING RAIL...................................... 949 ADJUSTMENTS.......................................................................... 949 INSTALLATION - TIMING CHAIN...................................................... 949 TIMING CHAIN TENSIONER................................................................... 953 REMOVAL.............................................................................. 953 INSTALLATION......................................................................... 953 11-EXHAUST SYSTEM............................................................................ 955 EXHAUST SYSTEM........................................................................... 955 DESCRIPTION - 2.7L DIESEL............................................................ 955 DIAGNOSIS AND TESTING - DIESEL ENGINE................................................ 956 CATALYTIC CONVERTER...................................................................... 957 REMOVAL.............................................................................. 957 INSTALLATION......................................................................... 957 EXHAUST PIPE............................................................................. 957 REMOVAL.............................................................................. 957 INSTALLATION......................................................................... 957 TAILPIPE................................................................................. 957 REMOVAL.............................................................................. 957 INSTALLATION......................................................................... 957 TURBOCHARGER SYSTEM...................................................................... 957 DESCRIPTION.......................................................................... 957 OPERATION............................................................................ 958 CHARGE AIR COOLER AND PLUMBING........................................................... 958 DESCRIPTION.......................................................................... 958 OPERATION............................................................................ 959 DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS............................. 959 REMOVAL.............................................................................. 959 CLEANING............................................................................. 959 INSPECTION........................................................................... 960 INSTALLATION......................................................................... 960 TURBOCHARGER............................................................................. 960 DESCRIPTION.......................................................................... 960 OPERATION............................................................................ 960 REMOVAL.............................................................................. 961 REMOVAL.......................................................................... 961 REMOVAL - VACUUM TRANSDUCER...................................................... 962 INSTALLATION......................................................................... 962 INSTALLATION..................................................................... 962 INSTALLATION - VACUUM TRANSDUCER................................................. 963 13-FRAME & BUMPERS........................................................................... 965 BUMPERS.................................................................................. 965 SPECIFICATIONS - TORQUE.............................................................. 965 FRONT BUMPER - STEPS..................................................................... 966 REMOVAL.............................................................................. 966 INSTALLATION......................................................................... 966 FRONT FASCIA............................................................................. 966 REMOVAL.............................................................................. 966 INSTALLATION......................................................................... 966 REAR BUMPER - STEP....................................................................... 966 REMOVAL.............................................................................. 966 INSTALLATION......................................................................... 967 REAR FASCIA.............................................................................. 967 REMOVAL.............................................................................. 967 INSTALLATION......................................................................... 967 FRAME.................................................................................... 967 SPECIFICATIONS....................................................................... 967 SPECIFICATIONS - FRAME DIMENSIONS................................................ 967 VEHICLE PREPARATION.......................................................... 967 SPECIFICATIONS - TORQUE.......................................................... 972 ENGINE CRADLE CROSSMEMBER................................................................ 972 REMOVAL.............................................................................. 972 INSTALLATION......................................................................... 974 REAR CROSSMEMBER - TRANSMISSION.......................................................... 975 REMOVAL.............................................................................. 975 INSTALLATION......................................................................... 975 TRAILER HITCH............................................................................ 975 REMOVAL.............................................................................. 975 INSTALLATION......................................................................... 976 14-FUEL SYSTEM............................................................................... 979 FUEL SYSTEM.............................................................................. 979 WARNING.............................................................................. 979 WARNING - HIGH FUEL SYSTEM PRESSURE.............................................. 979 WARNING.......................................................................... 979 DIAGNOSIS AND TESTING................................................................ 979 DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES................................. 979 DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM....................................... 980 DIAGNOSIS AND TESTING - INJECTOR LEAK QUANTITY................................... 980 CRANKING TEST................................................................ 980 RUNNING TEST................................................................. 981 STANDARD PROCEDURE................................................................... 981 STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS............................ 981 STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER............................ 981 STANDARD PROCEDURE - LOW PRESSURE FUEL PUMP TEST................................. 982 FUEL DELIVERY............................................................................ 984 FUEL DELIVERY........................................................................ 984 DESCRIPTION...................................................................... 984 OPERATION........................................................................ 985 Start of Actuation........................................................... 985 Switching Off Main Injection................................................. 986 Calculating Main Injection................................................... 986 Period of Actuation.......................................................... 986 Deceleration Mode............................................................ 986 Full Load Injected Quantity.................................................. 986 Limiting Maximum Engine Speed................................................ 986 Fuel Quantity Control........................................................ 986 Boiling Protection........................................................... 986 Fuel Tank Protection......................................................... 986 STANDARD PROCEDURE............................................................... 986 STANDARD PROCEDURE - DRAINING FUEL TANK - DIESEL............................. 986 FUEL CONTAMINATION........................................................... 986 SPECIFICATIONS................................................................... 987 TORQUE....................................................................... 987 SPECIAL TOOLS.................................................................... 987 FUEL SYSTEM.................................................................. 987 FUEL DRAIN TUBES..................................................................... 988 DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS................................. 988 LOW - PRESSURE LINES......................................................... 988 HIGH - PRESSURE LINES........................................................ 988 FUEL FILTER.......................................................................... 988 DESCRIPTION...................................................................... 988 REMOVAL.......................................................................... 988 INSTALLATION..................................................................... 989 FUEL LINES........................................................................... 989 REMOVAL - HIGH PRESSURE LINES.................................................... 989 INSTALLATION - HIGH PRESSURE LINES............................................... 990 FUEL RAIL PRESSURE SENSOR............................................................ 990 DESCRIPTION...................................................................... 990 OPERATION........................................................................ 990 REMOVAL.......................................................................... 990 INSTALLATION..................................................................... 991 FUEL PUMP............................................................................ 991 DESCRIPTION...................................................................... 991 DESCRIPTION - HIGH PRESSURE PUMP............................................. 991 DESCRIPTION - LOW PRESSURE PUMP.............................................. 991 OPERATION........................................................................ 991 OPERATION.................................................................... 991 LOW PRESSURE SIDE........................................................ 991 HIGH PRESSURE SIDE....................................................... 993 OPERATION - LOW PRESSURE PUMP................................................ 994 REMOVAL - HIGH PRESSURE PUMP..................................................... 995 INSTALLATION - HIGH PRESSURE PUMP................................................ 995 FUEL PUMP MODULE..................................................................... 996 DESCRIPTION...................................................................... 996 REMOVAL.......................................................................... 996 INSTALLATION..................................................................... 998 FUEL QUANTITY CONTROL VALVE.......................................................... 999 DESCRIPTION...................................................................... 999 OPERATION........................................................................ 999 REMOVAL.......................................................................... 999 INSTALLATION..................................................................... 999 FUEL RAIL............................................................................1000 DESCRIPTION......................................................................1000 OPERATION........................................................................1000 REMOVAL..........................................................................1000 INSTALLATION.....................................................................1000 FUEL TANK............................................................................1001 DESCRIPTION......................................................................1001 REMOVAL..........................................................................1003 INSTALLATION.....................................................................1004 FUEL LEVEL SENDING UNIT / SENSOR.....................................................1006 DESCRIPTION......................................................................1006 REMOVAL..........................................................................1007 INSTALLATION.....................................................................1007 WATER IN FUEL SENSOR.................................................................1008 DESCRIPTION......................................................................1008 OPERATION........................................................................1008 FUEL INJECTION...........................................................................1009 ACCELERATOR PEDAL POSITION SENSOR....................................................1010 DESCRIPTION......................................................................1010 REMOVAL..........................................................................1010 INSTALLATION.....................................................................1010 BOOST PRESSURE SENSOR................................................................1011 DESCRIPTION......................................................................1011 OPERATION........................................................................1011 DIAGNOSIS AND TESTING - BOOST PRESSURE SENSOR....................................1011 REMOVAL..........................................................................1011 INSTALLATION.....................................................................1011 CAMSHAFT POSITION SENSOR.............................................................1011 DESCRIPTION......................................................................1011 OPERATION........................................................................1012 REMOVAL..........................................................................1012 INSTALLATION.....................................................................1012 CRANKSHAFT POSITION SENSOR...........................................................1013 DESCRIPTION......................................................................1013 OPERATION........................................................................1013 REMOVAL..........................................................................1013 INSTALLATION.....................................................................1013 FUEL INJECTOR........................................................................1013 DESCRIPTION......................................................................1013 FUEL INJECTOR................................................................1013 OPERATION........................................................................1014 Injector closed (with high pressure applied).................................1014 Injector opens (start of injection)..........................................1015 Injector opens fully.........................................................1015 Injector closes (end of injection)...........................................1015 STANDARD PROCEDURE...............................................................1015 STANDARD PROCEDURE - INJECTOR CLASSIFICATION.................................1015 INJECTOR CLASSIFICATION PROCEDURE........................................1016 CLEANING FUEL INJECTORS......................................................1016 REMOVAL..........................................................................1016 INSTALLATION.....................................................................1017 FUEL PRESSURE SENSOR.................................................................1017 DESCRIPTION......................................................................1017 OPERATION........................................................................1017 REMOVAL..........................................................................1017 INSTALLATION.....................................................................1018 FUEL PRESSURE SOLENOID...............................................................1018 DESCRIPTION......................................................................1018 OPERATION........................................................................1018 STANDARD PROCEDURE - FUEL PRESSURE SOLENOID TEST.................................1019 REMOVAL..........................................................................1019 INSTALLATION.....................................................................1019 FUEL TEMPERATURE SENSOR..............................................................1020 DESCRIPTION......................................................................1020 OPERATION........................................................................1020 REMOVAL..........................................................................1020 INSTALLATION.....................................................................1020 INTAKE AIR TEMPERATURE SENSOR........................................................1020 DESCRIPTION......................................................................1020 OPERATION........................................................................1021 REMOVAL..........................................................................1021 INSTALLATION.....................................................................1021 INTAKE AIR PRESSURE SENSOR...........................................................1021 DESCRIPTION......................................................................1021 OPERATION........................................................................1021 REMOVAL..........................................................................1021 INSTALLATION.....................................................................1022 MANIFOLD AIR FLOW (MAF) SENSOR.......................................................1022 DESCRIPTION......................................................................1022 OPERATION........................................................................1022 REMOVAL..........................................................................1022 INSTALLATION.....................................................................1023 O2 SENSOR............................................................................1023 DESCRIPTION......................................................................1023 OPERATION........................................................................1023 REMOVAL..........................................................................1026 INSTALLATION.....................................................................1026 19-STEERING..................................................................................1027 STEERING.................................................................................1027 DESCRIPTION..........................................................................1027 OPERATION............................................................................1027 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM........................................1027 COLUMN...................................................................................1030 COLUMN...............................................................................1030 SPECIFICATIONS - TORQUE CHART....................................................1030 INTERMEDIATE SHAFT...................................................................1030 REMOVAL..........................................................................1030 INSTALLATION.....................................................................1031 KEY / LOCK CYLINDER..................................................................1031 REMOVAL..........................................................................1031 INSTALLATION.....................................................................1032 STEERING WHEEL.......................................................................1032 REMOVAL..........................................................................1032 INSTALLATION.....................................................................1032 GEAR.....................................................................................1033 GEAR.................................................................................1033 DESCRIPTION......................................................................1033 REMOVAL..........................................................................1033 INSTALLATION.....................................................................1033 SPECIFICATIONS - TORQUE CHART....................................................1034 LINKAGE..................................................................................1035 LINKAGE..............................................................................1035 DIAGNOSIS AND TESTING - OUTER TIE ROD END........................................1035 SPECIFICATIONS - TORQUE CHART....................................................1035 SPECIAL TOOLS....................................................................1036 FRONT SUSPENSION.............................................................1036 TIE ROD END..........................................................................1036 REMOVAL..........................................................................1036 INSTALLATION.....................................................................1036 PUMP.....................................................................................1037 PUMP.................................................................................1037 DESCRIPTION......................................................................1037 OPERATION........................................................................1037 DIAGNOSIS AND TESTING - PUMP LEAKAGE.............................................1037 STANDARD PROCEDURE...............................................................1037 STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION.................1037 STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM..........................1038 REMOVAL..........................................................................1038 INSTALLATION.....................................................................1038 SPECIFICATIONS - TORQUE CHART....................................................1039 FLUID................................................................................1039 STANDARD PROCEDURE...............................................................1039 POWER STEERING PUMP FILL AND BLEED PROCEDURE.................................1039 FLUID COOLER TUBE....................................................................1039 REMOVAL..........................................................................1039 INSTALLATION.....................................................................1039 HOSES................................................................................1040 REMOVAL..........................................................................1040 REMOVAL - PRESSURE HOSE......................................................1040 REMOVAL - RETURN LINE FROM PUMP TO COOLER TUBE...............................1040 REMOVAL - RETURN HOSE FROM GEAR TO COOLER TUBE...............................1040 INSTALLATION.....................................................................1040 INSTALLATION - PRESSURE HOSE.................................................1040 INSTALLATION - RETURN LINE FROM PUMP TO COOLER TUBE..........................1040 INSTALLATION - RETURN HOSE FROM GEAR TO COOLER TUBE..........................1040 21-TRANSMISSION..............................................................................1041 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION........................................1041 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION....................................1043 DESCRIPTION......................................................................1043 TRANSMISSION IDENTIFICATION..................................................1044 TRANSMISSION GEAR RATIOS.....................................................1044 TRANSMISSION HOUSING.........................................................1044 MECHANICAL SECTION...........................................................1044 ELECTROHYDRAULIC CONTROL UNIT................................................1044 SHIFT GROUPS.................................................................1044 OPERATION........................................................................1044 EMERGENCY RUNNING FUNCTION...................................................1045 CLUTCH APPLICATION...........................................................1045 FIRST GEAR POWERFLOW.........................................................1046 SECOND GEAR POWERFLOW........................................................1049 THIRD GEAR POWERFLOW.........................................................1052 FOURTH GEAR POWERFLOW........................................................1054 FIFTH GEAR POWERFLOW.........................................................1056 REVERSE GEAR POWERFLOW.......................................................1059 REVERSE GEAR POWERFLOW - LIMP IN.............................................1062 SHIFT GROUPS/ SHIFT SEQUENCE.................................................1064 DIAGNOSIS AND TESTING............................................................1079 AUTOMATIC TRANSMISSION.......................................................1079 PRELIMINARY..................................................................1079 VEHICLE IS DRIVABLE......................................................1079 VEHICLE IS DISABLED......................................................1079 ROAD TESTING.................................................................1079 AUTOMATIC TRANSMISSION.......................................................1080 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR......................................1082 REMOVAL..........................................................................1082 DISASSEMBLY......................................................................1086 ASSEMBLY.........................................................................1092 INSTALLATION.....................................................................1100 SCHEMATICS AND DIAGRAMS..........................................................1105 SPECIFICATIONS - NAG1 AUTOMATIC TRANSMISSION.....................................1126 SPECIAL TOOLS - AUTOMATIC TRANSMISSION - NAG1....................................1127 INPUT CLUTCHES.......................................................................1130 DESCRIPTION......................................................................1130 OPERATION........................................................................1131 INPUT CLUTCH K1......................................................................1132 DISASSEMBLY......................................................................1132 ASSEMBLY.........................................................................1134 INPUT CLUTCH K2......................................................................1137 DISASSEMBLY......................................................................1137 ASSEMBLY.........................................................................1139 INPUT CLUTCH K3......................................................................1142 DISASSEMBLY......................................................................1142 ASSEMBLY.........................................................................1143 ELECTROHYDRAULIC UNIT................................................................1145 DESCRIPTION......................................................................1145 ELECTRICAL CONTROL UNIT .....................................................1145 HYDRAULIC CONTROL UNIT.......................................................1145 OPERATION........................................................................1152 ELECTRICAL CONTROL UNIT .....................................................1152 HYDRAULIC CONTROL UNIT.......................................................1153 REMOVAL..........................................................................1160 DISASSEMBLY......................................................................1161 ASSEMBLY.........................................................................1165 INSTALLATION.....................................................................1169 FLUID AND FILTER.....................................................................1171 DESCRIPTION......................................................................1171 OPERATION........................................................................1171 DIAGNOSIS AND TESTING............................................................1171 EFFECTS OF INCORRECT FLUID LEVEL.............................................1171 CAUSES OF BURNT FLUID........................................................1172 FLUID CONTAMINATION..........................................................1172 STANDARD PROCEDURE...............................................................1172 CHECK OIL LEVEL..............................................................1172 TRANSMISSION FILL............................................................1173 FLUID / FILTER SERVICE.......................................................1174 FREEWHEELING CLUTCH..................................................................1175 DESCRIPTION......................................................................1175 OPERATION........................................................................1175 DISASSEMBLY......................................................................1176 ASSEMBLY.........................................................................1178 GEARSHIFT CABLE......................................................................1178 DIAGNOSIS AND TESTING............................................................1178 GEARSHIFT CABLE..............................................................1178 REMOVAL..........................................................................1179 INSTALLATION.....................................................................1180 HOLDING CLUTCHES.....................................................................1181 DESCRIPTION......................................................................1181 OPERATION........................................................................1182 HOLDING CLUTCH B1....................................................................1183 DISASSEMBLY......................................................................1183 ASSEMBLY.........................................................................1185 HOLDING CLUTCH B2....................................................................1188 DISASSEMBLY......................................................................1188 ASSEMBLY.........................................................................1190 INPUT SPEED SENSORS..................................................................1193 DESCRIPTION......................................................................1193 OPERATION........................................................................1194 OIL PUMP.............................................................................1194 DESCRIPTION......................................................................1194 OPERATION........................................................................1194 DISASSEMBLY......................................................................1195 INSPECTION.......................................................................1195 SIDE CLEARANCE...............................................................1195 TIP CLEARANCE ...............................................................1195 ASSEMBLY.........................................................................1196 OUTPUT SHAFT BEARING.................................................................1196 REMOVAL..........................................................................1196 INSTALLATION.....................................................................1198 OUTPUT SHAFT SEAL....................................................................1199 REMOVAL..........................................................................1199 INSTALLATION.....................................................................1199 PARK LOCK CABLE......................................................................1200 REMOVAL..........................................................................1200 INSTALLATION.....................................................................1201 PISTONS..............................................................................1203 DESCRIPTION......................................................................1203 OPERATION........................................................................1203 PRESSURE.....................................................................1203 PRESSURE ON A CONFINED FLUID.................................................1203 FORCE MULTIPLICATION.........................................................1203 PISTON TRAVEL................................................................1204 PLANETARY GEARTRAIN..................................................................1204 DESCRIPTION......................................................................1204 OPERATION........................................................................1205 DISASSEMBLY......................................................................1206 ASSEMBLY.........................................................................1207 SHIFT MECHANISM......................................................................1208 DESCRIPTION......................................................................1208 OPERATION........................................................................1208 REMOVAL..........................................................................1209 INSTALLATION.....................................................................1210 SOLENOID.............................................................................1211 DESCRIPTION......................................................................1211 UPSHIFT / DOWNSHIFT SOLENOID VALVES .........................................1212 MODULATING PRESSURE CONTROL SOLENOID VALVE ..................................1213 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE ...........................1213 SHIFT PRESSURE CONTROL SOLENOID VALVE .......................................1214 OPERATION........................................................................1214 UPSHIFT / DOWNSHIFT SOLENOID VALVES .........................................1214 MODULATING PRESSURE CONTROL SOLENOID VALVE ..................................1215 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE ...........................1215 SHIFT PRESSURE CONTROL SOLENOID VALVE .......................................1216 TEMPERATURE SENSOR / PARK - NEUTRAL CONTACT..........................................1216 DESCRIPTION......................................................................1216 PARK / NEUTRAL CONTACT.......................................................1216 TRANSMISSION TEMPERATURE SENSOR..............................................1216 OPERATION........................................................................1217 PARK / NEUTRAL CONTACT.......................................................1217 TRANSMISSION TEMPERATURE SENSOR..............................................1217 TORQUE CONVERTER.....................................................................1218 DESCRIPTION......................................................................1218 IMPELLER.....................................................................1219 TURBINE......................................................................1220 STATOR ......................................................................1221 TORQUE CONVERTER CLUTCH (TCC) ...............................................1221 OPERATION........................................................................1222 TURBINE......................................................................1222 STATOR ......................................................................1222 TORQUE CONVERTER CLUTCH (TCC) ...............................................1223 REMOVAL..........................................................................1223 INSTALLATION.....................................................................1224 TORQUE CONVERTER HUB SEAL............................................................1224 REMOVAL..........................................................................1224 INSTALLATION.....................................................................1224 22-TIRES / WHEELS............................................................................1225 TIRES / WHEELS...........................................................................1225 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT........................................1225 METHOD 1 (RELOCATE WHEEL ON HUB).................................................1226 METHOD 2 (RELOCATE TIRE ON WHEEL)................................................1226 STANDARD PROCEDURE...................................................................1226 STANDARD PROCEDURE - MATCH MOUNTING..............................................1226 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE......................................1228 STANDARD PROCEDURE - TIRE ROTATION...............................................1230 SPECIFICATIONS.......................................................................1231 TORQUE CHART.....................................................................1231 TIRES....................................................................................1231 DESCRIPTION..........................................................................1231 DESCRIPTION - TIRES..............................................................1231 TIRE IDENTIFICATION..........................................................1231 TIRE CHAINS..................................................................1231 DESCRIPTION - RADIAL – PLY TIRES.................................................1231 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEEDS......................................1232 DESCRIPTION - REPLACEMENT TIRES..................................................1232 DESCRIPTION - TIRE INFLATION PRESSURES...........................................1232 DIAGNOSIS AND TESTING................................................................1233 DIAGNOSIS AND TESTING - PRESSURE GAUGES..........................................1233 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION..................................1233 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS....................................1233 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS.......................................1233 DIAGNOSIS AND TESTING - TIRE / VEHICLE LEAD......................................1234 STANDARD PROCEDURE - REPAIRING LEAKS.................................................1236 CLEANING.............................................................................1236 SPECIFICATIONS.......................................................................1236 TIRES............................................................................1236 SPARE TIRE CARRIER.......................................................................1236 REMOVAL..............................................................................1236 INSTALLATION.........................................................................1236 WHEELS...................................................................................1237 DESCRIPTION..........................................................................1237 OPERATION............................................................................1237 DIAGNOSIS AND TESTING................................................................1237 WHEEL INSPECTION.................................................................1237 STANDARD PROCEDURE...................................................................1237 STANDARD PROCEDURE - WHEEL REPLACEMENT...........................................1237 STANDARD PROCEDURE - DUAL REAR WHEEL INSTALLATION................................1237 REMOVAL..............................................................................1238 INSTALLATION.........................................................................1239 23-BODY......................................................................................1241 BODY.....................................................................................1241 WARNING..............................................................................1241 SAFETY PRECAUTIONS AND WARNINGS..................................................1241 DIAGNOSIS AND TESTING................................................................1241 DIAGNOSIS AND TESTING - WATER LEAKS..............................................1241 VISUAL INSPECTION BEFORE WATER LEAK TESTS....................................1241 WATER LEAK TESTS.............................................................1242 WATER LEAK DETECTION.........................................................1242 DIAGNOSIS AND TESTING - WIND NOISE...............................................1242 VISUAL INSPECTION BEFORE TESTS...............................................1242 STANDARD PROCEDURE...................................................................1243 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR...................................1243 Rigid Plastics:..............................................................1243 Semi - Rigid Plastics:.......................................................1243 Flexible Plastics:...........................................................1243 Repair Procedure:............................................................1243 Adhesion Promoter / Surface Modifier:........................................1243 SAFETY PRECAUTION AND WARNINGS...............................................1243 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES..........................1243 PANEL SECTIONING.............................................................1245 PANEL REINFORCEMENT..........................................................1246 VISUAL INSPECTION............................................................1247 PANEL SURFACE PREPARATION....................................................1247 PATCHING PANELS..............................................................1247 PANEL PATCH FABRICATIONS.....................................................1247 PANEL PATCH INSTALLATION.....................................................1248 PATCHED PANEL SURFACING......................................................1250 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE.......................................1250 SPECIFICATIONS.......................................................................1251 DOOR - FRONT.............................................................................1253 CHECK................................................................................1253 REMOVAL..........................................................................1253 INSTALLATION.....................................................................1253 DOOR.................................................................................1254 REMOVAL..........................................................................1254 INSTALLATION.....................................................................1254 ADJUSTMENTS......................................................................1255 ADJUSTMENT...................................................................1255 DOOR GLASS...........................................................................1255 REMOVAL..........................................................................1255 INSTALLATION.....................................................................1255 EXTERIOR HANDLE......................................................................1256 REMOVAL..........................................................................1256 INSTALLATION.....................................................................1256 HINGE................................................................................1257 REMOVAL..........................................................................1257 INSTALLATION.....................................................................1257 LATCH................................................................................1258 REMOVAL..........................................................................1258 INSTALLATION.....................................................................1258 LATCH STRIKER........................................................................1258 REMOVAL..........................................................................1258 INSTALLATION.....................................................................1258 LOCK CYLINDER........................................................................1258 REMOVAL..........................................................................1258 INSTALLATION.....................................................................1258 TRIM PANEL...........................................................................1258 REMOVAL..........................................................................1258 INSTALLATION.....................................................................1260 WINDOW REGULATOR - POWER.............................................................1260 REMOVAL..........................................................................1260 INSTALLATION.....................................................................1261 WINDOW REGULATOR - MANUAL............................................................1261 REMOVAL..........................................................................1261 INSTALLATION.....................................................................1262 DOORS - REAR.............................................................................1263 CHECK................................................................................1263 REMOVAL..........................................................................1263 INSTALLATION.....................................................................1263 DOOR.................................................................................1263 REMOVAL..........................................................................1263 DISASSEMBLY......................................................................1265 RIGHT DOOR...................................................................1265 LEFT DOOR....................................................................1266 ASSEMBLY.........................................................................1267 RIGHT DOOR...................................................................1267 LEFT DOOR....................................................................1268 INSTALLATION.....................................................................1268 ADJUSTMENTS......................................................................1269 ADJUSTMENT...................................................................1269 DOOR GLASS...........................................................................1270 REMOVAL..........................................................................1270 INSTALLATION.....................................................................1270 EXTERIOR HANDLE......................................................................1271 REMOVAL..........................................................................1271 INSTALLATION.....................................................................1271 HINGE................................................................................1272 REMOVAL..........................................................................1272 INSTALLATION.....................................................................1273 INSIDE HANDLE ACTUATOR...............................................................1273 REMOVAL..........................................................................1273 INSTALLATION.....................................................................1273 LATCH................................................................................1273 REMOVAL..........................................................................1273 INSTALLATION.....................................................................1274 TRIM PANEL...........................................................................1274 REMOVAL..........................................................................1274 INSTALLATION.....................................................................1274 DOORS - SLIDING..........................................................................1275 EXTERIOR HANDLE......................................................................1275 REMOVAL..........................................................................1275 INSTALLATION.....................................................................1276 INSIDE HANDLE ACTUATOR...............................................................1276 REMOVAL..........................................................................1276 INSTALLATION.....................................................................1276 UPPER ROLLER ARM.....................................................................1276 REMOVAL..........................................................................1276 INSTALLATION.....................................................................1276 CENTER ROLLER ARM....................................................................1276 REMOVAL..........................................................................1276 INSTALLATION.....................................................................1277 LOWER ROLLER ARM.....................................................................1277 REMOVAL..........................................................................1277 INSTALLATION.....................................................................1277 CENTER TRACK.........................................................................1277 REMOVAL..........................................................................1277 INSTALLATION.....................................................................1278 LATCH / LOCK CONTROL.................................................................1278 REMOVAL..........................................................................1278 INSTALLATION.....................................................................1279 REAR LATCH...........................................................................1280 REMOVAL..........................................................................1280 INSTALLATION.....................................................................1280 REAR LATCH STRIKER...................................................................1280 REMOVAL..........................................................................1280 INSTALLATION.....................................................................1280 SLIDING DOOR.........................................................................1280 REMOVAL..........................................................................1280 DISASSEMBLY......................................................................1282 ASSEMBLY.........................................................................1283 INSTALLATION.....................................................................1284 ADJUSTMENTS......................................................................1284 ADJUSTMENT...................................................................1284 Gaps and Ridge Adjustment................................................1284 Flush Adjustment.........................................................1285 Door Stop Bumper Adjust..................................................1285 STABILIZER...........................................................................1285 REMOVAL..........................................................................1285 INSTALLATION.....................................................................1285 TRIM PANEL...........................................................................1286 REMOVAL..........................................................................1286 Upper........................................................................1286 Lower........................................................................1286 INSTALLATION.....................................................................1286 Upper........................................................................1286 Lower........................................................................1286 DOOR GLASS...........................................................................1286 REMOVAL..........................................................................1286 INSTALLATION.....................................................................1286 EXTERIOR.................................................................................1288 FUEL FILL DOOR.......................................................................1288 REMOVAL..........................................................................1288 INSTALLATION.....................................................................1288 GRILLE...............................................................................1288 REMOVAL..........................................................................1288 INSTALLATION.....................................................................1288 LICENSE PLATE BRACKET................................................................1288 REMOVAL..........................................................................1288 INSTALLATION.....................................................................1288 RADIATOR CROSSMEMBER.................................................................1289 REMOVAL..........................................................................1289 INSTALLATION.....................................................................1289 SIDE VIEW MIRROR.....................................................................1289 REMOVAL..........................................................................1289 Driver's Side................................................................1289 Passenger Side...............................................................1289 INSTALLATION.....................................................................1290 Driver's Side................................................................1290 Passenger Side...............................................................1290 SIDE VIEW MIRROR - GLASS.............................................................1290 REMOVAL..........................................................................1290 INSTALLATION.....................................................................1290 HOOD.....................................................................................1291 HINGE................................................................................1291 REMOVAL..........................................................................1291 INSTALLATION.....................................................................1291 HOOD.................................................................................1291 REMOVAL..........................................................................1291 INSTALLATION.....................................................................1291 ADJUSTMENTS......................................................................1292 ADJUSTMENT...................................................................1292 LATCH................................................................................1292 REMOVAL..........................................................................1292 INSTALLATION.....................................................................1292 LATCH RELEASE CABLE..................................................................1292 REMOVAL..........................................................................1292 INSTALLATION.....................................................................1292 LATCH RELEASE HANDLE.................................................................1292 REMOVAL..........................................................................1292 INSTALLATION.....................................................................1292 PROP ROD.............................................................................1293 REMOVAL..........................................................................1293 INSTALLATION.....................................................................1293 SAFETY LATCH.........................................................................1293 REMOVAL..........................................................................1293 INSTALLATION.....................................................................1294 INSTRUMENT PANEL.........................................................................1295 CLUSTER BEZEL........................................................................1295 REMOVAL..........................................................................1295 INSTALLATION.....................................................................1296 ACCESSORY SWITCH BEZEL...............................................................1296 REMOVAL..........................................................................1296 INSTALLATION.....................................................................1296 INSTRUMENT PANEL CENTER BEZEL........................................................1297 REMOVAL..........................................................................1297 INSTALLATION.....................................................................1297 ASH RECEIVER.........................................................................1297 REMOVAL..........................................................................1297 INSTALLATION.....................................................................1297 CUP HOLDER...........................................................................1297 REMOVAL..........................................................................1297 INSTALLATION.....................................................................1298 GLOVE BOX............................................................................1298 REMOVAL..........................................................................1298 INSTALLATION.....................................................................1298 INSTRUMENT PANEL ASSEMBLY............................................................1299 REMOVAL..........................................................................1299 INSTALLATION.....................................................................1303 TOP COVER - CLUSTER..................................................................1304 REMOVAL..........................................................................1304 INSTALLATION.....................................................................1304 TOP COVER - TRAY.....................................................................1305 REMOVAL..........................................................................1305 INSTALLATION.....................................................................1306 TOP COVER............................................................................1307 REMOVAL..........................................................................1307 INSTALLATION.....................................................................1308 STEERING COLUMN OPENING COVER........................................................1308 REMOVAL..........................................................................1308 INSTALLATION.....................................................................1309 INTERIOR.................................................................................1310 INTERIOR.............................................................................1310 CAUTION..........................................................................1310 A - PILLAR TRIM......................................................................1310 REMOVAL..........................................................................1310 INSTALLATION.....................................................................1311 ASSIST HANDLE........................................................................1311 REMOVAL..........................................................................1311 INSTALLATION.....................................................................1311 B - PILLAR TRIM......................................................................1311 REMOVAL..........................................................................1311 INSTALLATION.....................................................................1312 BULKHEAD TRIM PANEL..................................................................1312 REMOVAL..........................................................................1312 INSTALLATION.....................................................................1312 CARPETS AND FLOOR MATS...............................................................1312 REMOVAL..........................................................................1312 Cargo / Passenger Van - Front................................................1312 Passenger Van - Rear.........................................................1312 Cargo Van - Rear.............................................................1313 INSTALLATION.....................................................................1313 Cargo / Passenger Van - Front................................................1313 Passenger Van - Rear.........................................................1313 Cargo Van - Rear.............................................................1313 COWL TRIM............................................................................1313 REMOVAL..........................................................................1313 INSTALLATION.....................................................................1313 D - PILLAR TRIM......................................................................1313 REMOVAL..........................................................................1313 INSTALLATION.....................................................................1313 HEADLINER............................................................................1313 REMOVAL..........................................................................1313 Cab Section..................................................................1313 Number 2 Section.............................................................1313 Number 3 Section.............................................................1313 Number 4 Section.............................................................1314 INSTALLATION.....................................................................1314 Cab Section..................................................................1314 Number 2 Section.............................................................1314 Number 3 Section.............................................................1314 Number 4 Section.............................................................1314 QUARTER TRIM PANEL...................................................................1314 REMOVAL..........................................................................1314 Passenger Van................................................................1314 Cargo Van....................................................................1314 INSTALLATION.....................................................................1315 Passenger Van................................................................1315 Cargo Van....................................................................1315 REAR VIEW MIRROR.....................................................................1315 REMOVAL..........................................................................1315 INSTALLATION.....................................................................1315 INSTALLATION.................................................................1315 INSTALLATION - REAR VIEW MIRROR SUPPORT BRACKET..............................1315 STEPWELL SCUFF PADS..................................................................1315 REMOVAL..........................................................................1315 INSTALLATION.....................................................................1316 SUN VISOR............................................................................1316 REMOVAL..........................................................................1316 INSTALLATION.....................................................................1316 PAINT....................................................................................1317 PAINT................................................................................1317 SPECIFICATIONS - PAINT CODES.....................................................1317 BASECOAT / CLEARCOAT FINISH..........................................................1317 DESCRIPTION......................................................................1317 PAINT TOUCH - UP.....................................................................1317 DESCRIPTION......................................................................1317 STANDARD PROCEDURE - PAINT TOUCH - UP............................................1317 FINESSE SANDING / BUFFING & POLISH...................................................1318 DESCRIPTION......................................................................1318 SEATS....................................................................................1319 ARMREST..............................................................................1319 REMOVAL..........................................................................1319 INSTALLATION.....................................................................1319 HEADREST.............................................................................1319 REMOVAL..........................................................................1319 INSTALLATION.....................................................................1319 SEAT - FRONT.........................................................................1319 REMOVAL..........................................................................1319 INSTALLATION.....................................................................1320 SEAT BACK - FRONT....................................................................1320 REMOVAL..........................................................................1320 INSTALLATION.....................................................................1320 SEAT CUSHION - FRONT.................................................................1320 REMOVAL..........................................................................1320 INSTALLATION.....................................................................1321 SEAT ADJUSTERS - FRONT...............................................................1321 REMOVAL..........................................................................1321 INSTALLATION.....................................................................1321 SEAT - REAR..........................................................................1321 REMOVAL..........................................................................1321 INSTALLATION.....................................................................1322 REAR SEAT BACK SHIELD................................................................1322 REMOVAL..........................................................................1322 INSTALLATION.....................................................................1322 SEAT BACK CUSHION / COVER - REAR.....................................................1322 REMOVAL..........................................................................1322 INSTALLATION.....................................................................1322 SEAT CUSHION / COVER - REAR..........................................................1323 REMOVAL..........................................................................1323 INSTALLATION.....................................................................1323 STATIONARY GLASS.........................................................................1324 BACKLITE - BULKHEAD TRIM PANEL.......................................................1324 REMOVAL..........................................................................1324 INSTALLATION.....................................................................1324 QUARTER WINDOW.......................................................................1324 REMOVAL..........................................................................1324 INSTALLATION.....................................................................1324 WINDSHIELD...........................................................................1325 WARNING..........................................................................1325 WINDSHIELD SAFETY PRECAUTIONS................................................1325 REMOVAL..........................................................................1325 INSTALLATION.....................................................................1326 Windshield Preparation - Installing A Previously Installed Windshield........1326 Windshield Preparation - Installing A New Windshield.........................1328 Windshield Opening Preparation...............................................1328 Windshield Installation......................................................1328 WEATHERSTRIP / SEALS.....................................................................1330 FRONT DOOR INNER BELT WEATHERSTRIP...................................................1330 REMOVAL..........................................................................1330 INSTALLATION.....................................................................1330 FRONT DOOR OUTER BELT WEATHERSTRIP...................................................1330 REMOVAL..........................................................................1330 INSTALLATION.....................................................................1330 DOOR OPENING SEALS...................................................................1330 REMOVAL..........................................................................1330 INSTALLATION.....................................................................1330 BODY STRUCTURE...........................................................................1331 GAP AND FLUSH........................................................................1331 SPECIFICATIONS...................................................................1331 OPENING DIMENSIONS...................................................................1333 SPECIFICATIONS...................................................................1333 24-HEATING & AIR CONDITIONING................................................................1335 HEATING & AIR CONDITIONING...............................................................1335 DESCRIPTION..........................................................................1335 OPERATION............................................................................1336 DIAGNOSIS AND TESTING................................................................1337 A / C PERFORMANCE................................................................1337 A / C PERFORMANCE TEST.......................................................1337 HEATER PERFORMANCE TEST..........................................................1339 MAXIMUM HEATER OUTPUT........................................................1339 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.......................1340 POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT.............................1340 TEMPERATURE CONTROL..........................................................1340 ATC FUNCTION TEST................................................................1340 SPECIFICATIONS.......................................................................1340 HEATING - A / C SYSTEM...........................................................1340 CONTROLS - FRONT.........................................................................1342 A / C COMPRESSOR CLUTCH..............................................................1342 DESCRIPTION......................................................................1342 OPERATION........................................................................1343 STANDARD PROCEDURE...............................................................1343 A / C COMPRESSOR CLUTCH AIR GAP..............................................1343 A / C COMPRESSOR CLUTCH BREAK - IN...........................................1343 REMOVAL..........................................................................1343 INSPECTION.......................................................................1345 INSTALLATION.....................................................................1345 A / C COMPRESSOR CLUTCH COIL.........................................................1346 DIAGNOSIS AND TESTING............................................................1346 A / C COMPRESSOR CLUTCH COIL.................................................1346 A / C HEATER CONTROL.................................................................1346 DESCRIPTION......................................................................1346 OPERATION........................................................................1347 REMOVAL..........................................................................1347 INSTALLATION.....................................................................1347 A / C PRESSURE TRANSDUCER............................................................1348 DESCRIPTION......................................................................1348 OPERATION........................................................................1348 DIAGNOSIS AND TESTING............................................................1348 A / C PRESSURE TRANSDUCER....................................................1348 REMOVAL..........................................................................1349 INSTALLATION.....................................................................1349 AIR OUTLET TEMPERATURE SENSOR........................................................1350 DESCRIPTION......................................................................1350 OPERATION........................................................................1350 REMOVAL..........................................................................1350 INSTALLATION.....................................................................1350 AMBIENT TEMPERATURE SENSOR...........................................................1351 DESCRIPTION......................................................................1351 OPERATION........................................................................1351 REMOVAL..........................................................................1351 INSTALLATION.....................................................................1351 BLOWER MOTOR RESISTOR................................................................1351 DESCRIPTION......................................................................1351 OPERATION........................................................................1352 DIAGNOSIS AND TESTING............................................................1352 BLOWER MOTOR RESISTOR........................................................1352 REMOVAL..........................................................................1352 INSTALLATION.....................................................................1352 BLOWER MOTOR SWITCH..................................................................1353 DESCRIPTION......................................................................1353 OPERATION........................................................................1353 DIAGNOSIS AND TESTING............................................................1353 BLOWER MOTOR SWITCH..........................................................1353 EVAPORATOR TEMPERATURE SENSOR........................................................1353 DESCRIPTION......................................................................1353 OPERATION........................................................................1353 REMOVAL..........................................................................1354 INSTALLATION.....................................................................1354 IN - CAR TEMPERATURE SENSOR..........................................................1355 DESCRIPTION......................................................................1355 OPERATION........................................................................1355 DIAGNOSIS AND TESTING............................................................1355 IN - CAR TEMPERATURE SENSOR..................................................1355 MODE DOOR CABLES.....................................................................1355 REMOVAL..........................................................................1355 INSTALLATION.....................................................................1355 RECIRCULATION DOOR ACTUATOR..........................................................1356 DESCRIPTION......................................................................1356 OPERATION........................................................................1356 REMOVAL..........................................................................1356 INSTALLATION.....................................................................1357 CONTROLS - REAR..........................................................................1358 A / C CLUTCH RELAY...................................................................1358 DESCRIPTION......................................................................1358 OPERATION........................................................................1359 REMOVAL..........................................................................1359 INSTALLATION.....................................................................1360 A / C CONDENSER FAN RELAY............................................................1360 DESCRIPTION......................................................................1360 OPERATION........................................................................1360 REMOVAL..........................................................................1361 INSTALLATION.....................................................................1362 A / C CONTROL MODULE.................................................................1362 DESCRIPTION......................................................................1362 OPERATION........................................................................1362 REMOVAL..........................................................................1363 INSTALLATION.....................................................................1364 A / C HIGH PRESSURE SWITCH...........................................................1364 DESCRIPTION......................................................................1364 OPERATION........................................................................1364 REMOVAL..........................................................................1365 INSTALLATION.....................................................................1365 A / C LOW PRESSURE SWITCH............................................................1366 DESCRIPTION......................................................................1366 OPERATION........................................................................1366 REMOVAL..........................................................................1366 INSTALLATION.....................................................................1367 BLOWER MOTOR RELAY...................................................................1367 DESCRIPTION......................................................................1367 OPERATION........................................................................1367 REMOVAL..........................................................................1368 INSTALLATION.....................................................................1369 BLOWER MOTOR SWITCH..................................................................1369 DESCRIPTION......................................................................1369 OPERATION........................................................................1369 DIAGNOSIS AND TESTING............................................................1370 REAR BLOWER MOTOR SWITCH.....................................................1370 REMOVAL..........................................................................1370 INSTALLATION.....................................................................1371 EVAPORATOR TEMPERATURE SENSOR........................................................1371 DESCRIPTION......................................................................1371 OPERATION........................................................................1371 REMOVAL..........................................................................1371 INSTALLATION.....................................................................1372 TEMPERATURE CONTROL..................................................................1372 DESCRIPTION......................................................................1372 OPERATION........................................................................1372 DIAGNOSIS AND TESTING............................................................1373 REAR A / C TEMPERATURE CONTROL...............................................1373 REMOVAL..........................................................................1373 INSTALLATION.....................................................................1374 TEMPERATURE SENSOR...................................................................1374 DESCRIPTION......................................................................1374 OPERATION........................................................................1374 DIAGNOSIS AND TESTING............................................................1374 REAR TEMPERATURE SENSOR......................................................1374 REMOVAL..........................................................................1374 INSTALLATION.....................................................................1375 SUPPRESSOR FILTER - REAR BLOWER MOTOR................................................1375 DESCRIPTION......................................................................1375 OPERATION........................................................................1375 REMOVAL..........................................................................1376 INSTALLATION.....................................................................1377 SUPPRESSOR FILTER - REAR CONDENSER FAN...............................................1377 DESCRIPTION......................................................................1377 OPERATION........................................................................1378 REMOVAL..........................................................................1378 INSTALLATION.....................................................................1378 DISTRIBUTION - FRONT.....................................................................1379 AIR FILTER...........................................................................1379 REMOVAL..........................................................................1379 INSTALLATION.....................................................................1379 AIR OUTLETS..........................................................................1379 REMOVAL..........................................................................1379 INSTALLATION.....................................................................1380 BLOWER MOTOR.........................................................................1381 REMOVAL..........................................................................1381 INSTALLATION.....................................................................1381 DEFROSTER DUCTS......................................................................1381 REMOVAL..........................................................................1381 INSTALLATION.....................................................................1381 FLOOR DISTRIBUTION DUCTS.............................................................1381 REMOVAL..........................................................................1381 INSTALLATION.....................................................................1382 HVAC HOUSING.........................................................................1382 REMOVAL..........................................................................1382 DISASSEMBLY......................................................................1383 ASSEMBLY.........................................................................1384 INSTALLATION.....................................................................1384 INSTRUMENT PANEL DUCTS...............................................................1385 REMOVAL..........................................................................1385 INSTALLATION.....................................................................1385 DISTRIBUTION - REAR......................................................................1386 A / C CONDENSER COVER................................................................1386 REMOVAL..........................................................................1386 INSTALLATION.....................................................................1386 A / C CONDENSER HOUSING..............................................................1386 REMOVAL..........................................................................1386 INSTALLATION.....................................................................1388 A / C EVAPORATOR COVER...............................................................1389 REMOVAL..........................................................................1389 INSTALLATION.....................................................................1389 A / C EVAPORATOR HOUSING.............................................................1389 REMOVAL..........................................................................1389 INSTALLATION.....................................................................1391 AIR FILTER...........................................................................1392 REMOVAL..........................................................................1392 INSTALLATION.....................................................................1392 BLOWER MOTOR.........................................................................1392 REMOVAL..........................................................................1392 INSTALLATION.....................................................................1393 PLUMBING.................................................................................1394 PLUMBING.............................................................................1395 DESCRIPTION......................................................................1395 OPERATION........................................................................1395 WARNINGS.........................................................................1395 CAUTIONS.........................................................................1396 DIAGNOSIS AND TESTING............................................................1396 REFRIGERANT SYSTEM LEAKS.....................................................1396 STANDARD PROCEDURE...............................................................1397 REFRIGERANT SYSTEM SERVICE EQUIPMENT.........................................1397 MANIFOLD GAUGE SET CONNECTIONS...........................................1397 REFRIGERANT SYSTEM RECOVERY..................................................1398 REFRIGERANT SYSTEM EVACUATE..................................................1398 REFRIGERANT SYSTEM CHARGE....................................................1398 PARTIAL CHARGE METHOD....................................................1399 A / C COMPRESSOR.....................................................................1400 DESCRIPTION......................................................................1400 OPERATION........................................................................1400 DIAGNOSIS AND TESTING............................................................1400 A / C COMPRESSOR NOISE.......................................................1400 REMOVAL..........................................................................1401 DENSO 7SBU16C A / C COMPRESSOR...............................................1401 DENSO 10S17 A / C COMPRESSOR.................................................1402 INSTALLATION.....................................................................1402 DENSO 7SBU16C A / C COMPRESSOR...............................................1402 DENSO 10S17 A / C COMPRESSOR.................................................1403 A / C CONDENSER......................................................................1403 DESCRIPTION......................................................................1403 OPERATION........................................................................1403 REMOVAL..........................................................................1404 INSTALLATION.....................................................................1404 A / C DISCHARGE LINE.................................................................1405 REMOVAL..........................................................................1405 INSTALLATION.....................................................................1405 A / C EVAPORATOR.....................................................................1406 DESCRIPTION......................................................................1406 OPERATION........................................................................1406 REMOVAL..........................................................................1406 INSTALLATION.....................................................................1407 A / C EXPANSION VALVE................................................................1407 DESCRIPTION......................................................................1407 OPERATION........................................................................1407 DIAGNOSIS AND TESTING............................................................1408 A / C EXPANSION VALVE........................................................1408 REMOVAL..........................................................................1408 INSTALLATION.....................................................................1408 ELECTRIC COOLANT PUMP................................................................1409 DESCRIPTION......................................................................1409 OPERATION........................................................................1409 REMOVAL..........................................................................1409 INSTALLATION.....................................................................1410 HEATER CORE..........................................................................1410 DESCRIPTION......................................................................1410 OPERATION........................................................................1410 REMOVAL..........................................................................1410 INSTALLATION.....................................................................1411 LIQUID LINE..........................................................................1411 REMOVAL..........................................................................1411 INSTALLATION.....................................................................1413 RECEIVER / DRIER.....................................................................1413 DESCRIPTION......................................................................1413 OPERATION........................................................................1413 REMOVAL..........................................................................1414 INSTALLATION.....................................................................1414 REFRIGERANT..........................................................................1414 DESCRIPTION......................................................................1414 OPERATION........................................................................1414 REFRIGERANT OIL......................................................................1415 DESCRIPTION......................................................................1415 OPERATION........................................................................1415 STANDARD PROCEDURE...............................................................1415 REFRIGERANT OIL LEVEL........................................................1415 SUCTION LINE.........................................................................1415 REMOVAL..........................................................................1415 INSTALLATION.....................................................................1416 WATER VALVE..........................................................................1417 REMOVAL..........................................................................1417 INSTALLATION.....................................................................1417 REAR A / C CONDENSER FAN.............................................................1417 REMOVAL..........................................................................1417 INSTALLATION.....................................................................1418 REAR A / C EVAPORATOR................................................................1418 REMOVAL..........................................................................1418 INSTALLATION.....................................................................1419 REAR A / C EXPANSION VALVE...........................................................1419 DESCRIPTION......................................................................1419 OPERATION........................................................................1419 REMOVAL..........................................................................1420 INSTALLATION.....................................................................1421 REAR DISCHARGE LINE..................................................................1422 DESCRIPTION......................................................................1422 REMOVAL..........................................................................1422 INSTALLATION.....................................................................1424 REAR LIQUID LINE.....................................................................1425 DESCRIPTION......................................................................1425 REMOVAL..........................................................................1425 INSTALLATION.....................................................................1427 REAR RECEIVER / DRIER................................................................1428 REMOVAL..........................................................................1428 INSTALLATION.....................................................................1428 REAR REFRIGERANT RESERVOIR...........................................................1429 REMOVAL..........................................................................1429 INSTALLATION.....................................................................1429 REAR SUCTION LINE....................................................................1430 DESCRIPTION......................................................................1430 REMOVAL..........................................................................1430 INSTALLATION.....................................................................1432 REFRIGERANT LINE COUPLER.............................................................1432 DESCRIPTION......................................................................1432 OPERATION........................................................................1432 REMOVAL..........................................................................1433 INSTALLATION.....................................................................1433 UNDERBODY LINES......................................................................1434 REMOVAL..........................................................................1434 INSTALLATION.....................................................................1436 CABIN HEATER.............................................................................1438 CABIN HEATER.........................................................................1438 DESCRIPTION......................................................................1438 OPERATION........................................................................1438 DIAGNOSIS AND TESTING............................................................1438 SUPPLEMENTAL CABIN HEATER....................................................1438 EXHAUST TUBE.........................................................................1439 REMOVAL..........................................................................1439 INSTALLATION.....................................................................1440 FUEL DOSING PUMP.....................................................................1440 DESCRIPTION......................................................................1440 OPERATION........................................................................1440 REMOVAL..........................................................................1440 INSTALLATION.....................................................................1441 FUEL LINE............................................................................1441 STANDARD PROCEDURE...............................................................1441 CLEANING.....................................................................1441 REMOVAL..........................................................................1442 INSTALLATION.....................................................................1443 HEATER UNIT..........................................................................1444 REMOVAL..........................................................................1444 HEATER UNIT..................................................................1444 WIRE HARNESS.................................................................1444 INSTALLATION.....................................................................1444 HEATER UNIT..................................................................1444 WIRE HARNESS.................................................................1445 INLET HOSE...........................................................................1445 REMOVAL..........................................................................1445 INSTALLATION.....................................................................1446 25-EMISSIONS CONTROL.........................................................................1447 EVAPORATIVE EMISSIONS....................................................................1447 CRANKCASE VENTILATION HEATER.........................................................1447 REMOVAL..........................................................................1447 INSTALLATION.....................................................................1447 CRANKCASE VENTILATION BREATHER.......................................................1448 DESCRIPTION......................................................................1448 REMOVAL..........................................................................1448 INSTALLATION.....................................................................1449 EXHAUST GAS RECIRCULATION................................................................1450 EXHAUST GAS RECIRCULATION............................................................1450 DESCRIPTION......................................................................1450 VALVE................................................................................1451 DESCRIPTION......................................................................1451 OPERATION........................................................................1452 REMOVAL..........................................................................1452 INSTALLATION.....................................................................1452 VALVE COOLER.........................................................................1452 DESCRIPTION......................................................................1452 INDEX........................................................................................1455 COMMENTS.....................................................................................1457
DESCRIPTION:
Sprinter 2006 VA Service Manual – PDF DOWNLOAD
INTRODUCTION:
VEHICLE IDENTIFICATION:
NUMBER DESCRIPTION:
- The Vehicle Identification Number (VIN) plate is located on the lower windshield fence next to the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle.
- Refer to the VIN DECODING INFORMATION table to determine the identification of a vehicle.
- To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number.
- The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.
INTERNATIONAL SYMBOLS DESCRIPTION:
- The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 1) are used to identify various instrument controls.
- The symbols correspond to the controls and displays that are located on the instrument panel
G.B 07/04/25
