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Description
Sprinter 2007 Service Information Manual – PDF DOWNLOAD
FILE DETAILS:
Sprinter 2007 Service Information Manual – PDF DOWNLOAD
Language : English
Pages : 12732
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sprinter 2007 Service Information Manual – PDF DOWNLOAD
VEHICLE DATA....................................................................... 1 VEHICLE IDENTIFICATION NUMBER.................................................. 2 DESCRIPTION................................................................ 2 INTERNATIONAL SYMBOLS.......................................................... 3 DESCRIPTION................................................................ 3 FASTENER IDENTIFICATION........................................................ 4 DESCRIPTION................................................................ 4 FASTENER USAGE................................................................. 6 DESCRIPTION - FASTENER USAGE............................................... 6 THREADED HOLE REPAIR........................................................... 7 DESCRIPTION - THREADED HOLE REPAIR......................................... 7 METRIC SYSTEM.................................................................. 8 DESCRIPTION................................................................ 8 TORQUE REFERENCES.............................................................. 10 DESCRIPTION................................................................ 10 0 - LUBRICATION & MAINTENANCE...................................................... 11 FLUID TYPES.................................................................... 12 DESCRIPTION................................................................ 12 PARTS AND LUBRICANT RECOMMENDATIONS.................................... 12 A/C REFRIGERANT........................................................ 12 AUTOMATIC TRANSMISSION FLUID - NAG1.................................... 13 FLUID ADDITIVES........................................................ 13 AXLE FLUID............................................................. 13 BRAKE FLUID............................................................ 13 FUEL REQUIREMENTS - DIESEL ENGINE...................................... 13 DIESEL FUELS FOR USE AT VERY LOW TEMPERATURE........................... 14 HOAT COOLANT........................................................... 14 COOLANT PERFORMANCE.................................................... 16 POWER STEERING FLUID................................................... 16 ENGINE OIL - DIESEL ENGINES............................................ 16 SAE VISCOSITY GRADE.................................................... 16 OPERATION.................................................................. 18 AUTOMATIC TRANSMISSION FLUID........................................... 18 FLUID - CAPACITIES & RECOMMENDED............................................... 19 SPECIFICATIONS............................................................. 19 RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS....................... 19 FLUID FILL/CHECK LOCATIONS..................................................... 22 INSPECTION - FLUID FILL/CHECK LOCATIONS.................................... 22 HOISTING....................................................................... 23 STANDARD PROCEDURE - HOISTING.............................................. 23 FLOOR JACK................................................................. 23 HOIST...................................................................... 23 HOIST LOCATIONS............................................................ 24 JUMP STARTING.................................................................. 25 STANDARD PROCEDURE......................................................... 25 TO JUMP START A DISABLED VEHICLE:.......................................... 26 DISCONNECT CABLE CLAMPS AS FOLLOWS:........................................ 26 TOWING......................................................................... 27 STANDARD PROCEDURE - TOWING................................................ 27 IF THE ENGINE IS DAMAGED................................................... 27 IF THE TRANSMISSION IS DAMAGED............................................. 27 IF THE FRONT AXLE IS DAMAGED............................................... 27 IF THE REAR AXLE IS DAMAGED................................................ 27 SAFETY PRECAUTIONS......................................................... 28 GROUND CLEARANCE........................................................... 28 RAMP ANGLE................................................................. 28 TOWING WHEN KEYS ARE NOT AVAILABLE......................................... 28 MAINTENANCE SCHEDULES.......................................................... 29 DESCRIPTION................................................................ 29 MAINTENANCE SCHEDULES.................................................. 29 MAINTENANCE – WITH ASSYST MAINTENANCE COMPUTER......................... 29 MAINTENANCE – WITHOUT ASSYST MAINTENANCE COMPUTER...................... 32 REGULAR CHECK-UPS...................................................... 32 SPECIAL MAINTENANCE REQUIREMENTS....................................... 32 ENGINE OIL CHANGE AND FILTER REPLACEMENT............................... 33 SCOPE OF WORK FOR MAINTENANCE SERVICE.................................. 33 ADDITIONAL MAINTENANCE WORK............................................ 35 ADDITIONAL MAINTENANCE WORK AFTER....YEARS............................. 35 REQUIRED MAINTENANCE INTERVALS......................................... 36 INTERNATIONAL SYMBOLS.......................................................... 37 DESCRIPTION................................................................ 37 2 - SUSPENSION..................................................................... 38 WHEEL ALIGNMENT................................................................ 40 WHEEL ALIGNMENT............................................................ 40 DESCRIPTION............................................................ 40 DIAGNOSIS AND TESTING.................................................. 41 STANDARD PROCEDURE..................................................... 43 SPECIFICATIONS......................................................... 46 FRONT.......................................................................... 52 FRONT...................................................................... 52 SPECIFICATIONS......................................................... 52 SPECIAL TOOLS.......................................................... 53 BUSHINGS................................................................... 55 REMOVAL................................................................ 55 INSTALLATION........................................................... 56 HUB / BEARING.............................................................. 57 DESCRIPTION............................................................ 57 KNUCKLE.................................................................... 58 REMOVAL................................................................ 58 INSTALLATION........................................................... 59 LOWER BALL JOINT........................................................... 62 REMOVAL................................................................ 62 INSTALLATION........................................................... 64 LOWER CONTROL ARM.......................................................... 65 REMOVAL................................................................ 65 INSTALLATION........................................................... 67 SPRING..................................................................... 71 REMOVAL................................................................ 71 INSTALLATION........................................................... 72 LOWER SPRING CLAMP PLATES.................................................. 76 REMOVAL................................................................ 76 INSTALLATION........................................................... 76 UPPER SPRING STOP PLATES................................................... 77 REMOVAL................................................................ 77 INSTALLATION........................................................... 78 STABILIZER BAR............................................................. 79 DESCRIPTION............................................................ 79 OPERATION.............................................................. 79 REMOVAL................................................................ 80 INSTALLATION........................................................... 81 STABILIZER LINK............................................................ 82 REMOVAL................................................................ 82 INSTALLATION........................................................... 82 STRUT...................................................................... 83 REMOVAL................................................................ 83 INSTALLATION........................................................... 84 REAR........................................................................... 85 REAR....................................................................... 85 DESCRIPTION............................................................ 85 DIAGNOSIS AND TESTING.................................................. 86 SPECIFICATIONS......................................................... 87 SHOCK...................................................................... 88 DIAGNOSIS AND TESTING.................................................. 88 SPRING..................................................................... 90 DESCRIPTION............................................................ 90 OPERATION.............................................................. 90 REMOVAL................................................................ 91 INSTALLATION........................................................... 92 SPRING SHACKLE............................................................. 93 REMOVAL................................................................ 93 INSTALLATION........................................................... 94 STABILIZER BAR............................................................. 95 REMOVAL................................................................ 95 INSTALLATION........................................................... 97 STABILIZER LINK............................................................ 99 REMOVAL................................................................ 99 INSTALLATION........................................................... 100 3 - DIFFERENTIAL & DRIVELINE....................................................... 101 PROPELLER SHAFT................................................................ 102 PROPELLER SHAFT............................................................ 102 DIAGNOSIS AND TESTING.................................................. 102 STANDARD PROCEDURE..................................................... 106 SPECIFICATIONS......................................................... 109 SPECIAL TOOLS.......................................................... 110 PROPELLER SHAFT............................................................ 112 REMOVAL................................................................ 112 INSTALLATION........................................................... 113 CENTER BEARING............................................................. 114 REMOVAL................................................................ 114 INSTALLATION........................................................... 116 REAR AXLE...................................................................... 117 REAR AXLE.................................................................. 117 DIAGNOSIS AND TESTING.................................................. 117 STANDARD PROCEDURE..................................................... 119 SPECIFICATIONS......................................................... 128 SPECIAL TOOLS.......................................................... 129 SHAFT-AXLE................................................................. 142 REMOVAL................................................................ 142 INSTALLATION........................................................... 145 BEARING/SEAL-AXLE.......................................................... 148 REMOVAL................................................................ 148 INSTALLATION........................................................... 149 BEARING/SEAL-AXLE HUB...................................................... 152 REMOVAL................................................................ 152 INSTALLATION........................................................... 153 DIFFERENTIAL............................................................... 156 REMOVAL................................................................ 156 INSTALLATION........................................................... 157 BEARINGS-DIFFERENTIAL CASE................................................. 158 REMOVAL................................................................ 158 INSTALLATION........................................................... 158 SEAL-PINION................................................................ 159 REMOVAL................................................................ 159 INSTALLATION........................................................... 160 GEAR-PINION/RING........................................................... 163 REMOVAL................................................................ 163 INSTALLATION........................................................... 164 4 - VEHICLE QUICK REFERENCE........................................................ 168 FLUID - CAPACITIES & RECOMMENDED............................................... 169 SPECIFICATIONS............................................................. 169 RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS....................... 169 FUSE LOCATIONS & TYPES......................................................... 172 SPECIFICATIONS............................................................. 172 Power Distribution Centers............................................. 172 FRONT POWER DISTRIBUTION CENTER FUSES.................................. 172 POWER DISTRIBUTION CENTER.............................................. 175 DRIVER SEAT POWER DISTRIBUTION......................................... 175 MAINTENANCE SCHEDULES.......................................................... 179 DESCRIPTION................................................................ 179 MAINTENANCE SCHEDULES.................................................. 179 MAINTENANCE – WITH ASSYST MAINTENANCE COMPUTER......................... 179 MAINTENANCE – WITHOUT ASSYST MAINTENANCE COMPUTER...................... 182 REGULAR CHECK-UPS...................................................... 182 SPECIAL MAINTENANCE REQUIREMENTS....................................... 182 ENGINE OIL CHANGE AND FILTER REPLACEMENT............................... 183 SCOPE OF WORK FOR MAINTENANCE SERVICE.................................. 183 ADDITIONAL MAINTENANCE WORK............................................ 185 ADDITIONAL MAINTENANCE WORK AFTER....YEARS............................. 185 REQUIRED MAINTENANCE INTERVALS......................................... 186 REPLACEMENT BULBS.............................................................. 187 SPECIFICATIONS............................................................. 187 REPLACEMENT LIGHT BULBS - EXTERIOR..................................... 187 TRAILER TOWING................................................................. 188 SPECIFICATIONS............................................................. 188 TRAILER TOWING - NAFTA................................................. 188 COMMON TOWING DEFINITIONS.............................................. 188 TRAILER HITCHES........................................................ 189 VEHICLE AND TRAILER WEIGHTS AND RATINGS................................ 190 TRAILER AND TONGUE WEIGHT.............................................. 191 LOADING A TRAILER...................................................... 191 CHECKING WEIGHTS OF VEHICLE AND TRAILER................................ 192 TOWING REQUIREMENTS.................................................... 192 TOWING REQUIREMENTS - TRAILER LIGHTS & WIRING.......................... 194 TOWING TIPS............................................................ 195 5 - BRAKES......................................................................... 196 BRAKES - BASE - SERVICE INFORMATION............................................ 205 BRAKES - BASE - SERVICE INFORMATION........................................ 205 WARNING................................................................ 205 DIAGNOSIS AND TESTING.................................................. 206 STANDARD PROCEDURE..................................................... 211 HYDRAULIC/MECHANICAL....................................................... 213 SPECIFICATIONS......................................................... 213 SPECIAL TOOLS.......................................................... 215 BRAKE LINES................................................................ 216 STANDARD PROCEDURE..................................................... 216 REMOVAL................................................................ 218 INSTALLATION........................................................... 219 BRAKE PADS/SHOES........................................................... 220 REMOVAL................................................................ 220 INSTALLATION........................................................... 222 DISC BRAKE CALIPERS........................................................ 225 REMOVAL................................................................ 225 INSTALLATION........................................................... 228 DISC BRAKE CALIPER ADAPTER................................................. 231 REMOVAL................................................................ 231 INSTALLATION........................................................... 232 FLUID...................................................................... 234 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION...................... 234 STANDARD PROCEDURE..................................................... 235 SPECIFICATIONS......................................................... 236 FLUID RESERVOIR............................................................ 237 REMOVAL................................................................ 237 INSTALLATION........................................................... 238 ALB LEVER.................................................................. 239 REMOVAL................................................................ 239 INSTALLATION........................................................... 240 MASTER CYLINDER............................................................ 241 DIAGNOSIS AND TESTING.................................................. 241 STANDARD PROCEDURE..................................................... 243 PEDAL...................................................................... 246 REMOVAL................................................................ 246 INSTALLATION........................................................... 247 POWER BRAKE BOOSTER........................................................ 248 DESCRIPTION............................................................ 248 OPERATION.............................................................. 248 REMOVAL................................................................ 248 INSTALLATION........................................................... 249 ROTORS..................................................................... 250 REMOVAL................................................................ 250 INSTALLATION........................................................... 254 SUPPORT PLATE.............................................................. 258 REMOVAL................................................................ 258 INSTALLATION........................................................... 258 PARKING BRAKE.............................................................. 259 SPECIAL TOOLS.......................................................... 259 CABLES..................................................................... 261 REMOVAL................................................................ 261 INSTALLATION........................................................... 264 ADJUSTMENTS............................................................ 268 LEVER...................................................................... 269 REMOVAL................................................................ 269 INSTALLATION........................................................... 269 SHOES...................................................................... 270 REMOVAL................................................................ 270 INSTALLATION........................................................... 273 ADJUSTMENTS............................................................ 276 BRAKES - ELECTRICAL DIAGNOSTICS................................................ 277 BRAKES - ELECTRICAL DIAGNOSTICS............................................ 277 CAUTION................................................................ 277 DIAGNOSIS AND TESTING.................................................. 284 STANDARD PROCEDURE..................................................... 1329 BRAKES - ABS - SERVICE INFORMATION............................................. 1330 BRAKES - ABS - SERVICE INFORMATION......................................... 1330 SPECIFICATIONS......................................................... 1330 ELECTRICAL................................................................. 1331 DESCRIPTION............................................................ 1331 OPERATION.............................................................. 1332 FRONT WHEEL SPEED SENSOR................................................... 1333 REMOVAL................................................................ 1333 INSTALLATION........................................................... 1333 REAR WHEEL SPEED SENSOR.................................................... 1334 REMOVAL................................................................ 1334 INSTALLATION........................................................... 1335 TONE WHEEL................................................................. 1336 REMOVAL – DUAL REAR WHEEL (DRW)........................................ 1336 INSTALLATION – DUAL REAR WHEEL (DRW)................................... 1336 STEERING ANGLE SENSOR...................................................... 1337 DESCRIPTION............................................................ 1337 REMOVAL................................................................ 1337 INSTALLATION........................................................... 1338 SENSOR - DYNAMICS.......................................................... 1339 DESCRIPTION............................................................ 1339 REMOVAL................................................................ 1340 INSTALLATION........................................................... 1341 HCU (HYDRAULIC CONTROL UNIT)............................................... 1342 DESCRIPTION............................................................ 1342 REMOVAL................................................................ 1343 INSTALLATION........................................................... 1344 7 - COOLING........................................................................ 1345 COOLING........................................................................ 1347 OPERATION.................................................................. 1347 DIAGNOSIS AND TESTING...................................................... 1348 PRELIMINARY CHECKS..................................................... 1348 ENGINE COOLING SYSTEM OVERHEATING...................................... 1348 LEAK TESTING........................................................... 1351 ULTRAVIOLET LIGHT METHOD............................................... 1351 PRESSURE TESTER METHOD................................................. 1352 INTERNAL LEAKAGE INSPECTION............................................ 1353 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER...................... 1354 STANDARD PROCEDURE......................................................... 1355 DRAINING COOLING SYSTEM................................................ 1355 ADDING ADDITIONAL COOLANT.............................................. 1356 REFILLING COOLING SYSTEM............................................... 1356 CLEANING/REVERSE FLUSHING.............................................. 1356 CLEANING............................................................... 1356 REVERSE FLUSHING....................................................... 1356 REVERSE FLUSHING RADIATOR.............................................. 1357 REVERSE FLUSHING ENGINE................................................ 1357 CHEMICAL CLEANING...................................................... 1357 SPECIFICATIONS............................................................. 1358 FILL VOLUMES........................................................... 1358 SPECIAL TOOLS.......................................................... 1358 ACCESSORY DRIVE................................................................ 1359 BELT-ACCESSORY DRIVE....................................................... 1359 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT........................... 1359 VISUAL DIAGNOSIS....................................................... 1359 NOISE DIAGNOSIS........................................................ 1359 REMOVAL................................................................ 1362 INSTALLATION........................................................... 1364 BELT-FAN DRIVE............................................................. 1366 REMOVAL................................................................ 1366 INSTALLATION........................................................... 1367 TENSIONER-ACCESSORY DRIVE BELT............................................. 1368 DESCRIPTION............................................................ 1368 OPERATION.............................................................. 1368 REMOVAL................................................................ 1369 INSTALLATION........................................................... 1370 PULLEY-IDLER............................................................... 1371 REMOVAL................................................................ 1371 INSTALLATION........................................................... 1372 ENGINE......................................................................... 1373 COOLANT.................................................................... 1373 DESCRIPTION............................................................ 1373 DIAGNOSIS AND TESTING.................................................. 1376 CONTAINER-COOLANT RECOVERY................................................. 1377 REMOVAL................................................................ 1377 INSTALLATION........................................................... 1377 SENSOR-COOLANT LEVEL....................................................... 1378 REMOVAL................................................................ 1378 INSTALLATION........................................................... 1379 FAN-RADIATOR............................................................... 1380 REMOVAL................................................................ 1380 HEATER-ENGINE BLOCK........................................................ 1382 REMOVAL................................................................ 1382 INSTALLATION........................................................... 1383 SENSOR-ENGINE COOLANT TEMPERATURE.......................................... 1384 DESCRIPTION............................................................ 1384 REMOVAL................................................................ 1385 INSTALLATION........................................................... 1386 THERMOSTAT-ENGINE COOLANT.................................................. 1387 DESCRIPTION - 3.5L..................................................... 1387 OPERATION.............................................................. 1387 FULL THROTTLING........................................................ 1388 SHORT CIRCUIT OPERATION................................................ 1388 MIXED OPERATION........................................................ 1389 RADIATOR OPERATION..................................................... 1389 REMOVAL................................................................ 1390 INSTALLATION........................................................... 1391 RADIATOR................................................................... 1392 REMOVAL................................................................ 1392 INSTALLATION........................................................... 1394 CAP-RADIATOR PRESSURE...................................................... 1396 DESCRIPTION............................................................ 1396 OPERATION.............................................................. 1396 DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP.......................... 1397 PUMP-WATER................................................................. 1398 REMOVAL................................................................ 1398 INSTALLATION........................................................... 1399 TRANSMISSION................................................................... 1400 COOLER-TRANSMISSION OIL.................................................... 1400 REMOVAL................................................................ 1400 INSTALLATION........................................................... 1400 LINES- TRANSMISSION COOLER................................................. 1401 STANDARD PROCEDURE..................................................... 1401 8 - ELECTRICAL..................................................................... 1403 8A - AUDIO/VIDEO............................................................... 1435 AUDIO-ELECTRICAL DIAGNOSTICS............................................... 1435 AUDIO-ELECTRICAL DIAGNOSTICS........................................... 1435 AUDIO-SERVICE INFORMATION.................................................. 1490 AUDIO-SERVICE INFORMATION.............................................. 1490 ANTENNA BODY & CABLE................................................... 1494 CD CHANGER............................................................. 1496 INSTRUMENT PANEL ANTENNA CABLE......................................... 1497 RADIO.................................................................. 1499 SPEAKER................................................................ 1500 8B - CHIME/BUZZER.............................................................. 1504 CHIME/BUZZER - ELECTRICAL DIAGNOSTICS...................................... 1504 CHIME/BUZZER - ELECTRICAL DIAGNOSTICS.................................. 1504 CHIME/BUZZER............................................................... 1661 CHIME/BUZZER........................................................... 1661 PARK ASSIST BUZZER..................................................... 1670 DISPLAY-PARK ASSIST.................................................... 1672 MODULE-PARK ASSIST..................................................... 1676 SENSOR-PARK ASSIST..................................................... 1680 PARK ASSIST SWITCH..................................................... 1682 8E - ELECTRONIC CONTROL MODULES................................................ 1684 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS........................ 1684 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS.................... 1684 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION........................... 1959 ANTILOCK BRAKE MODULE.................................................. 1959 COMMUNICATION.......................................................... 1962 DATA LINK CONNECTOR.................................................... 1966 MODULE-BODY CONTROL.................................................... 1967 MODULE-DOOR CONTROL.................................................... 1974 MODULE-ENGINE CONTROL DIESEL........................................... 1976 MODULE-GLOW PLUG....................................................... 1989 MODULE-POWERTRAIN CONTROL.............................................. 1991 MODULE-PROGRAMMABLE SPECIAL............................................ 1995 MODULE-ROOF CONTROL.................................................... 1999 MODULE-STEERING CONTROL................................................ 2004 MODULE-TRANSMISSION CONTROL............................................ 2007 8F - ENGINE SYSTEMS............................................................ 2014 BATTERY SYSTEM............................................................. 2014 BATTERY SYSTEM......................................................... 2014 BATTERY-AUXILIARY...................................................... 2023 BATTERY-STARTER........................................................ 2031 BATTERY-STARTER-ABSORBENT GLASS MAT.................................... 2046 CABLES-BATTERY......................................................... 2053 TRAY-AUXILIARY BATTERY................................................. 2058 CHARGING SYSTEM............................................................ 2060 CHARGING SYSTEM........................................................ 2060 GENERATOR.............................................................. 2061 GENERATOR DECOUPLER PULLEY............................................. 2064 STARTING SYSTEM............................................................ 2071 STARTING SYSTEM........................................................ 2071 STARTER MOTOR.......................................................... 2081 STARTER MOTOR RELAY.................................................... 2084 8G - HEATED SYSTEMS............................................................ 2085 HEATED GLASS - ELECTRICAL DIAGNOSTICS...................................... 2085 HEATED GLASS - ELECTRICAL DIAGNOSTICS.................................. 2085 HEATED GLASS - SERVICE INFORMATION......................................... 2108 HEATED GLASS - SERVICE INFORMATION..................................... 2108 GRID-REAR WINDOW DEFOGGER.............................................. 2112 SWITCH-REAR WINDOW DEFOGGER............................................ 2114 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS.................................... 2116 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS................................ 2116 HEATED MIRRORS - SERVICE INFORMATION....................................... 2131 HEATED MIRRORS - SERVICE INFORMATION................................... 2131 HEATED SEATS - ELECTRICAL DIAGNOSTICS...................................... 2132 HEATED SEATS - ELECTRICAL DIAGNOSTICS.................................. 2132 HEATED SEATS - SERVICE INFORMATION......................................... 2157 HEATED SEATS - SERVICE INFORMATION..................................... 2157 HEATER-SEAT ELEMENT.................................................... 2160 SWITCH - HEATED SEAT................................................... 2164 8H - HORN...................................................................... 2168 HORN SYSTEM - ELECTRICAL DIAGNOSTICS....................................... 2168 HORN SYSTEM - ELECTRICAL DIAGNOSTICS................................... 2168 HORN-SERVICE INFORMATION................................................... 2174 HORN-SERVICE INFORMATION............................................... 2174 HORN................................................................... 2177 HORN SWITCH............................................................ 2178 8I - IGNITION CONTROL.......................................................... 2179 IGNITION CONTROL- ELECTRICAL DIAGNOSTICS................................... 2179 IGNITION CONTROL- ELECTRICAL DIAGNOSTICS............................... 2179 IGNITION CONTROL........................................................... 2217 IGNITION CONTROL....................................................... 2217 CAMSHAFT POSITION SENSOR - GAS......................................... 2222 IGNITION COIL.......................................................... 2227 GLOW PLUG.............................................................. 2228 IGNITION SWITCH........................................................ 2231 KNOCK SENSOR........................................................... 2237 SPARK PLUG............................................................. 2241 8J - INSTRUMENT CLUSTER........................................................ 2242 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS................................ 2242 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS............................ 2242 INSTRUMENT CLUSTER......................................................... 2300 INSTRUMENT CLUSTER..................................................... 2300 ABS INDICATOR.......................................................... 2315 ADR INDICATOR.......................................................... 2317 AIRBAG INDICATOR....................................................... 2319 AIR CLEANER INDICATOR.................................................. 2321 AJAR INDICATOR......................................................... 2323 AMBIENT TEMPERATURE INDICATOR.......................................... 2325 ASR/BAS INDICATOR...................................................... 2327 ASR/ESP WARNING INDICATOR.............................................. 2329 BRAKE INDICATOR........................................................ 2331 BRAKE WEAR INDICATOR................................................... 2333 CHARGING INDICATOR..................................................... 2335 CLOCK.................................................................. 2337 COOLANT LOW INDICATOR.................................................. 2338 ENGINE TEMPERATURE INDICATOR........................................... 2340 ESP INDICATOR.......................................................... 2342 FUEL GAUGE............................................................. 2344 GEAR SELECTOR INDICATOR................................................ 2347 HIGH BEAM INDICATOR.................................................... 2349 INSTRUMENT PANEL SWITCH POD............................................ 2351 LAMP OUT INDICATOR..................................................... 2354 LOW BEAM INDICATOR..................................................... 2356 LOW FUEL INDICATOR..................................................... 2358 LOW OIL LEVEL INDICATOR................................................ 2360 MAINTENANCE INDICATOR.................................................. 2362 MALFUNCTION INDICATOR LAMP (MIL)....................................... 2364 MULTI-FUNCTION INDICATOR............................................... 2366 ODOMETER............................................................... 2368 PARK BRAKE INDICATOR................................................... 2370 SEATBELT INDICATOR..................................................... 2372 SPEEDOMETER............................................................ 2374 TACHOMETER............................................................. 2376 TIRE PRESSURE MONITOR INDICATOR........................................ 2377 TURN SIGNAL INDICATOR.................................................. 2379 WAIT-TO-START INDICATOR................................................ 2381 WASHER FLUID INDICATOR................................................. 2383 WATER-IN-FUEL INDICATOR................................................ 2385 8L - LAMPS..................................................................... 2387 LAMPS/LIGHTING - EXTERIOR DIAGNOSTICS...................................... 2387 LAMPS/LIGHTING - EXTERIOR DIAGNOSTICS.................................. 2387 LAMPS/LIGHTING - EXTERIOR.................................................. 2422 LAMPS/LIGHTING - EXTERIOR.............................................. 2422 AXLE SENSOR............................................................ 2436 SWITCH-BACK UP LAMP.................................................... 2441 BRAKE LAMP SWITCH...................................................... 2442 CENTER HIGH MOUNTED STOP LAMP.......................................... 2447 CLEARANCE LAMP......................................................... 2448 FRONT FOG LAMP......................................................... 2450 FRONT LAMP UNIT........................................................ 2453 HAZARD SWITCH.......................................................... 2466 HEADLAMP LEVELING MODULE............................................... 2468 HEADLAMP LEVELING MOTOR................................................ 2471 HEADLAMP LEVELING SWITCH............................................... 2475 HEADLAMP SWITCH........................................................ 2478 IDENTIFICATION LAMP.................................................... 2481 LICENSE PLATE LAMP..................................................... 2483 MARKER LAMP............................................................ 2487 MULTI-FUNCTION SWITCH.................................................. 2491 PARK BRAKE SWITCH...................................................... 2496 REAR LAMP UNIT......................................................... 2499 REPEATER LAMP.......................................................... 2505 MODULE-TRAILER TOW..................................................... 2507 TRAILER TOW CONNECTOR.................................................. 2512 MODULE-XENON LAMP...................................................... 2513 LAMPS/LIGHTING - INTERIOR DIAGNOSTICS...................................... 2517 LAMPS/LIGHTING - INTERIOR DIAGNOSTICS.................................. 2517 LAMPS/LIGHTING - INTERIOR.................................................. 2530 LAMPS/LIGHTING - INTERIOR.............................................. 2530 AJAR SWITCH............................................................ 2536 ASH RECEIVER/CIGAR LIGHTER LAMP........................................ 2537 CARGO/DOME LAMP........................................................ 2538 DOME/READING LAMP...................................................... 2540 ENTRY/EXIT LAMP........................................................ 2542 GLOVE BOX LAMP/SWITCH.................................................. 2545 ILLUMINATION RELAY..................................................... 2549 MASTER SWITCH.......................................................... 2551 MOTION DETECTOR........................................................ 2555 8M - MESSAGE SYSTEMS........................................................... 2558 MESSAGE CENTER - SERVICE INFORMATION....................................... 2558 ELECTRONIC VEHICLE INFORMATION CENTER.................................. 2558 TEMPERATURE FUNCTION................................................... 2576 SENSOR-AMBIENT TEMPERATURE............................................. 2579 OVERHEAD CONSOLE - ELECTRICAL DIAGNOSTICS.................................. 2583 OVERHEAD CONSOLE - ELECTRICAL DIAGNOSTICS.............................. 2583 OVERHEAD CONSOLE........................................................... 2626 OVERHEAD CONSOLE....................................................... 2626 8N - POWER SYSTEMS............................................................. 2629 POWER LOCKS - ELECTRICAL DIAGNOSTICS....................................... 2629 POWER LOCKS - ELECTRICAL DIAGNOSTICS................................... 2629 POWER LOCKS-SERVICE INFORMATION............................................ 2687 DOOR LOCK MOTOR........................................................ 2687 REMOTE KEYLESS ENTRY TRANSMITTER....................................... 2690 ANTENNA-REMOTE KEYLESS ENTRY........................................... 2691 MASTER LOCK SWITCH..................................................... 2693 POWER MIRRORS-SERVICE INFORMATION.......................................... 2694 POWER MIRRORS-SERVICE INFORMATION...................................... 2694 POWER MIRROR SWITCH.................................................... 2695 POWER WINDOWS - ELECTRICAL DIAGNOSTICS..................................... 2696 POWER WINDOWS - ELECTRICAL DIAGNOSTICS................................. 2696 POWER WINDOWS-SERVICE INFORMATION.......................................... 2752 POWER WINDOWS-SERVICE INFORMATION...................................... 2752 WINDOW MOTOR........................................................... 2753 POWER WINDOW SWITCH.................................................... 2754 8O - RESTRAINTS................................................................ 2756 RESTRAINTS - ELECTRICAL DIAGNOSTICS........................................ 2756 RESTRAINTS - ELECTRICAL DIAGNOSTICS.................................... 2756 RESTRAINTS................................................................. 3969 RESTRAINTS............................................................. 3969 CHILD RESTRAINT ANCHOR................................................. 3985 CLOCKSPRING............................................................ 3987 CURTAIN AIRBAG......................................................... 3993 DRIVER AIRBAG.......................................................... 3999 IMPACT SENSOR.......................................................... 4004 OCCUPANT RESTRAINT CONTROLLER.......................................... 4012 PASSENGER AIRBAG....................................................... 4018 SEAT AIRBAG............................................................ 4024 SEAT BELT BUCKLE....................................................... 4029 SEAT BELT & RETRACTOR.................................................. 4039 SEAT BELT SWITCH....................................................... 4054 SEAT BELT TENSIONER.................................................... 4056 SEAT BELT TURNING LOOP ADJUSTER........................................ 4058 8P - SPEED CONTROL............................................................. 4060 SPEED CONTROL.............................................................. 4060 DESCRIPTION............................................................ 4060 OPERATION.............................................................. 4062 SPECIFICATIONS......................................................... 4063 CABLE...................................................................... 4064 DESCRIPTION............................................................ 4064 SERVO...................................................................... 4065 DESCRIPTION............................................................ 4065 SWITCH..................................................................... 4066 REMOVAL................................................................ 4066 INSTALLATION........................................................... 4067 8Q - VEHICLE THEFT SECURITY.................................................... 4068 VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS............................ 4068 VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS........................ 4068 VEHICLE THEFT SECURITY..................................................... 4124 VEHICLE THEFT SECURITY................................................. 4124 DOOR CYLINDER LOCK SWITCH.............................................. 4133 HOOD AJAR SWITCH....................................................... 4134 INTRUSION SENSOR....................................................... 4135 SHAFT LOCK MODULE...................................................... 4140 SIREN.................................................................. 4142 TRANSMITTER KEY........................................................ 4145 8R - WIPERS/WASHERS............................................................ 4147 WIPERS/WASHERS - DIAGNOSTICS............................................... 4147 WIPERS/WASHERS - DIAGNOSTICS........................................... 4147 WIPERS/WASHERS............................................................. 4156 WIPERS/WASHERS......................................................... 4156 CHECK VALVE............................................................ 4178 HEADLAMP WASHER RELAY.................................................. 4180 RAIN/LIGHT SENSOR...................................................... 4182 WASHER FLUID LEVEL SWITCH.............................................. 4186 WASHER HOSES/TUBES..................................................... 4190 WASHER NOZZLE.......................................................... 4192 WASHER PUMP/MOTOR...................................................... 4202 WASHER RESERVOIR....................................................... 4213 WIPER ARM.............................................................. 4216 WIPER BLADE............................................................ 4225 WIPER MODULE........................................................... 4232 WIPER MOTOR............................................................ 4235 WIPER RELAY............................................................ 4239 8T - NAVIGATION/TELECOMMUNICATION.............................................. 4241 NAVIGATION/TELECOMMUNICATION - ELECTRICAL DIAGNOSTICS...................... 4241 NAVIGATION/TELECOMMUNICATION - ELECTRICAL DIAGNOSTICS.................. 4241 NAV/TELECOM-SERVICE INFORMATION............................................ 4276 NAV/TELECOM-SERVICE INFORMATION........................................ 4276 TELEPHONE MODULE....................................................... 4277 8W - WIRING.................................................................... 4278 WIRING DIAGRAM INFORMATION................................................. 4278 WIRING DIAGRAM INFORMATION............................................. 4278 CONNECTOR.............................................................. 4292 DIODE.................................................................. 4293 TERMINAL............................................................... 4294 WIRE................................................................... 4295 CONNECTOR/GROUND/SPLICE LOCATION........................................... 4296 CONNECTOR/GROUND/SPLICE LOCATION....................................... 4296 POWER DISTRIBUTION......................................................... 4328 POWER DISTRIBUTION..................................................... 4328 CIGAR LIGHTER OUTLET................................................... 4334 FUSE BLOCK #1 AND #2................................................... 4337 FUSE BLOCK #3 THROUGH #6............................................... 4339 FUSE/RELAY BLOCK #1.................................................... 4341 FUSE/RELAY BLOCK #2.................................................... 4344 POWER OUTLET........................................................... 4347 POWER DISTRIBUTION CENTER.............................................. 4349 9 - ENGINE......................................................................... 4354 ENGINE - ELECTRICAL DIAGNOSTICS - GAS.......................................... 4377 ENGINE - ELECTRICAL DIAGNOSTICS - GAS...................................... 4377 DIAGNOSIS AND TESTING.................................................. 4377 STANDARD PROCEDURE..................................................... 7603 ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL....................................... 7606 ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL................................... 7606 DIAGNOSIS AND TESTING.................................................. 7606 STANDARD PROCEDURE.....................................................10485 ENGINE 3.5L - SERVICE INFORMATION..............................................10488 ENGINE 3.5L - SERVICE INFORMATION..........................................10488 DIAGNOSIS AND TESTING..................................................10488 STANDARD PROCEDURE.....................................................10498 ELEMENT-AIR CLEANER........................................................10526 REMOVAL................................................................10526 INSTALLATION...........................................................10527 HOUSING-AIR CLEANER........................................................10528 REMOVAL................................................................10528 INSTALLATION...........................................................10528 CYLINDER HEAD(S)...........................................................10529 DESCRIPTION............................................................10529 DIAGNOSIS AND TESTING..................................................10530 REMOVAL................................................................10532 INSTALLATION...........................................................10548 SEAL-CAMSHAFT OIL..........................................................10565 REMOVAL................................................................10565 REMOVAL................................................................10565 INSTALLATION...........................................................10565 CAMSHAFT(S)................................................................10566 REMOVAL................................................................10566 INSTALLATION...........................................................10573 COVER-CYLINDER HEAD........................................................10581 REMOVAL................................................................10581 INSTALLATION...........................................................10587 UPPER LEFT FRONT COVER.....................................................10594 REMOVAL................................................................10594 INSTALLATION...........................................................10595 UPPER RIGHT FRONT COVER....................................................10598 REMOVAL................................................................10598 INSTALLATION...........................................................10599 HYDRAULIC LIFTERS..........................................................10602 REMOVAL................................................................10602 INSTALLATION...........................................................10602 ENGINE BLOCK...............................................................10603 CLEANING...............................................................10603 INSPECTION.............................................................10603 ENGINE BLOCK...........................................................10603 CYLINDER BORE..........................................................10603 BEARINGS-CONNECTING ROD....................................................10605 STANDARD PROCEDURE - CONNECTING RODS AND BEARINGS......................10605 CONNECTING ROD BEARINGS................................................10606 CONNECTING ROD BOLTS...................................................10607 CONNECTING ROD SIDE CLEARANCE..........................................10607 CRANKSHAFT.................................................................10608 DESCRIPTION............................................................10608 REMOVAL................................................................10608 INSTALLATION...........................................................10612 BEARINGS-CRANKSHAFT MAIN...................................................10618 STANDARD PROCEDURE.....................................................10618 OIL SEAL-CRANKSHAFT-FRONT..................................................10622 REMOVAL................................................................10622 INSTALLATION...........................................................10622 RETAINER OIL SEAL-CRANK-REAR...............................................10623 REMOVAL................................................................10623 INSTALLATION...........................................................10623 PLATE-FLEX.................................................................10624 REMOVAL................................................................10624 INSTALLATION...........................................................10624 ROD-PISTON AND CONNECTING..................................................10625 DESCRIPTION............................................................10625 STANDARD PROCEDURE - FITTING PISTONS...................................10625 REMOVAL................................................................10625 INSTALLATION...........................................................10628 RINGS-PISTON...............................................................10631 DESCRIPTION............................................................10631 STANDARD PROCEDURE - PISTON RING FITTING...............................10631 REMOVAL................................................................10634 INSTALLATION...........................................................10635 DAMPER-VIBRATION...........................................................10636 REMOVAL................................................................10636 INSTALLATION...........................................................10637 BALANCE SHAFT MODULE.......................................................10640 REMOVAL................................................................10640 INSTALLATION...........................................................10642 CRANKSHAFT LOCK............................................................10645 INSTALLATION...........................................................10645 ENGINE MOUNTING............................................................10646 DESCRIPTION............................................................10646 MOUNT-LEFT.................................................................10647 REMOVAL................................................................10647 INSTALLATION...........................................................10647 MOUNT-RIGHT................................................................10648 REMOVAL................................................................10648 INSTALLATION...........................................................10648 INTAKE MANIFOLD............................................................10649 REMOVAL................................................................10649 INSTALLATION...........................................................10652 EXHAUST MANIFOLD...........................................................10657 REMOVAL................................................................10657 INSTALLATION...........................................................10658 LUBRICATION................................................................10659 DIAGNOSIS AND TESTING..................................................10660 OIL........................................................................10661 DESCRIPTION............................................................10661 STANDARD PROCEDURE.....................................................10662 OIL PAN....................................................................10664 REMOVAL................................................................10664 INSTALLATION...........................................................10672 OIL PUMP...................................................................10678 REMOVAL................................................................10678 INSTALLATION...........................................................10679 OIL FILTER HOUSING.........................................................10681 REMOVAL................................................................10681 INSTALLATION...........................................................10682 OIL SEPARATOR..............................................................10685 REMOVAL................................................................10685 INSTALLATION...........................................................10686 OIL COOLER.................................................................10688 REMOVAL................................................................10688 INSTALLATION...........................................................10689 OIL PRESSURE PORT..........................................................10692 REMOVAL................................................................10692 INSTALLATION...........................................................10692 FRONT COVER................................................................10695 REMOVAL................................................................10695 INSTALLATION...........................................................10707 TIMING BELT/CHAIN AND SPROCKETS............................................10720 REMOVAL................................................................10720 INSTALLATION...........................................................10723 TMNG BELT CHAIN............................................................10728 INSTALLATION...........................................................10728 ENGINE - 3.0L TD - SERVICE INFORMATION.........................................10730 ENGINE - 3.0L TD - SERVICE INFORMATION.....................................10730 DESCRIPTION............................................................10730 DIAGNOSIS AND TESTING..................................................10733 STANDARD PROCEDURE.....................................................10740 REMOVAL................................................................10743 INSTALLATION...........................................................10749 SPECIFICATIONS.........................................................10755 SYSTEM-AIR INTAKE..........................................................10782 REMOVAL................................................................10782 ELEMENT-AIR CLEANER........................................................10783 REMOVAL................................................................10783 INSTALLATION...........................................................10784 HEAD-CYLINDER..............................................................10785 DESCRIPTION............................................................10785 STANDARD PROCEDURE.....................................................10786 REMOVAL................................................................10787 INSTALLATION...........................................................10803 SEAL(S)-CAMSHAFT OIL.......................................................10825 REMOVAL................................................................10825 INSTALLATION...........................................................10830 CAMSHAFT(S)................................................................10835 DESCRIPTION............................................................10835 OPERATION..............................................................10835 REMOVAL................................................................10836 INSTALLATION...........................................................10841 COVER-CYLINDER HEAD........................................................10852 DESCRIPTION............................................................10852 REMOVAL................................................................10853 INSTALLATION...........................................................10857 ARMS-ROCKER................................................................10862 DESCRIPTION............................................................10862 OPERATION..............................................................10862 REMOVAL................................................................10862 INSTALLATION...........................................................10863 LIFTERS-HYDRAULIC..........................................................10864 DESCRIPTION............................................................10864 REMOVAL................................................................10864 INSPECTION.............................................................10865 INSTALLATION...........................................................10866 INTAKE/EXHAUST VALVES & SEATS..............................................10867 STANDARD PROCEDURE.....................................................10867 BLOCK-ENGINE...............................................................10871 DESCRIPTION............................................................10871 CRANKSHAFT.................................................................10873 DESCRIPTION............................................................10873 OPERATION..............................................................10873 STANDARD PROCEDURE.....................................................10874 BEARINGS-CRANKSHAFT MAIN...................................................10886 DESCRIPTION............................................................10886 INSTALLATION...........................................................10887 CRANKSHAFT MAIN BEARINGS...............................................10887 SEAL - CRANKSHAFT OIL - FRONT..............................................10890 REMOVAL................................................................10890 INSTALLATION...........................................................10891 SEAL-CRANKSHAFT OIL - REAR.................................................10895 DESCRIPTION............................................................10895 REMOVAL................................................................10895 INSTALLATION...........................................................10896 FLEXPLATE..................................................................10897 DESCRIPTION............................................................10897 REMOVAL................................................................10897 INSTALLATION...........................................................10898 LINERS-CYLINDER............................................................10899 DESCRIPTION............................................................10899 INSPECTION.............................................................10899 ROD-PISTON AND CONNECTING..................................................10900 DESCRIPTION............................................................10900 STANDARD PROCEDURE.....................................................10902 DAMPER-VIBRATION...........................................................10909 REMOVAL................................................................10909 INSTALLATION...........................................................10910 PUMP-VACUUM................................................................10912 DESCRIPTION............................................................10912 OPERATION..............................................................10913 REMOVAL................................................................10913 INSTALLATION...........................................................10914 MOUNT-LEFT.................................................................10915 REMOVAL................................................................10915 INSTALLATION...........................................................10916 MOUNT-RIGHT................................................................10917 REMOVAL................................................................10917 INSTALLATION...........................................................10918 LUBRICATION................................................................10919 DESCRIPTION............................................................10919 OIL........................................................................10920 DESCRIPTION............................................................10920 FILTER-OIL.................................................................10921 REMOVAL................................................................10921 INSTALLATION...........................................................10921 PAN-OIL....................................................................10922 REMOVAL................................................................10922 INSTALLATION...........................................................10923 VALVE-OIL PRESSURE RELIEF..................................................10925 DESCRIPTION............................................................10925 OIL PRESSURE SENDING UNIT..................................................10926 DESCRIPTION............................................................10926 OPERATION..............................................................10926 REMOVAL................................................................10927 INSTALLATION...........................................................10927 PUMP-OIL...................................................................10928 REMOVAL................................................................10928 INSTALLATION...........................................................10929 JET-OIL....................................................................10931 DESCRIPTION............................................................10931 REMOVAL................................................................10932 INSTALLATION...........................................................10933 PCV........................................................................10934 DESCRIPTION............................................................10934 REMOVAL................................................................10934 INSTALLATION...........................................................10935 COOLER-OIL.................................................................10936 DESCRIPTION............................................................10936 REMOVAL................................................................10937 INSTALLATION...........................................................10938 MANIFOLD-EXHAUST...........................................................10939 REMOVAL................................................................10939 INSTALLATION...........................................................10941 LINKAGE-SWIRL VALVE........................................................10943 DESCRIPTION............................................................10943 REMOVAL................................................................10943 INSTALLATION...........................................................10945 ACTUATOR-SWIRL VALVE.......................................................10948 DESCRIPTION............................................................10948 REMOVAL................................................................10949 INSTALLATION...........................................................10949 COVER-TIMING CHAIN.........................................................10953 REMOVAL................................................................10953 INSTALLATION...........................................................10955 SPROCKETS-TIMING CHAIN AND.................................................10958 REMOVAL................................................................10958 INSTALLATION...........................................................10965 ADJUSTMENTS............................................................10968 TENSIONER-TIMING CHAIN.....................................................10974 DESCRIPTION............................................................10974 REMOVAL................................................................10974 INSTALLATION...........................................................10975 BALANCE SHAFT..............................................................10976 REMOVAL - BALANCE SHAFT................................................10976 INSTALLATION — BALANCE SHAFT...........................................10977 11 - EXHAUST SYSTEM................................................................10980 EXHAUST SYSTEM AND TURBOCHARGER................................................10981 DESCRIPTION................................................................10981 DESCRIPTION............................................................10981 3.0L DIESEL............................................................10982 DIAGNOSIS AND TESTING......................................................10983 LEAK TESTING...........................................................10983 DIAGNOSIS AND TESTING - DIESEL ENGINE..................................10984 SPECIAL TOOLS..........................................................10985 CONVERTER-CATALYTIC............................................................10986 REMOVAL....................................................................10986 3.5L...................................................................10986 REMOVAL................................................................10987 INSTALLATION...............................................................10988 INSTALLATION...........................................................10988 INSTALLATION...........................................................10989 MUFFLER........................................................................10990 REMOVAL....................................................................10990 3.5L...................................................................10990 3.0L DIESEL............................................................10991 INSTALLATION...............................................................10992 3.5L...................................................................10992 3.0L DIESEL............................................................10993 FILTER-DIESEL PARTICULATE......................................................10994 REMOVAL....................................................................10994 INSTALLATION...............................................................10995 TAILPIPE.......................................................................10996 REMOVAL....................................................................10996 INSTALLATION...............................................................10996 TURBOCHARGER...................................................................10997 DESCRIPTION................................................................10997 OPERATION..................................................................10998 DIAGNOSIS AND TESTING - TURBOCHARGER.......................................10998 TURBOCHARGER DIAGNOSTIC PROCEDURE..........................................10999 REMOVAL....................................................................11000 INSTALLATION...............................................................11002 COOLER-CHARGE AIR AND PLUMBING.................................................11004 DESCRIPTION................................................................11004 OPERATION..................................................................11004 REMOVAL....................................................................11004 CLEANING...................................................................11005 INSPECTION.................................................................11005 INSTALLATION...............................................................11005 POSITIONER-BOOST-PRESSURE......................................................11006 DESCRIPTION................................................................11006 OPERATION..................................................................11006 REMOVAL....................................................................11006 INSTALLATION...............................................................11007 13 - FRAME & BUMPERS...............................................................11008 BUMPERS........................................................................11009 SPECIFICATIONS - TORQUE....................................................11009 FRONT BUMPER...................................................................11010 REMOVAL....................................................................11010 REMOVAL....................................................................11010 DISASSEMBLY................................................................11011 INSTALLATION...............................................................11011 ASSEMBLY...................................................................11012 INSTALLATION...............................................................11012 REAR BUMPER - STEP.............................................................11014 REMOVAL....................................................................11014 BUMPER REMOVAL.............................................................11014 BUMPER DISASSEMBLY.........................................................11014 INSTALLATION...............................................................11015 BUMPER ASSEMBLY............................................................11015 BUMPER INSTALLATION........................................................11016 FRAME..........................................................................11017 SPECIFICATIONS.............................................................11017 SPECIFICATIONS - FRAME DIMENSIONS......................................11017 VEHICLE PREPARATION....................................................11017 SPECIFICATIONS - TORQUE................................................11021 ENGINE CRADLE CROSSMEMBER......................................................11022 REMOVAL....................................................................11022 INSTALLATION...............................................................11023 REAR CROSSMEMBER - TRANSMISSION................................................11027 REMOVAL....................................................................11027 INSTALLATION...............................................................11028 14 - FUEL SYSTEM...................................................................11029 FUEL DELIVERY - 3.0L DIESEL....................................................11033 FUEL DELIVERY - 3.0L DIESEL................................................11033 DESCRIPTION............................................................11033 OPERATION..............................................................11033 START OF ACTUATION.....................................................11034 SWITCHING OFF MAIN INJECTION...........................................11034 CALCULATING MAIN INJECTION.............................................11035 PERIOD OF ACTUATION....................................................11035 DECELERATION MODE......................................................11035 FULL LOAD INJECTED QUANTITY............................................11035 LIMITING MAXIMUM ENGINE SPEED..........................................11035 FUEL QUANTITY CONTROL..................................................11035 BOILING PROTECTION.....................................................11036 FUEL TANK PROTECTION...................................................11036 WARNING - HIGH FUEL SYSTEM PRESSURE....................................11036 DIAGNOSIS AND TESTING..................................................11037 STANDARD PROCEDURE.....................................................11039 SPECIFICATIONS.........................................................11043 SPECIAL TOOLS..........................................................11044 FUEL DRAIN TUBES...........................................................11046 DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS.......................11046 LOW-PRESSURE LINES.....................................................11046 HIGH-PRESSURE LINES....................................................11046 FUEL FILTER................................................................11047 DESCRIPTION............................................................11047 REMOVAL................................................................11047 INSTALLATION...........................................................11048 FUEL LINES.................................................................11049 REMOVAL - HIGH PRESSURE LINES..........................................11049 INSTALLATION - HIGH PRESSURE LINES.....................................11050 FUEL RAIL..................................................................11051 DESCRIPTION............................................................11051 OPERATION..............................................................11051 REMOVAL................................................................11052 INSTALLATION...........................................................11054 FUEL RAIL PRESSURE SENSOR..................................................11057 DESCRIPTION............................................................11057 OPERATION..............................................................11057 REMOVAL................................................................11057 INSTALLATION...........................................................11058 FUEL PUMP..................................................................11059 DESCRIPTION............................................................11059 OPERATION..............................................................11060 FUEL PUMP MODULE...........................................................11064 DESCRIPTION............................................................11064 REMOVAL................................................................11064 INSTALLATION...........................................................11066 FUEL QUANTITY CONTROL VALVE................................................11068 DESCRIPTION............................................................11068 OPERATION..............................................................11068 REMOVAL................................................................11069 INSTALLATION...........................................................11069 FUEL TANK..................................................................11070 DESCRIPTION............................................................11070 REMOVAL................................................................11071 INSTALLATION...........................................................11073 FUEL LEVEL SENDING UNIT / SENSOR...........................................11076 DESCRIPTION............................................................11076 REMOVAL................................................................11077 INSTALLATION...........................................................11078 WATER IN FUEL SENSOR.......................................................11079 DESCRIPTION............................................................11079 OPERATION..............................................................11079 FUEL INJECTION - 3.0L DIESEL...................................................11080 FUEL INJECTION - 3.0L DIESEL...............................................11080 WARNING................................................................11080 SPECIFICATIONS.........................................................11081 ACTUATOR-INTAKE PORT SWIRL.................................................11082 DESCRIPTION............................................................11082 OPERATION..............................................................11083 REMOVAL................................................................11084 INSTALLATION...........................................................11085 ACCELERATOR PEDAL POSITION SENSOR..........................................11086 DESCRIPTION............................................................11086 REMOVAL................................................................11086 INSTALLATION...........................................................11087 BOOST PRESSURE SENSOR......................................................11088 DESCRIPTION............................................................11088 OPERATION..............................................................11088 DIAGNOSIS AND TESTING - BOOST PRESSURE SENSOR..........................11088 REMOVAL................................................................11089 INSTALLATION...........................................................11089 CAMSHAFT POSITION SENSOR...................................................11090 DESCRIPTION............................................................11090 OPERATION..............................................................11090 REMOVAL................................................................11091 INSTALLATION...........................................................11091 CRANKSHAFT POSITION SENSOR.................................................11092 DESCRIPTION............................................................11092 OPERATION..............................................................11092 REMOVAL................................................................11092 INSTALLATION...........................................................11093 FUEL INJECTOR..............................................................11094 DESCRIPTION............................................................11094 OPERATION..............................................................11094 INJECTION STAGES.......................................................11096 STANDARD PROCEDURE.....................................................11100 REMOVAL................................................................11103 INSTALLATION...........................................................11105 FUEL PRESSURE SENSOR.......................................................11107 DESCRIPTION............................................................11107 OPERATION..............................................................11107 REMOVAL................................................................11107 INSTALLATION...........................................................11108 FUEL PRESSURE SOLENOID.....................................................11109 DESCRIPTION............................................................11109 OPERATION..............................................................11109 REMOVAL................................................................11110 INSTALLATION...........................................................11110 FUEL TEMPERATURE SENSOR....................................................11111 DESCRIPTION............................................................11111 OPERATION..............................................................11111 REMOVAL................................................................11111 INSTALLATION...........................................................11112 INTAKE AIR TEMPERATURE SENSOR..............................................11113 DESCRIPTION............................................................11113 OPERATION..............................................................11113 REMOVAL................................................................11113 INSTALLATION...........................................................11114 MASS AIR FLOW SENSOR.......................................................11115 DESCRIPTION............................................................11115 OPERATION..............................................................11115 REMOVAL................................................................11116 INSTALLATION...........................................................11116 O2 SENSOR..................................................................11117 DESCRIPTION............................................................11117 OPERATION..............................................................11117 REMOVAL................................................................11119 INSTALLATION...........................................................11120 FUEL DELIVERY - 3.5L GAS.......................................................11121 FUEL DELIVERY - 3.5L GAS...................................................11121 DESCRIPTION............................................................11121 DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM...........................11121 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE - 3.5L GAS ENGINE....11121 FUEL PUMP MODULE...........................................................11122 DESCRIPTION............................................................11122 OPERATION..............................................................11122 REMOVAL................................................................11122 INSTALLATION...........................................................11124 FUEL RAIL..................................................................11128 DESCRIPTION............................................................11128 OPERATION..............................................................11128 REMOVAL................................................................11129 INSTALLATION...........................................................11130 FUEL LINES.................................................................11131 DESCRIPTION - FUEL LINES/HOSES AND CLAMPS..............................11131 STANDARD PROCEDURE - HOSES AND CLAMP...................................11131 FUEL TANK..................................................................11132 DESCRIPTION............................................................11132 OPERATION..............................................................11132 REMOVAL................................................................11132 INSTALLATION...........................................................11134 QUICK CONNECT FITTING......................................................11138 DESCRIPTION............................................................11138 STANDARD PROCEDURE - QUICK-CONNECT FITTINGS............................11138 DISCONNECTING..........................................................11138 CONNECTING.............................................................11143 FUEL INJECTION - 3.5L GAS......................................................11145 FUEL INJECTION - 3.5L GAS..................................................11145 OPERATION..............................................................11145 ACCELERATOR PEDAL POSITION SENSOR..........................................11146 DESCRIPTION............................................................11146 REMOVAL................................................................11146 INSTALLATION...........................................................11146 CRANKSHAFT POSITION SENSOR.................................................11147 DESCRIPTION............................................................11147 OPERATION..............................................................11148 REMOVAL................................................................11149 INSTALLATION...........................................................11149 FUEL INJECTOR..............................................................11150 DESCRIPTION............................................................11150 OPERATION..............................................................11150 REMOVAL................................................................11151 INSTALLATION...........................................................11153 INLET AIR TEMPERATURE SENSOR...............................................11154 DESCRIPTION............................................................11154 MASS AIR FLOW SENSOR.......................................................11155 DESCRIPTION............................................................11155 OPERATION..............................................................11155 REMOVAL................................................................11155 INSTALLATION...........................................................11156 MAP SENSOR.................................................................11157 DESCRIPTION............................................................11157 OPERATION..............................................................11158 REMOVAL................................................................11159 INSTALLATION...........................................................11159 O2 SENSOR..................................................................11160 DESCRIPTION............................................................11160 OPERATION..............................................................11161 REMOVAL................................................................11161 INSTALLATION...........................................................11162 THROTTLE BODY..............................................................11163 DESCRIPTION............................................................11163 OPERATION..............................................................11163 REMOVAL................................................................11164 INSTALLATION...........................................................11165 MANIFOLD FLOW VALVE SOLENOID...............................................11166 OPERATION..............................................................11166 REMOVAL................................................................11166 INSTALLATION...........................................................11167 MANIFOLD SWIRL VALVE SOLENOID..............................................11168 OPERATION..............................................................11168 REMOVAL................................................................11168 INSTALLATION...........................................................11169 SENSOR-MANIFOLD SWIRL VALVE POSITION.......................................11170 DESCRIPTION............................................................11170 OPERATION..............................................................11170 REMOVAL................................................................11171 INSTALLATION...........................................................11171 19 - STEERING......................................................................11173 STEERING - ELECTRICAL DIAGNOSIS................................................11175 COLUMN ELECTRICAL DIAG.....................................................11175 COLUMN ELECTRICAL DIAG.................................................11175 STEERING - SERVICE INFORMATION.................................................11218 STEERING - SERVICE INFORMATION.............................................11218 STEERING - SERVICE INFORMATION.........................................11218 COLUMN.....................................................................11226 COLUMN.................................................................11226 INTERMEDIATE SHAFT.....................................................11231 STEERING WHEEL.........................................................11234 GEAR.......................................................................11236 GEAR...................................................................11236 LINKAGE....................................................................11240 LINKAGE................................................................11240 TIE ROD END............................................................11243 PUMP.......................................................................11249 PUMP...................................................................11249 FLUID..................................................................11254 FLUID COOLER TUBE......................................................11255 HOSES..................................................................11257 PULLEY.................................................................11261 21 - TRANSMISSION..................................................................11263 AUTOMATIC TRANSMISSION NAG1 - SHIFTER DIAGNOSTICS..............................11267 AUTOMATIC TRANSMISSION NAG1 - SHIFTER DIAGNOSTICS..........................11267 DIAGNOSIS AND TESTING..................................................11267 STANDARD PROCEDURE.....................................................11280 AUTOMATIC TRANSMISSION NAG1 - ELECTRICAL DIAGNOSTICS...........................11283 AUTOMATIC TRANSMISSION NAG1 - ELECTRICAL DIAGNOSTICS.......................11283 DIAGNOSIS AND TESTING..................................................11283 STANDARD PROCEDURE.....................................................11553 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION..............................11556 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION..........................11556 DESCRIPTION............................................................11556 TRANSMISSION IDENTIFICATION............................................11557 TRANSMISSION GEAR RATIOS...............................................11557 TRANSMISSION HOUSING...................................................11557 MECHANICAL SECTION.....................................................11557 ELECTROHYDRAULIC CONTROL UNIT..........................................11557 SHIFT GROUPS...........................................................11557 OPERATION..............................................................11558 EMERGENCY RUNNING FUNCTION.............................................11558 CLUTCH APPLICATION.....................................................11559 FIRST GEAR POWERFLOW...................................................11559 SECOND GEAR POWERFLOW..................................................11560 THIRD GEAR POWERFLOW...................................................11561 FOURTH GEAR POWERFLOW..................................................11563 FIFTH GEAR POWERFLOW...................................................11564 REVERSE GEAR POWERFLOW.................................................11565 REVERSE GEAR POWERFLOW - LIMP IN.......................................11566 SHIFT GROUPS/ SHIFT SEQUENCE...........................................11567 DIAGNOSIS AND TESTING..................................................11577 INPUT CLUTCHES.............................................................11642 DESCRIPTION............................................................11642 OPERATION..............................................................11643 INPUT CLUTCH K1............................................................11644 DISASSEMBLY............................................................11644 ASSEMBLY...............................................................11644 INPUT CLUTCH K2............................................................11648 DISASSEMBLY............................................................11648 ASSEMBLY...............................................................11649 INPUT CLUTCH K3............................................................11652 DISASSEMBLY............................................................11652 ASSEMBLY...............................................................11652 ELECTROHYDRAULIC CONTROL UNIT..............................................11656 DESCRIPTION............................................................11656 ELECTRICAL CONTROL UNIT................................................11657 HYDRAULIC CONTROL UNIT.................................................11657 OPERATION..............................................................11662 ELECTRICAL CONTROL UNIT................................................11662 HYDRAULIC CONTROL UNIT.................................................11662 REMOVAL................................................................11667 DISASSEMBLY............................................................11669 CLEANING...............................................................11678 INSPECTION.............................................................11678 ASSEMBLY...............................................................11678 INSTALLATION...........................................................11687 FLUID AND FILTER...........................................................11689 DESCRIPTION............................................................11689 OPERATION..............................................................11689 DIAGNOSIS AND TESTING..................................................11690 STANDARD PROCEDURE.....................................................11691 FREEWHEELING CLUTCH........................................................11696 DESCRIPTION............................................................11696 OPERATION..............................................................11696 DISASSEMBLY............................................................11697 ASSEMBLY...............................................................11698 GEARSHIFT CABLE............................................................11699 DIAGNOSIS AND TESTING..................................................11699 HOLDING CLUTCHES...........................................................11703 DESCRIPTION............................................................11703 OPERATION..............................................................11704 HOLDING CLUTCH B1..........................................................11705 DISASSEMBLY............................................................11705 ASSEMBLY...............................................................11707 HOLDING CLUTCH B2..........................................................11710 DISASSEMBLY............................................................11710 ASSEMBLY...............................................................11711 SPEED SENSORS..............................................................11714 DESCRIPTION............................................................11714 OPERATION..............................................................11714 OIL PUMP...................................................................11715 DESCRIPTION............................................................11715 OPERATION..............................................................11715 DISASSEMBLY............................................................11716 INSPECTION.............................................................11716 SIDE CLEARANCE.........................................................11717 TIP CLEARANCE..........................................................11717 ASSEMBLY...............................................................11718 OUTPUT SHAFT BEARING.......................................................11719 REMOVAL................................................................11719 INSTALLATION...........................................................11720 OUTPUT SHAFT SEAL..........................................................11723 REMOVAL................................................................11723 INSTALLATION...........................................................11724 PARK LOCK CABLE............................................................11725 REMOVAL................................................................11725 INSTALLATION...........................................................11726 PISTONS....................................................................11727 DESCRIPTION............................................................11727 OPERATION..............................................................11727 PRESSURE...............................................................11727 PRESSURE ON A CONFINED FLUID...........................................11727 FORCE MULTIPLICATION...................................................11728 PISTON TRAVEL..........................................................11729 PLANETARY GEARTRAIN........................................................11730 DESCRIPTION............................................................11730 OPERATION..............................................................11730 DISASSEMBLY............................................................11731 ASSEMBLY...............................................................11731 SEAL-FILL TUBE.............................................................11734 REMOVAL................................................................11734 INSTALLATION...........................................................11735 SHIFT MECHANISM............................................................11739 DESCRIPTION............................................................11739 OPERATION..............................................................11740 REMOVAL................................................................11740 INSTALLATION...........................................................11742 SOLENOID...................................................................11743 DESCRIPTION............................................................11743 UPSHIFT/DOWNSHIFT SOLENOID VALVES......................................11744 MODULATING PRESSURE CONTROL SOLENOID VALVE.............................11744 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE......................11745 SHIFT PRESSURE CONTROL SOLENOID VALVE..................................11746 OPERATION..............................................................11746 UPSHIFT/DOWNSHIFT SOLENOID VALVES......................................11747 MODULATING PRESSURE CONTROL SOLENOID VALVE.............................11747 TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE......................11748 SHIFT PRESSURE CONTROL SOLENOID VALVE..................................11748 TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT....................................11749 DESCRIPTION............................................................11749 OPERATION..............................................................11750 TORQUE CONVERTER...........................................................11752 DESCRIPTION............................................................11752 IMPELLER...............................................................11753 TURBINE................................................................11754 STATOR.................................................................11755 TORQUE CONVERTER CLUTCH (TCC)..........................................11756 OPERATION..............................................................11756 TURBINE................................................................11757 STATOR.................................................................11758 TORQUE CONVERTER CLUTCH (TCC)..........................................11758 REMOVAL................................................................11759 INSTALLATION...........................................................11760 TORQUE CONVERTER HUB SEAL..................................................11761 REMOVAL................................................................11761 INSTALLATION...........................................................11761 22 - TIRES/WHEELS..................................................................11762 TIRES/WHEELS - ELECTRICAL DIAGNOSTICS..........................................11764 TIRE PRESSURE MONITORING SYSTEM - ELECTRICAL DIAGNOSIS.....................11764 DIAGNOSIS AND TESTING..................................................11764 STANDARD PROCEDURE.....................................................11880 TIRES/WHEELS - SERVICE INFORMATION.............................................11883 TIRES/WHEELS - SERVICE INFORMATION.........................................11883 DIAGNOSIS AND TESTING..................................................11883 STANDARD PROCEDURE.....................................................11886 SPECIFICATIONS.........................................................11890 TIRES......................................................................11891 DESCRIPTION............................................................11891 DIAGNOSIS AND TESTING..................................................11895 STANDARD PROCEDURE.....................................................11898 CLEANING...............................................................11899 SPECIFICATIONS.........................................................11900 SPARE TIRE CARRIER.........................................................11901 REMOVAL................................................................11901 INSTALLATION...........................................................11901 WHEELS.....................................................................11902 DESCRIPTION............................................................11902 OPERATION..............................................................11903 DIAGNOSIS AND TESTING..................................................11904 STANDARD PROCEDURE.....................................................11905 TIRE PRESSURE MONITORING SYSTEM............................................11908 DESCRIPTION............................................................11908 OPERATION..............................................................11909 DIAGNOSIS AND TESTING..................................................11910 SPECIFICATIONS.........................................................11911 SENSOR.....................................................................11912 DESCRIPTION............................................................11912 OPERATION..............................................................11912 CAUTION................................................................11913 DIAGNOSIS AND TESTING..................................................11914 TRANSPONDER................................................................11918 DESCRIPTION............................................................11918 REMOVAL................................................................11919 INSTALLATION...........................................................11921 23 - BODY..........................................................................11923 BODY...........................................................................11928 WARNING....................................................................11928 SAFETY PRECAUTIONS AND WARNINGS........................................11928 DIAGNOSIS AND TESTING......................................................11929 DIAGNOSIS AND TESTING - WATER LEAKS....................................11929 VISUAL INSPECTION BEFORE WATER LEAK TESTS..............................11929 WATER LEAK TESTS.......................................................11929 WATER LEAK DETECTION...................................................11930 DIAGNOSIS AND TESTING - WIND NOISE.....................................11931 VISUAL INSPECTION BEFORE TESTS.........................................11931 STANDARD PROCEDURE.........................................................11932 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR.........................11932 RIGID PLASTICS:........................................................11932 SEMI-RIGID PLASTICS:...................................................11932 FLEXIBLE PLASTICS:.....................................................11932 REPAIR PROCEDURE:......................................................11932 ADHESION PROMOTER/SURFACE MODIFIER:....................................11932 SAFETY PRECAUTION AND WARNINGS.........................................11933 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES....................11933 PANEL SECTIONING.......................................................11936 PANEL REINFORCEMENT....................................................11937 VISUAL INSPECTION......................................................11938 PANEL SURFACE PREPARATION..............................................11938 PATCHING PANELS........................................................11939 PANEL PATCH FABRICATIONS...............................................11939 PANEL PATCH INSTALLATION...............................................11940 PATCHED PANEL SURFACING................................................11942 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE.............................11942 SPECIFICATIONS.........................................................11944 DOOR - FRONT...................................................................11946 CHECK......................................................................11946 REMOVAL................................................................11946 INSTALLATION...........................................................11947 DOOR.......................................................................11948 REMOVAL................................................................11948 DISASSEMBLY............................................................11948 ASSEMBLY...............................................................11951 INSTALLATION...........................................................11955 ADJUSTMENTS............................................................11956 DOOR GLASS.................................................................11957 REMOVAL................................................................11957 INSTALLATION...........................................................11957 HINGE......................................................................11958 REMOVAL................................................................11958 INSTALLATION...........................................................11959 INSIDE HANDLE ACTUATOR.....................................................11960 REMOVAL................................................................11960 INSTALLATION...........................................................11960 LATCH......................................................................11961 REMOVAL................................................................11961 INSTALLATION...........................................................11961 LOCK CYLINDER..............................................................11962 REMOVAL................................................................11962 INSTALLATION...........................................................11962 TRIM PANEL.................................................................11963 REMOVAL................................................................11963 INSTALLATION...........................................................11963 WINDOW REGULATOR - POWER...................................................11964 REMOVAL................................................................11964 INSTALLATION...........................................................11965 WATERSHIELD................................................................11966 REMOVAL................................................................11966 INSTALLATION...........................................................11967 DOORS - REAR...................................................................11968 CHECK......................................................................11968 REMOVAL................................................................11968 INSTALLATION...........................................................11968 DOOR.......................................................................11969 REMOVAL................................................................11969 DISASSEMBLY............................................................11969 RIGHT DOOR.............................................................11969 LEFT DOOR..............................................................11972 ASSEMBLY...............................................................11975 RIGHT DOOR.............................................................11975 LEFT DOOR..............................................................11978 INSTALLATION...........................................................11981 ADJUSTMENTS............................................................11982 DOOR GLASS.................................................................11989 REMOVAL................................................................11989 INSTALLATION...........................................................11990 EXTERIOR HANDLE............................................................11991 REMOVAL................................................................11991 INSTALLATION...........................................................11991 HINGE......................................................................11992 REMOVAL................................................................11992 INSTALLATION...........................................................11993 INSIDE HANDLE ACTUATOR.....................................................11994 REMOVAL................................................................11994 RIGHT DOOR INSIDE HANDLE...............................................11994 LEFT DOOR INSIDE HANDLE................................................11994 INSTALLATION...........................................................11995 RIGHT DOOR INSIDE HANDLE...............................................11995 LEFT DOOR INSIDE HANDLE................................................11995 LATCH - LEFT DOOR..........................................................11996 REMOVAL................................................................11996 DOOR LATCH – LEFT DOOR INNER...........................................11996 DOOR LATCH – LEFT DOOR UPPER...........................................11997 DOOR LATCH – LEFT DOOR LOWER...........................................11998 INSTALLATION...........................................................11998 DOOR LATCH – LEFT DOOR INNER...........................................11999 DOOR LATCH – LEFT DOOR UPPER...........................................11999 DOOR LATCH – LEFT DOOR LOWER...........................................12000 LATCH - RIGHT DOOR.........................................................12002 REMOVAL................................................................12002 DOOR LATCH – RIGHT DOOR................................................12002 DOOR LATCH – RIGHT DOOR UPPER..........................................12002 INSTALLATION...........................................................12003 DOOR LATCH – RIGHT DOOR................................................12003 DOOR LATCH – RIGHT DOOR UPPER..........................................12004 TRIM PANEL.................................................................12005 REMOVAL................................................................12005 INSTALLATION...........................................................12005 DOORS - SLIDING................................................................12006 CENTER ROLLER ARM..........................................................12006 REMOVAL................................................................12006 INSTALLATION...........................................................12006 CENTER TRACK...............................................................12007 REMOVAL................................................................12007 INSTALLATION...........................................................12008 DOOR GLASS.................................................................12009 REMOVAL................................................................12009 INSTALLATION...........................................................12009 EXTERIOR HANDLE............................................................12010 REMOVAL................................................................12010 INSTALLATION...........................................................12010 INSIDE HANDLE ACTUATOR.....................................................12011 REMOVAL................................................................12011 INSTALLATION...........................................................12012 LATCH / LOCK CONTROL.......................................................12013 REMOVAL................................................................12013 INSTALLATION...........................................................12014 LOWER ROLLER ARM...........................................................12016 REMOVAL................................................................12016 INSTALLATION...........................................................12017 REAR LATCH.................................................................12018 REMOVAL................................................................12018 INSTALLATION...........................................................12018 REAR LATCH STRIKER.........................................................12019 REMOVAL................................................................12019 INSTALLATION...........................................................12019 SLIDING DOOR...............................................................12020 REMOVAL................................................................12020 DISASSEMBLY............................................................12023 ASSEMBLY...............................................................12025 INSTALLATION...........................................................12026 ADJUSTMENTS............................................................12030 STABILIZER.................................................................12033 REMOVAL................................................................12033 INSTALLATION...........................................................12033 STOP BUMPER................................................................12034 REMOVAL................................................................12034 UPPER..................................................................12034 LOWER..................................................................12034 INSTALLATION...........................................................12035 LOWER..................................................................12035 UPPER..................................................................12035 TRIM PANEL.................................................................12036 REMOVAL................................................................12036 INSTALLATION...........................................................12036 UPPER ROLLER ARM...........................................................12037 REMOVAL................................................................12037 INSTALLATION...........................................................12037 EXTERIOR.......................................................................12038 FUEL FILL DOOR.............................................................12038 REMOVAL................................................................12038 INSTALLATION...........................................................12038 GRILLE.....................................................................12039 REMOVAL................................................................12039 GRILLE.................................................................12039 GRILLE COVERING........................................................12039 INSTALLATION...........................................................12040 GRILLE.................................................................12040 GRILLE COVERING........................................................12040 SIDE VIEW MIRROR...........................................................12041 REMOVAL................................................................12041 MIRROR REMOVAL.........................................................12041 DISASSEMBLY............................................................12041 INSTALLATION...........................................................12042 MIRROR INSTALLATION....................................................12043 ASSEMBLY...............................................................12043 SIDE VIEW MIRROR - GLASS...................................................12045 REMOVAL................................................................12045 INSTALLATION...........................................................12046 FRONT FENDER...............................................................12047 REMOVAL................................................................12047 INSTALLATION...........................................................12048 HOOD...........................................................................12050 HOOD.......................................................................12050 REMOVAL................................................................12050 INSTALLATION...........................................................12050 ADJUSTMENTS............................................................12052 LATCH......................................................................12053 REMOVAL................................................................12053 INSTALLATION...........................................................12054 PROP ROD...................................................................12055 REMOVAL................................................................12055 INSTALLATION...........................................................12055 INSTRUMENT PANEL...............................................................12056 BEZEL-CLUSTER..............................................................12056 REMOVAL................................................................12056 INSTALLATION...........................................................12057 BEZEL-CENTER...............................................................12060 REMOVAL................................................................12060 INSTALLATION...........................................................12060 GLOVE BOX..................................................................12061 REMOVAL................................................................12061 INSTALLATION...........................................................12061 INSTRUMENT PANEL ASSEMBLY..................................................12062 REMOVAL................................................................12062 INSTALLATION...........................................................12064 TOP COVER..................................................................12067 REMOVAL................................................................12067 INSTALLATION...........................................................12068 COVER-STEERING COLUMN OPENING..............................................12069 REMOVAL................................................................12069 INSTALLATION...........................................................12070 COVER-INSTRUMENT PANEL CENTER FOOTWELL.....................................12071 REMOVAL................................................................12071 INSTALLATION...........................................................12071 COVER-GEAR SELECTOR........................................................12072 REMOVAL................................................................12072 INSTALLATION...........................................................12073 END CAP....................................................................12074 REMOVAL................................................................12074 INSTALLATION...........................................................12074 INTERIOR.......................................................................12075 INTERIOR...................................................................12075 CAUTION................................................................12075 A-PILLAR TRIM..............................................................12076 REMOVAL................................................................12076 INSTALLATION...........................................................12076 TRIM-B-PILLAR..............................................................12077 REMOVAL................................................................12077 INSTALLATION...........................................................12077 BULKHEAD TRIM PANEL........................................................12079 REMOVAL................................................................12079 INSTALLATION...........................................................12079 CARPETS AND FLOOR MATS.....................................................12080 REMOVAL................................................................12080 CARGO/PASSENGER VAN - FRONT............................................12080 PASSENGER VAN - REAR...................................................12080 CARGO VAN - REAR.......................................................12080 INSTALLATION...........................................................12081 CARGO/PASSENGER VAN - FRONT............................................12081 PASSENGER VAN - REAR...................................................12081 CARGO VAN - REAR.......................................................12081 COWL TRIM..................................................................12082 REMOVAL................................................................12082 INSTALLATION...........................................................12082 D-PILLAR TRIM..............................................................12083 REMOVAL................................................................12083 INSTALLATION...........................................................12083 HEADLINER..................................................................12084 REMOVAL................................................................12084 CAB SECTION............................................................12084 NUMBER 2 SECTION.......................................................12084 NUMBER 3 SECTION.......................................................12085 NUMBER 4 SECTION.......................................................12085 INSTALLATION...........................................................12086 CAB SECTION............................................................12086 NUMBER 2 SECTION.......................................................12086 NUMBER 3 SECTION.......................................................12087 NUMBER 4 SECTION.......................................................12087 QUARTER TRIM PANEL.........................................................12089 REMOVAL................................................................12089 PASSENGER VAN..........................................................12089 CARGO VAN..............................................................12089 INSTALLATION...........................................................12089 PASSENGER VAN..........................................................12089 CARGO VAN..............................................................12089 REAR VIEW MIRROR...........................................................12090 REMOVAL................................................................12090 INSTALLATION...........................................................12091 SUN VISOR..................................................................12093 REMOVAL................................................................12093 INSTALLATION...........................................................12093 TRIM-DOOR SILL.............................................................12094 REMOVAL................................................................12094 FRONT..................................................................12094 REAR...................................................................12094 INSTALLATION...........................................................12095 FRONT..................................................................12095 REAR...................................................................12095 PAINT..........................................................................12096 PAINT......................................................................12096 SPECIFICATIONS.........................................................12096 BASECOAT/CLEARCOAT FINISH..................................................12097 DESCRIPTION............................................................12097 PAINT TOUCH-UP.............................................................12098 DESCRIPTION............................................................12098 STANDARD PROCEDURE - PAINT TOUCH-UP....................................12098 FINESSE SANDING/BUFFING & POLISH...........................................12099 DESCRIPTION............................................................12099 SEATS..........................................................................12100 ARMREST....................................................................12100 REMOVAL................................................................12100 DRIVER SIDE............................................................12100 PASSENGER SIDE.........................................................12100 INSTALLATION...........................................................12101 DRIVER SIDE............................................................12101 PASSENGER SIDE.........................................................12101 HEADREST...................................................................12102 REMOVAL................................................................12102 INSTALLATION...........................................................12102 SEAT - FRONT...............................................................12103 REMOVAL................................................................12103 DRIVER SEAT............................................................12103 PASSENGER SEAT.........................................................12103 INSTALLATION...........................................................12104 DRIVER SEAT............................................................12104 PASSENGER SEAT.........................................................12104 SEAT BACK - FRONT..........................................................12105 REMOVAL................................................................12105 INSTALLATION...........................................................12106 SEAT CUSHION - FRONT.......................................................12107 REMOVAL................................................................12107 INSTALLATION...........................................................12107 SEAT ADJUSTERS - FRONT.....................................................12108 REMOVAL................................................................12108 INSTALLATION...........................................................12108 SEAT - REAR................................................................12109 REMOVAL................................................................12109 TWO PASSENGER BENCH....................................................12109 THREE PASSENGER BENCH..................................................12109 INSTALLATION...........................................................12110 TWO PASSENGER BENCH....................................................12110 THREE PASSENGER BENCH..................................................12110 REAR SEAT BACK SHIELD......................................................12111 REMOVAL................................................................12111 INSTALLATION...........................................................12111 SEAT BACK CUSHION/COVER - REAR.............................................12112 REMOVAL................................................................12112 INSTALLATION...........................................................12113 SEAT CUSHION/COVER - REAR..................................................12114 REMOVAL................................................................12114 INSTALLATION...........................................................12114 SEAT RISER.................................................................12115 REMOVAL................................................................12115 INSTALLATION...........................................................12116 STATIONARY GLASS...............................................................12117 BACKLITE - BULKHEAD TRIM PANEL.............................................12117 REMOVAL................................................................12117 INSTALLATION...........................................................12118 QUARTER WINDOW.............................................................12119 REMOVAL................................................................12119 INSTALLATION...........................................................12119 WINDSHIELD.................................................................12121 WARNING................................................................12121 WEATHERSTRIP/SEALS.............................................................12128 FRONT DOOR INNER BELT WEATHERSTRIP.........................................12128 REMOVAL................................................................12128 INSTALLATION...........................................................12128 FRONT DOOR OUTER BELT WEATHERSTRIP.........................................12129 REMOVAL................................................................12129 INSTALLATION...........................................................12129 DOOR OPENING SEALS.........................................................12130 REMOVAL................................................................12130 INSTALLATION...........................................................12130 BODY STRUCTURE.................................................................12131 OPENING DIMENSIONS.........................................................12131 SPECIFICATIONS.........................................................12131 24 - HEATING & AIR CONDITIONING....................................................12135 HVAC-ELECTRICAL DIAGNOSTICS....................................................12142 HVAC-ELECTRICAL DIAGNOSTICS................................................12142 DIAGNOSIS AND TESTING..................................................12142 HVAC - SERVICE INFORMATION.....................................................12402 HVAC - SERVICE INFORMATION.................................................12402 DESCRIPTION............................................................12402 DIAGNOSIS AND TESTING..................................................12406 SPECIFICATIONS.........................................................12414 SPECIAL TOOLS..........................................................12416 CONTROLS - FRONT...........................................................12417 ACTUATOR-BLEND DOOR....................................................12417 ACTUATOR-MODE DOOR.....................................................12421 ACTUATOR-RECIRCULATION DOOR............................................12424 CONTROL-A/C HEATER.....................................................12428 MODULE-POWER-BLOWER MOTOR..............................................12435 RELAY-CONDENSER FAN....................................................12439 RESISTOR-BLOWER MOTOR..................................................12442 SENSOR-AMBIENT AIR TEMPERATURE.........................................12446 SENSOR-EVAPORATOR TEMPERATURE..........................................12448 SENSOR-INFRARED........................................................12452 TRANSDUCER-A/C PRESSURE-FRONT..........................................12453 CONTROLS - REAR............................................................12457 CLUTCH-A/C COMPRESSOR..................................................12457 CONTROL-A/C-HEATER.....................................................12467 SENSOR-EVAPORATOR TEMPERATURE..........................................12468 TRANSDUCER-A/C PRESSURE-REAR...........................................12472 RELAY-CONDENSER FAN....................................................12476 MODULE-POWER-BLOWER MOTOR..............................................12478 ACTUATOR-RECIRCULATION DOOR............................................12481 DISTRIBUTION - FRONT.......................................................12486 DUCT-INSTRUMENT PANEL..................................................12486 FILTER-PARTICULATE AIR.................................................12489 HOUSING-HVAC...........................................................12491 MOTOR-BLOWER...........................................................12497 OUTLET-AIR.............................................................12501 DISTRIBUTION - REAR........................................................12507 DUCT-DISTRIBUTION......................................................12507 FILTER-PARTICULATE AIR.................................................12509 HOUSING-EVAPORATOR.....................................................12511 MOTOR-BLOWER...........................................................12515 OUTLET-AIR.............................................................12518 PLUMBING - FRONT...........................................................12519 PLUMBING - FRONT.......................................................12519 COMPRESSOR-A/C.........................................................12530 CONDENSER-A/C..........................................................12541 CORE-HEATER............................................................12547 CORE-VALVE-SERVICE PORT................................................12551 EVAPORATOR-A/C.........................................................12555 FAN-A/C CONDENSER......................................................12558 LINE-A/C DISCHARGE.....................................................12562 LINE-A/C LIQUID........................................................12565 LINE-A/C SUCTION.......................................................12576 OIL-A/C REFRIGERANT....................................................12587 PUMP-COOLANT-ELECTRIC..................................................12591 RECEIVER/DRIER-A/C.....................................................12594 REFRIGERANT-A/C........................................................12598 VALVE-A/C EXPANSION....................................................12600 PLUMBING - REAR............................................................12605 COMPRESSOR-A/C.........................................................12605 CONDENSER-A/C..........................................................12612 EVAPORATOR-A/C.........................................................12619 FAN-A/C CONDENSER......................................................12623 LINES-A/C INTERIOR.....................................................12626 LINES-A/C UNDERBODY....................................................12638 RECEIVER/DRIER-A/C.....................................................12645 VALVE-A/C EXPANSION....................................................12649 CORE-VALVE-SERVICE PORT................................................12654 HEATER-CABIN...............................................................12655 HEATER-AUXILIARY.......................................................12655 HEATER UNIT-BOOSTER....................................................12657 HEATER UNIT-PTC........................................................12661 25 - EMISSIONS CONTROL.............................................................12665 EMISSIONS CONTROL..............................................................12667 DESCRIPTION................................................................12667 DESCRIPTION - MONITORED COMPONENTS.....................................12667 DESCRIPTION - NON-MONITORED CIRCUITS...................................12672 DESCRIPTION - SCAN TOOL STATE DISPLAY TEST MODE........................12673 DESCRIPTION - HIGH AND LOW LIMITS......................................12673 DESCRIPTION - TRIP DEFINITION..........................................12674 OPERATION – EMISSION CONTROLS..........................................12675 EXHAUST GAS RECIRCULATION - 3.0L DIESEL........................................12676 VALVE - EGR 3.0L DIESEL....................................................12676 REMOVAL – 3.0L DIESEL..................................................12676 INSTALLATION – 3.0L DIESEL.............................................12678 SENSOR - EGR BACK PRESSURE.................................................12679 DESCRIPTION............................................................12679 OPERATION..............................................................12679 REMOVAL................................................................12679 INSTALLATION...........................................................12680 VALVE COOLER - EGR.........................................................12681 REMOVAL................................................................12681 INSTALLATION...........................................................12684 TUBE - EGR.................................................................12689 REMOVAL................................................................12689 INSTALLATION...........................................................12691 SENSOR-EGR TEMPERATURE.....................................................12693 REMOVAL................................................................12693 INSTALLATION...........................................................12694 VALVE-EGR AIR FLOW CONTROL.................................................12695 DESCRIPTION............................................................12695 OPERATION..............................................................12695 REMOVAL................................................................12695 INSTALLATION...........................................................12697 EVAPORATIVE EMISSIONS - 3.5L GAS...............................................12700 EVAPORATIVE EMISSIONS - 3.5L GAS...........................................12700 DESCRIPTION - EVAPORATION CONTROL SYSTEM...............................12700 CRANKCASE VENT HOSE........................................................12701 DESCRIPTION............................................................12701 CCV RESTRICTER.............................................................12703 DESCRIPTION............................................................12703 EVAP/PURGE SOLENOID........................................................12706 DESCRIPTION............................................................12706 OPERATION..............................................................12707 REMOVAL................................................................12707 INSTALLATION...........................................................12707 FUEL FILLER CAP............................................................12708 DESCRIPTION............................................................12708 OPERATION..............................................................12708 VAPOR CANISTER.............................................................12709 DESCRIPTION............................................................12709 OPERATION..............................................................12710 REMOVAL................................................................12710 INSTALLATION...........................................................12711 AIR INJECTION - 3.5L GAS.......................................................12712 AIR INJECTION - 3.5L GAS...................................................12712 DESCRIPTION............................................................12712 OPERATION..............................................................12713 SPECIFICATIONS.........................................................12714 AIR PUMP...................................................................12715 REMOVAL................................................................12715 INSTALLATION...........................................................12716 SWITCHOVER SOLENOID........................................................12718 REMOVAL................................................................12718 INSTALLATION...........................................................12718 SWITCHOVER VALVE...........................................................12719 REMOVAL................................................................12719 INSTALLATION...........................................................12721 ON-BOARD DIAGNOSTICS...........................................................12723 ON-BOARD DIAGNOSTICS.......................................................12723 DESCRIPTION............................................................12723 OPERATION..............................................................12726 TASK MANAGER...............................................................12729 DESCRIPTION............................................................12729 OPERATION - TASK MANAGER...............................................12729 MIL ILLUMINATION.......................................................12729 DIAGNOSTIC TROUBLE CODES (DTCS)........................................12729 PRIORITIES.............................................................12729 DTC AUTOMATIC ERASURE..................................................12730 TRIP INDICATOR.........................................................12730 FREEZE FRAME DATA STORAGE..............................................12732
DESCRIPTION:
Sprinter 2007 Service Information Manual – PDF DOWNLOAD
OPERATION:
AUTOMATIC TRANSMISSION FLUID:
- The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components.
- The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent.
- Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.
SAFETY PRECAUTIONS:
1. Secure loose and protruding parts.
2. Always use a safety chain system that is independent of the lifting and towing equipment.
3. Do not allow towing equipment to contact the disabled vehicle’s fuel tank.
4. Do not allow anyone under the disabled vehicle while it is lifted by the towing device.
5. Do not allow passengers to ride in a vehicle being towed.
6. Always observe state and local laws regarding towing regulations.
7. Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians
or other motorists.
8. Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive
shafts or a non-reinforced frame hole.
9. Remove exhaust pipe tips that interfere with the tow sling and crossbar
10. Padding should be placed between the tow sling/crossbar and any painted surfaces
11. When placing tow hooks on the rear axle, position them so they do not damage the brake
tubing or hoses
12. Do not tow the vehicle by connecting to the front or rear shock absorbers
13. Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device
to transport a loaded vehicle
G.B 07/04/25
