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2005 Sprinter
Mercedes-Benz 2005 Sprinter User Manual
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OPENING
DIMENSIONS
SPECIFICA
TIONS
BODY
OPENING
DIMENSIONS
INDEX
DESCRIPTION
FIGURE
WINDSHIELD
OPENING
4
Fig.
4
WINDSHIELD
OPENING
23
-
90
BODY
STRUCTURE
VA
1127
1129
Table of Contents
Default Chapter
1
Group Tab Locator
1
Description
3
Table of Contents
3
Vehicle Identification Number
3
Vin Decoding Information
3
Fastener Identification
4
International Control and Display Symbols
4
International Symbols
4
Number
4
Bolt Markings and Torque Values
5
Bolt Markings and Torque - Metric
5
How to Determine Bolt Strength
6
Conversion Formulas and Equivalent Values
7
Fastener Usage
7
Metric System
7
Threaded Hole Repair
7
Specified Torque for Standard Bolts
9
Torque References
9
Table of Contents
11
Lubrication & Maintenance
11
Description - Engine Coolant
11
Fluid Types
11
Description - Fuel Requirements - Diesel Engine
11
Fluid Types
12
Coolant Performance
12
Description - Hoat Coolant
12
Propylene-Glycol Mixtures
12
Coolant Selection and Additives
13
Description - Brake Fluid
13
Description - Engine Oil - Diesel Engines
13
Description - Power Steering Fluid
13
Description - Automatic Transmission Fluid - Nag1
14
Fluid Capacities
14
Specifications - Fluid Capacities
14
Fluid Types
14
Fluid Fill/Check Locations
14
Inspection - Fluid Fill/Check
14
Floor Jack
15
Parts & Lubricant Recommendation Standard Procedure - Parts & Lubricant Recommendations
15
Standard Procedure - Hoisting
15
Suspension
15
Jump Starting
16
Standard Procedure - Jump Starting
16
To Jump Start a Disabled Vehicle:
16
Ground Clearance
17
Maintenance Schedules Description
17
Ramp Angle
17
Safety Precautions
17
Engine Oil Change and Filter Replacement
18
Maintenance - with Assyst Maintenance Computer
18
Number
18
Regular Check-Ups
18
Special Maintenance Requirements
18
Additional Maintenance Work
19
Additional Maintenance Work after Years
19
International Symbols Description
19
Suspension
21
Front Suspension
22
Special Tool Cross Reference Chart
22
Special Tools Front Suspension
22
Specifications - Torque Chart
22
Ball Joint Separator
23
Installation
23
Lca Bushing Removal
23
Leaf Spring Wedge Block
23
Diagnosis and Testing
24
Front Wheel Hub with Single Rear Wheels (Srw)
24
Hub / Bearing
24
Lca Bushing Install
24
Measuring & Adjusting Wheel Bearing
24
Removal
24
Front Wheel Hub with Dual Rear Wheels (Drw)
25
Installation
25
Knuckle Removal
25
Steering Knuckle
25
Front
26
Installation
26
Lower Ball Joint Removal
26
Lower Control Arm Removal
26
Spring Removal
27
Front Spring
28
Installation
28
Spring Clamp Plates Removal
28
Installation
29
Operation
29
Removal
29
Spring Stop Plates Removal
29
Stabilizer Bar Description
29
Stabilizer Link
29
Strut Installation
30
Strut Removal
30
Diagnosis and Testing - Spring and Shock
31
Rear
31
Rear Description
32
Specifications - Torque Chart
32
Spring and Shock Absorber
32
Diagnosis and Testing - Shock
33
Shock
33
Installation
33
Removal
33
Shock Absorber
33
Spring Description
34
Installation Installation - (Srw)
34
Rear
34
Removal - (Drw)
34
Removal Removal - (Srw)
34
Spring Installation
34
Spring Operation
34
Spring Removal
34
Installation
35
Installation - (Drw)
35
Spring Shackle Removal
35
Stabilizer Bar Removal
35
Stabilizer Link Installation
36
Stabilizer Link Removal
36
Diagnosis and Testing - Pre-Alignment Inspection
37
Wheel Alignment
37
Wheel Alignment Measurements
37
Suspension and Steering System Diagnosis
38
Front Specifications
39
Rear Specifications
39
Standard Procedure - Toe Adjustment
39
Differential & Driveline
41
Propeller Shaft
41
Driveline Vibration
42
Propeller Shaft Balance
42
Clamp Screw
43
Propeller Shaft Angle
43
Propeller Shaft Runout
43
Runout Specifications
43
Standard Procedure
43
Two/Three-Piece Propeller Shaft
44
Universal Joint Angle Example
44
Special Tool Cross-Reference Chart
45
Specifications
45
Propeller Shaft
46
Alignment Marks
46
Alignment Marks 3 Piece Shaft
46
Propeller Shaft
46
Propeller Shaft Removal
46
Piece Propeller Shaft
47
Rear Axle
47
Center Bearing
48
Removal
48
Installation
49
Bearing Noise
50
Gear Noise
50
Rear Axle
50
Driveline Snap
51
Low Speed Knock
51
Removal
51
Standard Procedure - Drain and Fill
51
Vibration
51
Installation
52
Single Rear Wheel Axle
52
Axle Specifications
53
Dual Rear Wheel Axle
53
Special Tools
54
Axle Shafts
55
Installation
55
Removal
55
Axle Shafts
55
Axle Shaft and Tube
56
Bearing Cap Bolts
56
Rear Axle
56
Axle Bearings/Seals Removal
57
Bearing Nut and Locking Ring
57
Installation
57
Bearing Nut Wrench
57
Locking Ring
57
Axle Shaft Assembly
58
Bearings and Race
58
Pressing Bearing
58
Seal Installer
58
Axle Shafts - Dual Rear Wheels
59
Bearing and Shaft
59
Installation
59
Pressing Axle Shaft
59
Removal
59
Axle Hub Bearings/Seals
60
Hub Nuts
60
Installation
60
Removal
60
Inner Hub Nut
61
Locking Plate
61
Outer Hub Bearing
61
Thrust Washer
61
Collared Nut
62
Flange Puller
62
Installation
62
Pinion Seal Removal
62
Bend Collar of Nut
63
Fill Plug
63
Pinion Seal Installer
63
Brakes
65
Diagnosis and Testing - Base Brake System
66
Brakes - Base
66
Brakes - Base
66
Preliminary Brake Check
66
Low Pedal
67
Pedal Falls Away
67
Road Testing
67
Spongy Pedal
67
Brake Chatter
68
Brake Noises
68
Brake Squeak/Squeal
68
Standard Procedure - Manual
68
Standard Procedure
68
Thump/Clunk Noise
68
Bleed Hose Setup
69
Hydraulic/Mechanical
69
Specifications - Torque Chart
69
Standard Procedure - Pressure Bleeding
69
Base Brake
70
Brakes
71
Special Tools
71
Brake Lines
72
ISO Flaring
72
Standard Procedure - Double Inverted Flaring
72
Standard Procedure - Iso Flaring
72
Brake Pads/Shoes
73
Front Brake Pads
73
Front Disc Brake Pads with Dual Rear Wheels
73
Removal
73
Removal - Front (Drw)
73
Removal - Front (Srw)
73
Removal - Rear (15" Wheels) (Srw)
73
Removal - Rear (16" Wheels) (Srw)
73
Installation
74
Installation - Front (Srw)
74
Rear Disc Brake Pads - 15 Wheels
74
Rear Disc Brake Pads - 16 Wheels
74
Rear Disc Brake Pads with Dual Rear Wheels
74
Removal - Rear (Drw)
74
Disc Brake Calipers
75
Front Disc Brake Caliper
75
Installation - Front (Drw)
75
Installation - Rear (16" Wheels) (Srw)
75
Installation - Rear (Drw)
75
Removal
75
Removal - Front (Srw)
75
Brakes - Base
76
Disc Brake Caliper with Dual Rear Wheels
76
Installation
76
Installation - Front (Srw)
76
Rear Disc Brake Caliper
76
Removal - Front (Drw)
76
Removal - Rear (Drw)
76
Removal - Rear (Srw)
76
Disc Brake Caliper Adapter
77
Installation - Front (Drw)
77
Installation - Rear (Drw)
77
Installation - Rear (Srw)
77
Rear Disc Brake Caliper with Dual Rear Wheels
77
Removal
77
Removal - Front
77
Removal - Rear
77
Diagnosis and Testing - Brake Fluid Contamination
78
Standard Procedure - Brake Fluid Level
78
Hydraulic/Mechanical
78
Fluid Level Typical
78
Installation
78
Installation - Front
78
Installation - Rear
78
Specifications
78
Alb Controller
79
Alb Lever
79
Alb Lever Deflection
79
Fluid Reservoir Removal
79
Installation
79
Removal
79
Adjustments Adjustment
80
Alb Controller Adjuster Nut
80
Diagnosis and Testing - Master
80
Diagnosis and Testing - Master Cylinder/Power Booster
80
Master Cylinder
80
Power Booster Check Valve Test
81
Power Booster Vacuum Test
81
Removal
81
Standard Procedure - Master Cylinder Bleeding
81
Vacuum Check Valve and Seal
81
Brake Pedal
82
Installation
82
Pedal Removal
82
Master Cylinder (Drw)
82
Rotors
83
Front Disc Brake Rotor
84
Front Disc Brake Rotor with Dual Rear Wheels
84
Rear Disc Brake Rotor
84
Removal - Front (Drw)
84
Removal - Rear (Drw)
84
Removal - Rear (Srw)
84
Installation
85
Installation - Front (Drw)
85
Installation - Front (Srw)
85
Installation - Rear (Drw)
85
Installation - Rear (Srw)
85
Rear Disc Brake Rotor with Dual Rear Wheels
85
Installation - Rear
86
Parking Brake
86
Removal - Rear
86
Specifications
86
Support Plate
86
Torque Chart
86
Cable Tensioner
87
Park Brake
87
Parking Brake
86
Control Cable Lock
87
Special Tools
87
Cables
88
Front Park Brake Cable at Lever
88
Installation
88
Installation - Front
88
Rear Park Brake Cable Remove / Install
88
Removal
88
Removal - Front
88
Removal - Rear
88
Adjustment - Parking Brake Cables
89
Installation - Rear
89
Park Brake Adjuster
89
Shoes
90
Hand Brake Lever
90
Installation
90
Lever Removal
90
Park Brake Shoes
90
Removal
90
Removal - (Drw)
90
Removal - (Srw)
90
Adjustments Adjustment
91
Cleaning - Rear Drum in hat Brake
91
Installation
91
Installation - (Drw)
91
Installation - (Srw)
91
Park Brake Shoes with Dual Rear Wheels
91
Adjusting Rear Park Brake Shoes
92
Star Wheel Adjuster
92
Brakes - Abs
93
Brakes - Abs
94
Installation
94
Operation of the Wheel Speed Sensor
94
Rear Wheel Speed Sensors
94
Removal
94
Hcu (Hydraulic Control Unit)
95
Description
95
Hydraulic Control Unit (Abs)
95
Installation
95
Installation
96
Tone Wheel Removal
95
Cooling
97
Diagnosis and Testing - Preliminary Checks
97
Engine Cooling System Overheating
97
Operation—Cooling System
97
Cooling System Diagnosis—Diesel Engine
98
Accessory Drive
101
Belt Tensioners
101
Drive Belts
101
Visual Diagnosis
101
Accessory Drive Belt Diagnosis Chart
102
Noise Diagnosis
102
Accessory Drive Belt Routing
104
Drive Belt Tensioner
104
Coolant
105
Diagnosis and Testing - Cooling System Leaks
106
Engine
105
Coolant
106
Pressure Tester Method
106
Pressure Testing
106
Ultraviolet Light Method
106
Combustion Leakage Test - Without Pressure Tester
107
Internal Leakage Inspection
107
Standard Procedure - Adding Additional Coolant
107
Draining Coolant System
108
Standard Procedure - Draining Cooling System
108
Standard Procedure - Refilling Cooling System
108
Coolant Level Sensor Removal
109
Installation
109
Radiator Fan Removal
109
Description
110
Engine Block Heater Removal
110
Engine Coolant Temp Sensor
110
Installation
110
Engine Coolant Temperature Sensor
111
Installation
111
Removal
111
Engine Coolant Thermostat
111
Fan Drive Viscous Clutch Removal
112
Installation
112
Radiator Removal
112
Removal
112
Thermostat Housing Assembly
112
Installation
113
Radiator Assembly
113
Description
114
Operation
114
Radiator and Fan Shroud
114
Radiator Pressure Cap
114
Radiator Pressure Cap - Typical
114
Diagnosis and Testing - Radiator Pressure Cap
115
Removal
115
Water Pump
115
Installation
116
Antenna Body & Cable
117
Audio/Video
117
Instrument Panel Antenna Cable
117
Instrument Panel Speaker
118
Radio
118
Speaker
118
Chime/Buzzer
119
Diagnosis and Testing - Chime Warning System
120
Central Timer Module
121
Electronic Control Modules
121
Diagnosis and Testing - Central Timer Module
122
Hard Wired Inputs
122
Hard Wired Outputs
122
Messaging
122
Operation
122
Removal
122
Central Timer Module
123
Controller Antilock Brake
123
Description
123
Engine Control Module
123
Installation
123
Removal
123
Ecm
124
Installation
124
Removal
124
Description
125
Operation
125
Transmission Control Module
125
ATF Temperature Sensor
126
Brake Transmission Shift Interlock (Btsi)
126
Selector Lever Position
126
Tcm Signals
126
Adaptation
127
Downshift Safety
127
Driving Style Adaptation
127
Fill Pressure Adaptation
127
Controller Modes of Operation
128
Standard Procedure - Tcm Adaptation
128
Permanent Limp-In Mode
128
Under Voltage Limp-In Mode
128
Battery System
129
Engine Systems
129
Battery System
130
Battery Holddown
130
Battery Tray
130
Charging System
130
Diagnosis and Testing - Battery System
130
Micro 420 Battery Tester
130
Operation
130
Battery System Diagnosis
131
System
132
Abnormal Battery Discharging
133
Battery Cleaning - Typical
133
Clean Battery Cable Terminal Clamp - Typical
133
Battery Description
134
Battery System Special Tools
134
Special Tools
134
Diagnosis and Testing - Battery
135
Operation
135
Standard Procedure - Battery Charging
136
Battery Charging Time Table
137
Charging a Completely Discharged Battery
137
Charging Time Required
137
Voltmeter
137
Open Circuit Voltage Table
138
Standard Procedure - Ignition-Off Draw Test
138
Standard Procedure - Open-Circuit Voltage Test
138
Testing Open-Circuit Voltage
138
Battery Testing
139
Standard Procedure - Using Micro Battery Tester
139
Battery Cell Caps
140
Battery System
140
Hook Inside Battery Cap Holes
140
Standard Procedure - Checking Battery Electrolyte Level
140
Under Hood Battery Removal
140
Auxiliary Battery Installation
141
Auxiliary Battery Removal
141
Under Hood Battery Installation
141
Battery Cables
142
Battery Holddown Description
142
Description
142
Diagnosis and Testing - Battery Cables
142
Installation
142
Operation
142
Removal
142
Voltage Drop Test
142
Test Battery Negative Connection Resistance
143
Battery Tray Description
144
Installation
144
Operation
144
Removal
144
Charging System
145
Charging System
146
Generator Description
146
Generator Mounting
146
Installation
146
Operation
146
Removal
146
Description
147
Diagnosis and Testing - Generator Decoupler
147
Generator Decoupler Pulley
147
Operation
147
End of Generator Shaft (Hex)
148
Generator Decoupler Pulley (Ina)
148
Generator Decoupler Pulley (Litens)
148
INA Decoupler
148
Removal
148
Decoupler Removal (Ina-Hex)
149
Decoupler Removal (Ina-Splined)
149
End of Generator Shaft (Splined)
149
Installation
149
Litens Decoupler
149
Decoupler Installation (Ina Splined)
150
Decoupler Installation (Ina-Hex)
150
Decoupler Removal (Litens)
150
Decoupler Installation
151
Voltage Regulator Description
151
Starting System
152
Diagnosis and Testing - Starting System
153
Cold Cranking Test
154
Volts-Amps Tester Connections
154
Feed Circuit Test
155
Control Circuit Testing
156
Test Ground Circuit Resistance
156
Test Positive Battery Cable
156
Test Starter Ground - Typical
156
Diagnosis and Testing - Starter Motor
157
Starter and Solenoid Location
158
Starter Removal/Installation
158
Starter Solenoid
158
Fuse / Relay Block
159
Starter Motor Relay
159
Wiring Trough - for Starter Removal
159
Fuse / Relay Block Cover
160
Heated Seats
161
Heated Systems
161
Diagnosis and Testing - Driver Heated Seat Switch
162
Diagnosis and Testing - Heated Seats
162
Driver Heated Seat Switch Description
162
Operation
162
Diagnosis and Testing - Heated Seat Element
163
Heated Seat Element Description
163
Installation
163
Operation
163
Removal
163
Diagnosis and Testing - Heated Seat Relay
164
Diagnosis and Testing - Heated Seat Sensor
164
Heated Seat Relay Description
164
Heated Seat Sensor Description
164
Installation
164
Operation
164
Removal
164
Description
165
Diagnosis and Testing - Passenger Heated Seat Switch
165
Installation
165
Operation
165
Passenger Heated Seat Switch
165
Removal
165
Horn
167
Glow Plug
169
Glow Plug Pliers
169
Ignition Control
169
Diagnosis and Testing - Glow Plug Relays
170
Glow Plug Relay
170
Instrument Cluster
171
Instrument Cluster Components
172
Instrument Cluster Description
172
Gauges & Indicators
174
Gauges
175
Cluster Illumination
176
Diagnosis and Testing - Instrument Cluster
177
Indicators
176
Input and Output Circuits
176
Instrument Cluster
177
Grounds
177
Cluster Connectors
178
Instrument Cluster Remove/Install
178
Rke/Immobilizer Module
178
Abs Indicator
179
Description
179
Installation
179
Operation
179
Airbag Indicator
180
Description
180
Operation
180
Ambient Temperature Indicator
181
Brake/Park Brake Indicator Description
181
Operation
181
Brake Wear Indicator
182
Description
182
Operation
182
Charging Indicator
183
Clock
183
Description
183
Operation
183
Coolant Low Indicator
184
Description
184
Operation
184
Description
185
Engine Temperature Gauge
185
Fuel Filter Clogged Indicator
185
Operation
185
Clock
184
Fuel System
185
Description
186
Fuel Gauge
186
Operation
186
Description
187
Gear Selector Indicator
187
High Beam Indicator
187
Operation
187
Description
188
Low Fuel Indicator
188
Low Oil Level Indicator
188
Operation
188
Description
189
Maintenance Indicator
189
Operation
189
Description
190
Malfunction Indicator Lamp (Mil)
190
Multi-Function Indicator
190
Operation
190
Odometer
191
Speedometer
192
Operation
193
Speedometer
193
Description
194
Operation
194
Traction Control Indicator
194
Description
195
Operation
195
Traction Control Malfunction Indicator
195
Turn Signal Indicator
195
Description
196
Operation
196
Steering
196
Wait-To-Start Indicator
196
Operation
197
Washer Fluid Indicator
197
Water-In-Fuel Indicator Description
197
Operation
198
Lamps
199
Lamps/Lighting - Exterior
199
Lamps/Lighting - Exterior
201
Backup Lamps
201
Brake Lamps
201
Daytime Running Lamps
201
Operation
201
Transmission
201
Front Fog Lamps
202
Hazard Warning Lamps
202
Headlamps
202
Park Lamps
202
Backup Lamp Bulb
203
Bulb Specifications
203
Removal
203
Specifications - Lamps/Lighting - Exterior
203
Tail Lamp Socket Plate Remove/Install
203
Body
204
Brake Lamp Switch
204
Brake Lamp Switch Location
204
Brake Lamp Switch Remove/Install
204
Installation
204
Removal
204
Brake/Park Lamp Bulb
205
Center High Mounted Stop Lamp Bulb
205
CHMSL Bulb Remove/Install
205
Installation
205
Removal
205
Tail Lamp Bulb Remove/Install
205
Center High Mounted Stop Lamp un
206
Clearance Lamp Bulb
206
Clearance Lamp Unit
206
Clearance Lamp Unit Remove/Install
206
Installation
206
Removal
206
Daytime Running Lamp Relay
207
Installation
207
Removal
207
Seat Riser Cover
207
Fog Lamp Bulb Remove/Install
208
Fog Lamp Relay
208
Front Lamp Unit Bulbs Remove/Install
208
Installation
208
Removal
208
Fog Lamp Switch
209
Installation
209
Removal
209
Adjustment - Front Lamp Unit
210
Fog Lamp Switch Remove/Install
210
Front Lamp Unit
210
Installation
210
Lamps/Lighting - Interior
210
Removal
210
Vehicle Preparation for Front Lamp Unit Alignment
210
Fog Lamp Cut-Off Pattern
211
Front Lamp Unit Adjusting Screws
211
Front Lamp Unit Alignment
211
Low Beam Headlamp Cut-Off Pattern
211
Front Position Lamp Bulb Removal
212
Front Turn/Park/Side Marker Lamp
212
Installation
212
Position Lamp Bulb Remove/Install
212
Removal
212
Headlamp Leveling Motor
213
Installation
213
Removal
213
Headlamp Leveling Motor Remove/Install
214
Headlamp Leveling Switch Remove/Install
214
Installation
214
High Beam Headlamp Bulb Removal
215
High Beam Headlamp Bulb Remove/Install
215
Installation
215
License Plate Lamp Bulb
215
Installation
216
License Plate Lamp Unit Remove/Install
216
Low Beam Headlamp Bulb
216
Removal
216
Installation
217
Multi-Function Switch Removal
217
Installation
218
Park Brake Switch
218
Park Brake Switch Remove/Install
218
Removal
218
Rear Side Marker Lamp Bulb
219
Rear Turn Lamp Bulb
219
Repeater Lamp Bulb
220
Repeater Lamp Unit
220
Tail Lamp Unit
221
Tail Lamp Unit Remove/Install
221
Turn Signal Relay
222
Lamps/Lighting - Interior
223
Lamps/Lighting - Interior
224
Class
224
Exterior Lighting Circuit
224
Interior Lighting Circuit
224
Operation
224
Specifications - Interior Lighting
224
Van Models
224
Ash Receiver/Cigar Lighter Lamp Unit
225
Cargo/Dome Lamp Bulb
225
Installation
225
Removal
225
Cargo Lamp Switch
226
Cargo/Dome Lamp Unit
226
Installation
226
Removal
226
Removal - Bulkhead
226
Removal - Instrument Panel
226
Removal - Rear Pillar
226
Dome/Reading Lamp Bulb
227
Installation - Bulkhead
227
Installation - Instrument Panel
227
Installation - Rear Pillar
227
Removal
227
Dome Lamp/Intrusion Sensor Bulb
228
Dome/Reading Lamp Unit Removal
228
Installation
228
Dome Lamp/Intrusion Sensor
229
Door Jamb Switch
229
Entry/Exit Lamp Bulb
229
Installation
229
Removal
229
Entry/Exit Lamp Bulb Remove/Install
230
Entry/Exit Lamp Unit
230
Entry/Exit Lamp Unit Remove/Install
230
Installation
230
Removal
230
Installation
231
Time Delay Relay
230
Central Locking
233
Door Lock Motor
233
Power Locks
233
Power Systems
233
Master Lock Switch
234
Power Lock Switch
234
Remote Keyless Entry Transmitter
234
Diagnosis and Testing - Power Mirror Switch
235
Mirror Switch Test
235
Power Mirror Switch
235
Power Mirrors
235
Power Window Switch
237
Power Windows
237
Window Motor
237
Window Switch
237
Restraints
239
Restraints Description
240
Supplemental Restraint System
240
Active Restraints
241
Passive Restraints
241
SRS Logo
241
Operation
242
Diagnosis and Testing - Supplemental Restraint System
243
Warnings - Restraint System
243
Restraints
242
Standard Procedure - Handling Non-Deployed Supplemental Restraints
244
Standard Procedure - Service after a Supplemental Restraint Deployment
244
Supplemental Restraint Storage
244
Standard Procedure - Verification Test
245
Vacuum Heater and A/C Outlets - Typical
245
Wear Safety Glasses and Rubber Gloves
245
ACM Bracket
246
Airbag Control Module
246
Description
246
Way Data Link Connector
246
Operation
247
Airbag Control Module Location
248
Removal
248
ACM Cover
249
Airbag Control Module Remove/Install
249
Installation
249
Control Module Bracket
249
Clockspring
250
ACM Cover Base Plate
250
Description
250
Operation
251
Standard Procedure - Clockspring Centering
251
Clockspring Centering
252
Clockspring Remove/Install
253
Clockspring Pigtail Routing
254
Driver Airbag
254
Driver Airbag Housing
254
Driver Airbag Trim Cover
254
Driver Airbag Operation
255
Driver Airbag Remove/Install
256
Installation
256
Removal
256
Front Seat Belt & Retractor Removal
257
Operation
257
Front Seat Belt Lower Anchor
258
Front Seat Belt Turning Loop
258
Turning Loop Height Adjuster
258
Front Seat Belt Retractor
259
Installation
259
Front Seat Belt Buckle
260
Front Seat Belt Buckle Remove/Install
260
Removal
260
Description
261
Installation
261
Passenger Airbag
261
Passenger Airbag Door
261
Passenger Airbag Unit
261
Operation
262
Removal
262
Passenger Airbag Remove/Install
263
Installation
264
Installation
265
Passenger Airbag Bracket
265
Passenger Airbag Bracket Remove/Install
265
Rear Seat Belt & Retractor Removal
265
Left Outboard Rear Seat Belt Lower Anchor
266
Rear Seat Belt Turning Loop
266
Right Outboard or Center Rear Seat Belt Lower Anchor
266
Turning Loop Trim Cover
266
Installation
267
Rear Seat Belt Buckle
267
Rear Seat Belt Retractor
267
Removal - Inboard
267
Inboard Rear Seat Belt Buckle
268
Installation - Inboard
268
Outboard Rear Seat Belt Buckle
268
Removal - Outboard
268
Description
269
Installation - Outboard
269
Operation
269
Seat Belt Switch
269
Seat Belt Tensioner
269
Seat Belt Tensioner Operation
270
Removal
271
Seat Belt Turning Loop Adjuster
271
Installation
272
Seat Belt Turning Loop Adjuster Remove/Install
272
Speed Control
273
Speed Control Switch Functions
274
Cable
275
Servo
275
Speed Control Switch Location
275
Switch
275
Diagnosis and Testing - Vehicle Theft Security
277
Description
278
Installation
278
Intrusion Sensor Removal
278
Security System Module Removal
278
Sentry Key Remote Entry Module Description
278
Vehicle Theft Security
277
Vehicle Theft Security
278
Operation
279
Remote Keyless Entry (Rke)
279
Removal
279
Sentry Key Immobilizer
279
Sentry Key Remote Entry Module
279
Installation
280
Sentry Key Remote Entry Module Transponder Ring
280
Siren Removal
280
Operation
281
Transponder Key Description
281
Wipers/Washers
283
Wiper & Washer System
284
Wipers/Washers
285
Operating Modes
285
Windshield Wiper/Washer Switch
286
Cleaning - Wiper & Washer System
287
Diagnosis and Testing - Wiper & Washer System
287
Washer System
287
Wiper System
287
Inspection - Wiper & Washer System
288
Wiper Blade Inspection
288
Check Valve Description
289
Description
289
Installation
289
Operation
289
Removal
289
Washer Fluid Level Switch
289
Operation
290
Washer Hoses/Tubes Description
290
Washer Plumbing
290
Description
291
Installation
291
Operation
291
Removal
291
Washer Nozzle
291
Washer Nozzle Remove/Install
291
Washer Pump/Motor
291
Installation
292
Operation
292
Removal
292
Washer Pump/Motor Remove/Install
292
Description
293
Heat Shield & Air Cleaner Housing
293
Operation
293
Removal
293
Washer Reservoir
293
Installation
294
Washer Reservoir Mounting
294
Washer Reservoir Remove/Install
294
Wiper Arm Description
295
Installation
296
Operation
296
Removal
296
Wiper Arm Puller - Typical
296
Wiper Arm Remove/Install
296
Description
297
Operation
297
Wiper Blade
297
Installation
298
Removal
298
Wiper Blade Remove/Install
298
Operation
299
Removal
299
Wiper Linkage Description
299
Wiper Linkage Module
299
Ventilation Housing
300
Wiper Linkage Module Remove/Install
300
Description
301
Installation
301
Operation
301
Removal
301
Wiper Motor
301
Wiper Motor Remove/Install
302
Wiper Relay Description
302
Operation
303
Installation
304
Removal
304
Wiring
305
8W-01 Wiring Diagram Information
307
Description - How to Use Wiring Diagrams
307
Symbols
307
Wiring Diagram Information
307
Description - Circuit Information
311
Description - Connector, Ground and Splice Information
311
Description - Section Identification and Information
311
Wiring Section Chart
311
Diagnosis and Testing - Wiring Harness
312
Warnings - General
312
Intermittent and Poor Connections
313
Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
313
Standard Procedure - Testing of Voltage Potential
313
Removal
314
Standard Procedure - Testing for Ashort to Ground on Fuses Powering Several Loads
314
Standard Procedure - Testing for Avoltage Drop
314
Troubleshooting Wiring Problems
313
Diode
315
Diode Identification
315
Installation
315
Removal of Dress Cover
315
Testing for Voltage Drop
315
Wire
316
Standard Procedure - Wire Splicing
316
Terminal
316
Heat Shrink Tube
316
Installation
316
Solder Splice
316
Splice Band
316
8W-02 Component Index
317
8W-10 Power Distribution
319
8W-11 Fuse Block
353
Fuse/Relay Block
354
Relay Block
355
8W-15 Ground Distribution
393
8W-18 Bus Communications
421
8W-20 Charging System
427
8W-21 Starting System
433
8W-30 Fuel/Ignition System
435
8W-31 Transmission Control System
453
8W-33 Vehicle Speed Control
463
8W-35 Antilock Brakes
467
8W-39 Vehicle Theft Security System
475
8W-40 Instrument Cluster
489
8W-41 Horn/Cigar Lighter
497
8W-42 Air Conditioner/Heater
501
8W-43 Airbag System
525
8W-44 Interior Lighting
529
8W-45 Central Timer Module
541
8W-47 Audio System
549
8W-48 Rear Window Defogger
555
8W-50 Front Lighting
561
8W-51 Rear Lighting
577
8W-52 Turn Signals
587
8W-53 Wipers
593
8W-54 Trailer Tow
597
8W-55 Navigation/Telecommunications
601
8W-60 Power Windows
605
8W-61 Power Door Locks
609
8W-62 Power Mirrors
617
8W-63 Power Seats
621
8W-70 Splice Information
625
8W-80 Connector Pin-Outs
627
A/C Control Module-Roof - Black
630
A/C Fan Switch
630
A/C Switch-Roof
630
Accelerator Pedal Position Sensor - Black
631
Air Outlet Temperature Sensor
631
Airbag Control Module - Yellow
631
Airbag Squib-Driver
631
Airbag Squib-Passenger - Yellow
632
Ambient Temperature Sensor
632
Ash Receiver Lamp
632
Automatic Temperature Control Module C1 - Brown
632
Automatic Temperature Control Module C2
633
Auxiliary Heater Relay (in Relay Block)
635
Auxiliary Heater Switch
635
Battery Relay-Auxiliary - Black
635
Blower Motor Resistor Block
635
Blower Motor Resistor Block C2
636
Blower Motor Resistor Block C3
636
Blower Motor-Front - Black
636
Body Plug Connector
636
Boost Pressure Solenoid - Black
637
Brake Fluid Level Switch
637
Brake Lamp Switch C2 - Black
637
Brake Wear Sensor-Left Front
637
Brake Wear Sensor-Left Rear
638
Brake Wear Sensor-Right Front
638
Brake Wear Sensor-Right Rear
638
C100 - (Main Body Side)
638
C101 - Yellow (Engine Side)
639
C101 - Yellow (Main Body Side)
639
C200 - Black (Dash Side)
639
C200 - Black (Main Body Side)
640
C201 - (Dash Side)
640
C201 - Black (Main Body Side)
641
C202 - (Dash Side)
641
C202 - Black (Main Body Side)
641
C203 - (Dash Side)
642
C203 - Black (Main Body Side)
642
C204 - Gray (Dash Side)
642
C204 - Gray (Main Body Side)
642
C205 - Yellow (Dash Side)
643
C205 - Yellow (Main Body Side)
643
C206 - (Dash Side)
643
C206 - (Main Body Side)
643
C207 - (Dash Side)
644
C207 - (Main Body Side)
644
C208 - (Cabin Side)
644
C208 - (Dash Side)
644
C209 - (Dash Side)
645
C210 - (Driver Door Side)
645
C210 - Black (Main Body Side)
645
C211 - (Power Mirror Switch Side)
645
C214 - Lt. Blue (Cabin Side)
646
C214 - Lt.blue (Dash Side)
646
C215 - Black (Cabin Side)
646
C215 - Black (Main Body)
646
C217 - (Cabin Side)
647
C217 - (Main Body Side)
647
C218 - (Cabin Side)
647
C218 - (Main Body Side)
647
C219 - (Main Body Side)
648
C219 - Black (Cabin Side)
648
C220 - (Cigarette Side)
648
C220 - (Dash Side)
648
C221 - (Main Body Side)
649
C221 - (Passenger Door Side)
649
C224 - (Atc Motor/Solenoid Side)
649
C224 - (Main Body Side)
649
C225 - (Dash Side)
650
Cabin Heater Assembly C1
650
Cabin Heater Assembly C2
650
Camshaft Position Sensor - Black
650
Central Timer Module C1 - Pink
651
Central Timer Module C2 - Lt.green
651
Cigar Lighter
651
Cigar Lighter Lamp
652
Circulation Pump (Cabin Heater Module)
652
Circulation Pump (Rest System)
652
Circulation Pump Diode
652
Clockspring C2
653
Courtesy Lamp-Driver Door
653
Courtesy Lamp-Left Sliding Door
653
Courtesy Lamp-Passenger Door
654
Courtesy Lamp-Right Sliding Door
654
Crankcase Heater - Black
654
Crankshaft Position Sensor - Black
654
Cylinder Lock Switch-Driver
655
Data Link Connector - Black
655
Differential Lock Solenoid Valve
655
Dome Lamp
655
Door Lock Motor/Ajar Switch Assembly-Driver C1
656
Door Lock Motor/Ajar Switch Assembly-Driver C2
656
Door Lock Motor/Ajar Switch Assembly-Left Sliding C1
656
Door Lock Motor/Ajar Switch Assembly-Left Sliding C2
656
Door Lock Motor/Ajar Switch Assembly-Passenger C2
657
Door Lock Motor/Ajar Switch Assembly-Rear C1
657
Door Lock Motor/Ajar Switch Assembly-Rear C2
657
Door Lock Motor/Ajar Switch Assembly-Right Sliding C1
657
Dosing Pump
658
Egr Valve - Black
658
Engine Control Module C1 - Black
658
Engine Control Module C2 - Black
658
Engine Control Module C3 - Black
659
Engine Control Module C4 - Black
659
Engine Control Module C5 - Gray
660
Engine Coolant Level Switch - Black
660
Engine Coolant Temperature Sensor - Black
660
Engine Oil Sensor - Black
660
Evaporator Temperature Sensor
661
Fuel Injector No. 1 - Black
661
Fuel Injector No. 2 - Black
661
Fuel Injector No. 3 - Black
661
Fuel Injector No. 4 - Black
662
Fuel Injector No. 5 - Black
662
Fuel Level Sensor
662
Fuel Pressure Sensor - Black
662
Fuel Shutdown Solenoid
663
Fuel Temperature Sensor
663
Fuse Block No. 1 C1
663
Fuse Block No. 1 C2
663
Fuse Block No. 1 C3 - Black
664
Fuse Block No. 1 C4 - Black
664
Fuse Block No. 1 C5 - Black
664
Glow Plug Control Module C1 - Black
664
Glow Plug Control Module C2 - Black
665
Headlamp Adjust Switch - Black
665
Headlamp Assembly-Left - Black
665
Headlamp Assembly-Right - Black
666
Heat Exchanger Connector
666
Heat Exchanger Switch
666
Heated Seat Module-Driver
666
Heated Seat Module-Passenger
667
Heated Seat Switch-Driver
667
Heated Seat Switch-Passenger
667
Heater Timer-Auxiliary
667
Hood Ajar Switch - Black
668
Horn (Vtss)
668
Horn-Switch
668
Ignition Lock Switch - Black
669
Instrument Cluster C1
669
Instrument Cluster C2 - White
669
Instrument Panel Socket - Black
670
Intake Air Temperature Sensor - Black
670
Interior Lamp No. 1
670
Interior Lamp No. 2
670
Interior Lamp No. 4
671
Interior Lamp No. 5
671
Interior Lamp-Left - Black
671
Interior Lamp-Middle Front
671
Interior Lamp-Middle Rear
672
Interior Lamp-Rear No. 1 - Black
672
Interior Lamp-Rear No. 2 - Black
672
Interior Lamp-Right - Black
673
Interior Light Switch
673
Interior Light Switch-Driver
673
Interior Light Switch-Passenger
673
Interior Light Switch-Rear
674
Interior Lighting Connector
674
Intrusion Sensor No. 1 - Black
674
Intrusion Sensor No. 2 - Black
674
Kick down Switch - Black
675
License Plate Lamp No. 1
675
License Plate Lamp No. 2
675
Locker Switch No. 1
675
Low Fuel Pressure Sensor - Black
676
Map/Reading Lamp Switch
676
Marker Lamp No. 1-Left Front
676
Marker Lamp No. 1-Right Front
676
Marker Lamp No. 2-Left Front
677
Marker Lamp No. 2-Right Front
677
Marker Lamp-Left Center
677
Marker Lamp-Left Rear
677
Marker Lamp-Right Rear
678
Mass Air Flow Sensor - Black
678
Master Door Lock Switch
678
Metering Pump
678
Panic Alarm Switch - Black
679
Parking Brake Switch
679
Power Mirror Motor-Driver
679
Power Mirror Motor-Passenger - Black
679
Power Window Motor-Driver
680
Power Window Motor-Passenger
680
Power Window Switch-Driver
680
Power Window Switch-Master
680
Radio Antenna
681
Radio C1 - Black
681
Radio C2
681
Radio/Cellular Antenna
681
Reading Lamp Connector
682
Recirculated Air Solenoid Valve
682
Refrigerant Pressure Sensor
682
Remote Keyless Entry Antenna
682
Seat Belt Tensioner-Driver - Yellow
683
Seat Belt Tensioner-Passenger - Yellow
683
Security System Module C1 - Brown
683
Security System Module C2 - Lt.green
684
Sentry Key Remote Entry Module (Skreem)
684
Shifter Assembly - Black
684
Siren - Black
685
Speaker-Left Front Door Assembly C1
685
Speaker-Left Front Door Assembly C2
685
Speaker-Right Front Door
685
Speaker-Right Rear
686
Speed Control Switch
686
Tail Lamp Assembly-Left - Black
686
Tail Lamp Assembly-Right - Black
686
Temperature Switch
687
Towing/Intrusion Sensor On/Off Switch
687
Trailer Tow Connector - Black
687
Trailer Tow Control Module C1 - Black
688
Trailer Tow Control Module C2 - Black
688
Transmission Control Module C1 - Black
688
Transmission Control Module C2 - Black
688
Transmission Solenoid Assembly - Black
689
Turn Signal No. 1-Left Front - Black
689
Turn Signal No. 1-Right Front - Black
689
Turn Signal No. 2-Left Front
689
Turn Signal No. 2-Right Front
690
Warm Air Auxiliary Heater Assembly C1
690
Warm Air Auxiliary Heater Assembly C2
690
Washer Pump Motor-Front
690
Water in Fuel Sensor - Black
691
Wheel Speed Sensor-Left Front
691
Wheel Speed Sensor-Left Rear
691
Wheel Speed Sensor-Right Front
691
Window Defogger Module-Rear - Brown
692
Window Defogger Switch-Rear - Black
692
Window Defogger-Left Rear
692
Window Defogger-Right Rear
692
Wiper/Turn Signal/Engine Start Control Module (Fuse Block No. 1)
693
8W-91 Connector/Ground/Splice Location
695
Connector/Ground/Splice Location
695
Connectors
695
8W-97 Power Distribution
733
Fuse Block #1
734
Power Distribution
734
Circuit Breaker Description
734
Description
734
Diagnosis and Testing - Cigar Lighter Outlet
734
Diagnosis and Testing - Circuit Breaker
734
Operation
734
Removal
734
Description
735
Fuse Block #2
735
Installation
735
Operation
735
Power Distribution Center
735
Power Outlet
735
Removal
735
Cigar Lighter Outlet
735
Description
736
Diagnosis and Testing - Power Outlet
736
Installation
736
Operation
736
Relay
736
Removal
736
Relay
737
Diagnosis and Testing - Relay
737
Diagnosis and Testing - Relay Circuit Test
737
Installation
737
Operation
737
Removal
737
Engine Description
740
Compression Specifications
741
Engine Description
741
Standard Procedure - Compression Testing Engine
741
Standard Procedure - Cylinder Leak down Test
741
Cylinder Leak down Values
742
Possible Cause for Pressure Loss
742
Removal - Engine Cover
742
Standard Procedure - Determining Cylinder Pressure Loss
742
2.7L Engine
743
Engine Cover
743
Transmission Connections
744
Engine Hoist Connection
745
Engine Lifting Fixture
745
Front Cross Plate
745
Installation - Engine Cover
745
Specifications - Torque Specifications
746
Air Cleaner Element
758
Air Cleaner Housing Removal
758
Installation
758
Removal
758
Cylinder Head
759
Head Bolt Inspection
759
Standard Procedure - Cylinder
759
Standard Procedure - Measure Cylinder Head Surface
759
Camshaft Housing
760
Removal - Cylinder Head
760
Removal - Cylinder Head Front Cover
761
Cylinder Head Front Cover
762
Removal - Cylinder Head Guide Rail
762
Cylinder Head Bolt Torque Sequence
763
Cover
764
Installation - Cylinder Head Guide Rail
764
Standard Procedure - Checking Camshaft Position
765
Installation - Cylinder Head
763
Camshaft(S)
765
Checking Camshaft Position
765
Camshaft Alignment
766
Removal
766
Camshafts and Housing Assembly
767
Installation
767
Cylinder Head Cover
768
Cylinder Head Cover(S)
768
Installation
768
Removal
768
Removal - Valve Springs
769
Removal - Valves
769
Valve Compressor
769
Valve Springs
769
Installation - Valve Springs
770
Valve Assembly
770
Valve Stem Seal
770
Installation - Valves
771
Valve Seal Installation
771
Core Hole Plug Removal
772
Engine Block
772
Standard Procedure - Measuring Cylinder Bores
772
Standard Procedure - Replacing Engine Core and Oil Gallery Plugs
772
Crankshaft
773
Assign Crankshaft Bearing Shells
773
Crankshaft and Block Journals
773
Measuring Cylinder Bores
773
Removal
773
Standard Procedure - Measure Crankshaft and Block Journals
773
Crankshaft Assembly
774
Installation
774
Crankshaft Oil Seal - Rear
775
Installation
775
Rear Main Seal/Adapter
775
Removal
775
Crankshaft Oil Seal - Front
776
Front Seal Removal/Installation
776
Flywheel Assembly
777
Flywheel Removal
777
Installation
777
Crankshaft Lock
778
Description
778
Piston & Connecting Rod
778
Standard Procedure - Checking and Repairing Connecting Rods
778
Measuring Connecting Rods
779
Piston and Connecting Rod Assembly
779
Connecting Rod Specifications
780
Measuring Piston Protrusion
780
Removal
780
Standard Procedure - Measuring Piston Protrusion
780
Installation
781
Piston and Connecting Rod Installation
783
Measuring Piston Ring Side Clearance
784
Piston Rings
784
Ring Gap Measurement Chart
784
Standard Procedure - Piston Ring Fitting
784
Compression Ring Installation
785
Ring Gap Orientation
785
Vibration Damper Removal
785
Vibration Damper/Crankshaft Pulley
785
Description
786
Installation
786
Operation
786
Removal
786
Vacuum Pump
786
Installation
787
Left Mount Removal
787
Removal
787
Right Mount
787
Installation - Oil Separator
788
Oil Cooler & Lines
788
Removal - Oil Separator
788
Oil
788
Right Engine Mount
788
Engine Oil Cooler
789
Oil Jet
789
Description
789
Installation
789
Oil Filter Removal
789
Oil Jet Location
789
Removal
789
Installation
790
Oil Pan Removal
790
Oil Pan Bolts
791
Oil Pan Gasket
791
Oil Pump
791
Removal- Oil Pump Chain
791
Installation - Oil Pump Chain
792
Installing Oil Pump Chain Temporary Link
792
Oil Pump Chain Link Removal
792
Installing Assembly Inserts into Riveting Tool
793
Installing New Riveted Link
793
Removing Oil Pump Chain Temporary Link
793
Description
794
New Link Riveting
794
Oil Temperature Sensor
794
Operation
794
Rivet Inspection
794
Installation
795
Intake Manifold
795
Oil Level Sensor
795
Removal
795
Installation
796
Exhaust Manifold
797
Installation
797
Removal
797
Timing Chain Cover
797
Installation
798
Removal - Intermediate Gear
799
Removal - Tensioning and Slide Rails
799
Timing Belt/Chain and Sprockets
799
Tensioning and Slide Rails
800
High Ressure Pump Intermediate Gear
801
Removal - Timing Chain Tensioning Rail
801
Securing Timing Chain to Sprocket
802
Separating Timing Chain with Special
802
Thrust Pin Position
802
Installing Temporary Link
803
Timing Chain Temporary Link
803
Installation - Intermediate Gear
804
Installation - Tensioning and Slide Rail
804
Installation - Timing Chain Tensioning Rail
804
Installation - Timing Chain
805
Insert New Riveted Link
806
Removing Temporary Link
806
Installing Link Outer Plate
807
Installing Riveting Inserts into Riveting Tool
807
Pressing in New Riveted Link
807
Riveting Links of the Riveted Link
807
Timing Chain Tensioner Removal
808
Installation
809
Exhaust System
811
Diagnosis and Testing - Diesel Engine
812
Exhaust System
812
Exhaust System Diagnosis Chart
812
Tailpipe
813
Description
814
Diagnosis and Testing - Charge Air Cooler System - Leaks
814
Operation
814
Turbocharger Components
814
Charge Air Cooler
815
Cleaning
815
Inspection
815
Installation
815
Removal
815
Charge Pressure Vacuum Transducer
816
Operation
816
Turbocharger Description
816
Turbocharger Vacuum Routing
816
Removal - Vacuum Transducer
817
Installation - Vacuum Transducer
818
Frame & Bumpers
819
Front Bumper - Steps Removal
820
Front Fascia Removal
820
Installation
820
Installation
821
Rear Bumper - Step Removal
821
Rear Fascia Removal
821
Specifications - Frame Dimensions
822
Bumpers
820
Frame
822
Vehicle Preparation
822
Engine Cradle Crossmember
824
Engine Mount
824
Power Steering Hose Bracket
825
Steering Gear
825
Engine Cradle Bolts
826
Heat Shield
826
Identification Plate
826
Installation
826
Rear Crossmember - Transmission Removal
827
Trailer Hitch
827
Transmission Crossmember
827
Trailer Hitch Electrical Connection
828
Trailer Hitch Mounting
828
Diagnosis and Testing - High Pressure Fuel Lines
829
Fuel System
829
Warning - High Fuel System Pressure
829
Diagnosis and Testing - Air in Fuel System
830
Standard Procedure - Disconnecting and Connecting Fuel Lines
830
Standard Procedures - Cleaning Fuel System Components
830
Standard Procedures - Draining Water from Fuel Filter
830
Fuel Line Connector
831
Fuel Pressure Specifications
831
Standard Procedure - Low Pressure Fuel Pump Test
831
Fuel Delivery
832
Fuel Delivery
833
Fuel Drain Tubes
833
Description
833
Diagnosis and Testing - Fuel Supply
833
Fuel Filter
833
High-Pressure Lines
833
Low-Pressure Lines
833
Operation
833
Removal
833
Restrictions
833
Special Tools Fuel System
833
Fuel Filter and Bracket
834
Fuel Lines
834
Installation
834
Removal - High Pressure Lines
834
Description - Low Pressure Pump
835
Fuel Pump
835
Installation - High Pressure Lines
835
Low Pressure Side
835
Operation
835
High Pressure Pump
836
High Pressure Side
836
Operation - Low Pressure Pump
836
Removal - High Pressure Pump
836
Removal - Low Pressure Pump
837
Installation - High Pressure Pump
838
Vacuum Pump and Low Pressure Fuel Pump Assemblies
838
Description
839
Fuel Rail
839
Installation - Low Pressure Pump
839
Operation
839
Removal
839
Description
840
Fuel Pressure Solenoid
840
Fuel Tank
840
Removal
840
Fuel Tank Assembly
841
Fuel Tank Module Description
841
Installation
841
Removal
841
Align Tank Module
842
Fuel Gauge Sending Unit
842
Fuel Tank Module R/I
842
Installation
842
Fuel Level Sending Unit / Sensor Description
843
Installation
843
Removal
843
Description
844
Hi Pressure Fuel Shutoff Sol
844
Operation
844
Water in Fuel Sensor Description
844
Accelerator Pedal Position Sensor
845
Boost Pressure Sensor
845
Diagnosis and Testing - Boost Pressure Sensor
846
Installation
846
Operation
846
Removal
846
Camshaft Position Sensor
847
Fuel Injection
845
Accelerator Pedal Position Sensor
846
Cam Position Sensor
847
Description
847
Installation
847
Operation
847
Removal
847
Crankshaft Position Sensor
848
Description
848
Fuel Injector
848
Installation
848
Operation
848
Removal
848
Fuel Injector
848
Injector Closed (with High Pressure Applied)
849
Injector Opens (Start of Injection)
849
Injector Closes (End of Injection)
850
Injector Opens Fully
850
Standard Procedure - Cleaning Fuel Injectors
850
Standard Procedure - Injector
850
Installation
851
Removal
851
Fuel Injector Removal / Installation
852
Description
853
Fuel Pressure Sensor
853
Fuel Rail Pressure Sensor
854
Fuel Pressure Solenoid - Typical
855
Fuel Pressure Solenoid Operation
855
Fuel Pressure Solenoid Assembly
856
Description
857
Inlet Air Temperature Sensor
857
Operation
857
Manifold Air Flow (Maf) Sensor
858
Fuel Temperature Sensor
858
Description
858
Inlet Air Temperature
858
Installation
858
Operation
858
Removal
858
Installation
859
Removal
859
Steering
861
Steering Components
861
Diagnosis and Testing - Power Steering System
862
Steering Noise
862
Binding and Sticking
863
Insufficient Asst. or Poor Return to Center
863
Loose Steering and Vehicle Lead
864
Column
865
Intermediate Shaft
865
Key/Lock Cylinder
866
Steering Column Bolts
866
Transponder
866
U-Joint Remove / Install
866
1/4 Turn Left
867
Lock Cylinder off the Ignition Lock
867
Steering Wheel
867
Gear
868
Steering Gear Removal / Install
868
Diagnosis and Testing - Outer Tie Rod End
870
Linkage
870
Outer Tie Rod End
871
Tie Rod End
871
Diagnosis and Testing - Pump Leakage
872
Pump
872
Standard Procedure - Power Steering Pump - Initial Operation
872
Installation
873
Power Steering Pump
873
Removal
873
Standard Procedure - Flushing Power Steering System
873
Steering Pump Initial Operation
873
Fluid Cooler Tube Removal
874
Installation
874
Power Steering Pump Fill and Bleed
874
Installation - Pressure Hose
875
Removal - Pressure Hose
875
Removal - Return Hose from Gear to Cooler Tube
875
Removal - Return Line from Pump to Cooler Tube
875
Fluid
874
Automatic Transmission - Nag1
877
Transmission Gear Ratios
878
Transmission Housing
878
Transmission Identification
878
Electrohydraulic Control Unit
879
Mechanical Section
879
NAG1 Automatic Transmission
879
Clutch Application
880
Emergency Running Function
880
Shift Groups
880
First Gear Powerflow
881
Front Planetary Gear Set
881
Rear Planetary Gear Set
881
Center Planetary Gear Set
882
Second Gear Powerflow
883
Third Gear Powerflow
885
Fourth Gear Powerflow
887
1-2 Shift - First Gear Engaged
893
Shift Groups/ Shift Sequence
893
Shift Phase
894
Second Gear Engaged
895
Gear Shift N to D (1St Gear) - Engine Started
896
Activation Sequence
897
First Gear Engaged
898
Diagnosis and Testing - Automatic Transmission
899
Diagnosis and Testing - Preliminary
899
Vehicle Is Disabled
899
Vehicle Is Drivable
899
Drain Transmission
903
Remove Propeller Shaft and Heat Shield
903
Remove the Fill Tube
903
Standard Procedure - Aluminum Thread Repair
903
Remove Cable Support
904
Remove Cooler Line Supports
904
Remove Driver’s Side Cooler Line
904
Remove Transmission Electrical Connector and Cooler Line
904
Lower Steering Gear
905
Remove Shift Cable from Transmission
905
Remove Torque Converter Access Cover
905
Remove Torque Converter Bolts
905
Checking Input Shaft End Play
906
Remove Torque Converter
906
Support Transmission and Remove Bolts
906
Position Remover 9082 on Bearing
907
Remove Electrohydraulic Unit
907
Remove Rear Output Shaft Retaining Ring
907
Remove Output Shaft Bearing
908
Slide Remover 9082 Collar Downward
908
Remove K1, K2, and K3 Clutches
909
Remove Holding Clutch B1 and Oil Pump
910
Install B2, B3, and Parking Gear
911
Remove B2, B3, and Parking Gear
911
Check K1 Feed Hole
912
Measure B3 Clutch Clearance
912
Install Holding Clutch B1 and Oil Pump
913
Install New Oil Pump Seals
913
Install K1, K2, and K3 Clutches
914
Measure from Transmission Housing to Park Gear
914
Install Output Shaft Bearing
915
Install Rear Output Shaft Retaining Ring
915
Align Staking Tool 9078
916
Install Output Shaft Seal
916
Stake Output Shaft Nut
916
Install Electrohydraulic Unit
917
Install Torque Converter
917
Torque Converter Installation Depth
917
Position Driveplate as Shown
918
Position Torque Converter as Shown
918
Support Transmission and Install Bolts
918
Install Steering Gear
919
Install Torque Converter Access Cover
919
Install Torque Converter Bolts
919
Install Cable Support
920
Install Cooler Line Supports
920
Install Shift Cable Onto Transmission
920
Install Transmission Electrical Connector and Cooler Line
920
Install Driver’s Side Cooler Line
921
Install Propeller Shaft and Heat Shield
921
Install the Fill Tube
921
Install the Oil Drain Plug
922
Schematics and Diagrams
923
Hydraulic Flow in Reverse - Failsafe
924
Hydraulic Flow in Reverse
925
Hydraulic Flow in Neutral - Default
926
Hydraulic Flow in Neutral to Drive Transition
928
Hydraulic Flow in Drive - Failsafe
929
Hydraulic Flow in Drive - First Gear
930
Hydraulic Flow in Drive - First to Second Gear Transition
931
Hydraulic Flow in Drive - Second Gear
932
Hydraulic Flow in Drive - Second to Third Gear Transition
933
Hydraulic Flow in Drive - Third Gear
934
Hydraulic Flow in Drive - Third to Fourth Gear Transition
935
Hydraulic Flow in Drive - Fourth Gear
936
Hydraulic Flow in Drive - Fourth to Fifth Gear Transition
937
Hydraulic Flow in Drive - Fifth Gear
938
Hydraulic Flow in Drive - Fifth Gear - Emcc
939
Hydraulic Flow in Drive - Fifth to Fourth Gear Transition
940
Hydraulic Flow in Drive - Fourth to Third Gear Transition
941
Hydraulic Flow in Drive - Third to Second Gear Transition
942
Hydraulic Flow in Drive - Second to First Gear Transition
943
Gear Ratios
944
Specifications - Nag1 Automatic Transmission
944
Driving Clutches
948
Driving Clutch K1 Components
951
Driving Clutch K1 Stack-Up
952
Driving Clutch K2
952
Measure K1 Clutch Clearance
952
Driving Clutch K2 Components
953
Compress K2 Clutch Spring
954
Driving Clutch K2 Stack-Up
956
Driving Clutch K3
956
Measure K2 Clutch Clearance
956
Driving Clutch K3 Components
957
Electrical Control Unit
958
Electrohydraulic Unit
958
Hydraulic Control Unit
958
Working Pressure (Operating Pressure) (P-A)
958
Modulating Pressure (P-Mod)
959
Regulating Valve Pressure (P-RV)
959
Shift Pressure (P-S)
959
Shift Valve Pressure (P-SV)
959
Command Valve
960
Holding Pressure Shift Valve
960
Overlap Regulating Valve
960
Working Pressure Regulating Valve
960
Lubrication Pressure Regulating Valve
962
Shift Pressure Shift Valve
962
Regulating Valve Pressure Regulating Valve
963
Shift Pressure Regulating Valve
963
Shift Valve Pressure Regulating Valve
963
Torque Converter Lockup Clutch Regulating Valve
964
Working Pressure Regulating Valve (Operating Pressure)
964
Shift Valve Holding Pressure
965
Remove Heat Shield
968
Remove Wiring Connector Plug
968
Electrical Unit Components
969
Shift Plate Components
969
Shift Valve Group Locations
969
Check Balls and Strainer Location
970
Solenoid Valve Strainer Locations
970
Valve Body Components
971
Pressure Feed Valve Location
972
Valve Housing Components
972
Diagnosis and Testing - Causes of Burnt Fluid
978
Diagnosis and Testing - Effects of Incorrect Fluid Level
978
Diagnosis and Testing - Fluid Contamination
978
Standard Procedure - Check Oil Level
978
NAG1 Transmission Fill Graph
979
Standard Procedure - Transmission Fill
979
Dipstick Tube Cap Components
980
Fluid/Filter Service Points
980
Remove Dipstick Tube Cap Lock
980
Standard Procedure - Fluid/Filter Service
980
Freewheeling Clutch
981
Freewheeling Clutch F2
982
Freewheeling Clutch F2 Anti-Friction Bearing
983
Gearshift Cable
985
Remove Bottom Section of Center Instrument Panel
985
Remove Top Section of Center Instrument Panel
985
Holding Clutches
987
B2 Clutch Stack-Up
995
B2 Piston and Piston Guide Ring
995
Input Speed Sensors
995
Measure B2 Clutch Clearance
995
Shift Mechanism
1009
Torque Converter
1017
Diagnosis and Testing - Tire and Wheel Runout
1025
Tires/Wheels
1025
Lateral Runout
1026
Radial Runout
1026
Standard Procedure - Match Mounting
1026
First Measurement on Tire
1027
Remount Tire 180 Degrees
1027
Standard Procedure - Tire and Wheel Balance
1027
Dynamic Unbalance & Balance
1028
Static Unbalance & Balance
1028
Standard Procedure - Tire Rotation
1029
Description - Radial – Ply Tires
1030
Description - Tires
1030
Tire Chains
1030
Tire Identification
1030
Description - Replacement Tires
1031
Description - Tire Inflation Pressures
1031
Over Inflation Wear
1031
Under Inflation Wear
1031
Diagnosis and Testing - Pressure Gauges
1032
Diagnosis and Testing - Tire Noise or Vibration
1032
Diagnosis and Testing - Tire Wear Patterns
1032
Diagnosis and Testing - Tread Wear Indicators
1032
Vehicle Lead Diagnosis and Correction Chart
1033
Spare Tire Carrier
1034
Standard Procedure - Repairing Leaks
1034
Tire Repair Area
1034
Safety Rim
1035
Standard Procedure - Wheel Replacement
1035
Wheel Inspection
1035
Wheels
1035
(Drw) Wheel Cone Washers
1036
Dual Rear Wheel
1036
Standard Procedure - Dual Rear Wheel Installation
1036
Wheel Ring Flange Cone Washers
1036
Front Tire (Drw)
1037
Wheel Removal / Installation
1037
Body
1039
Diagnosis and Testing - Water Leaks
1039
Mirror Inspection Method
1040
Visual Inspection before Water Leak Tests
1040
Water Leak Detection
1040
Water Leak Tests
1040
Possible Cause of Wind Noise
1041
Road Testing Wind Noise
1041
Safety Precaution and Warnings
1041
Standard Procedure - Plastic Body Panel Repair
1041
Rigid, Semi-Rigid, and Flexible Plastic Parts Types
1042
Panel Reinforcement
1044
Panel Sectioning
1044
Softened Edges
1044
Panel Patch Fabrications
1045
Panel Surface Preparation
1045
Patching Panels
1045
Visual Inspection
1045
Damaged Panel Cutout and Patch
1046
Fabricated Panel
1046
Panel Patch Installation
1046
Secure Support Squares to Body Panel
1046
Apply Adhesive to Support Squares
1047
Grind Surface
1047
Install Screws
1047
Position Patch in Cutout and Align
1047
Cover Gaps with Mesh
1048
Cover Mesh with Adhesive
1048
Patched Panel Surfacing
1048
Standard Procedure - Buzz, Squeak & Rattle
1048
Buzz, Squeak & Rattle Kit
1049
Door - Front
1051
Front Door Check - Body
1051
Front Door Check - Door
1051
Electrical Connectors
1052
Front Door
1052
Door Glass
1053
Front Door Glass
1053
Glass Support
1053
Exterior Handle
1054
Exterior Handle Installation
1054
Latch Levers
1054
Latch/Handle Fasteners
1054
Hinge
1055
Front Door Latch
1056
Latch
1056
Latch Striker
1056
Lock Cylinder
1056
Trim Panel
1057
Trim Panel Fasteners
1057
Trim Panel Handle
1057
Control Cable
1058
Manual Regulator Assembly
1058
Window Regulator - Power
1058
Doors - Rear
1062
Check Strap
1063
Door Hinges
1063
Right Door
1064
Left Door
1065
Doors - Sliding
1074
Center Roller Arm
1075
Inside Handle Actuator
1075
Upper Roller Arm
1075
Lower Roller Arm
1076
Sliding Door Center Track
1076
Sliding Door Lower Roller Arm
1076
Sliding Door Scuff Pad
1076
Latch / Lock Control
1077
Lock Assembly Fasteners
1077
Sliding Door
1077
Lock Assembly
1078
Rear Latch
1078
Rear Latch Striker
1079
Sliding Door Assembly
1080
Hood
1088
Latch Release Cable
1089
Latch Release Handle
1090
Safety Latch
1090
Cluster Bezel
1091
Instrument Panel
1091
Accessory Switch Bezel
1092
Ash Receiver
1093
Cup Holder
1093
Instrument Panel Center Bezel
1093
Cup Holder Bottom
1094
Glove Box
1094
Hvac Control Module
1095
Instrument Panel Assembly
1095
Power Distribution Center Cover
1095
Passenger Side Air Nozzle Cover
1096
Power Distribution Center Connectors
1096
Center Vent Hose
1097
Instrument Panel Top Cover
1097
Protective Mat
1097
Side Covers & Nozzles
1097
Brake Pedal Spring
1098
Ignition Transponder
1098
Instrument Panel Fasteners
1098
Alignment Cutout
1099
Top Cover - Cluster
1100
Top Cover - Tray
1101
A-Pillar Trim
1105
Interior
1105
Assist Handle
1106
B-Pillar Trim
1106
Bulkhead Trim Panel
1107
Cargo/Passenger Van - Front
1107
Carpets and Floor Mats
1107
Passenger Van - Rear
1107
Cowl Trim
1108
D-Pillar Trim
1108
Headliner
1108
Passenger Van
1109
Quarter Trim Panel
1109
Rear View Mirror
1110
Stepwell Scuff Pads
1110
Sun Visor
1111
Basecoat/Clearcoat Finish
1112
Paint
1112
Paint Touch-Up
1112
Finesse Sanding/Buffing & Polish
1113
Standard Procedure - Paint Touch-Up
1113
Armrest
1114
Headrest
1114
Seats
1114
Seat - Front
1115
Seat Back - Front
1115
Comfort Seat Cushion
1116
Seat Adjusters - Front
1116
Seat Cushion - Front
1116
Standard Seat Cushion
1116
Rear Seat Back Shield
1117
Seat - Rear
1117
Three Passenger Bench
1117
Two Passenger Bench
1117
Seat Back Cushion/Cover - Rear
1118
Seat Cushion/Cover - Rear
1118
Backlite - Bulkhead Trim Panel
1119
Glass & Weatherstrip Seal Installation
1119
Quarter Window
1119
Stationary Glass
1119
Windshield
1120
Windshield Safety Precautions
1120
Adhesive Separation
1121
Instrument Panel Seal
1121
Windshield Seal
1121
Windshield Adhesive Preparation
1122
Windshield Positioning
1122
Windshield Primer
1122
Windshield Seal Installation
1122
Windshield Adhesive Application
1123
Windshield Installation
1123
Windshield Opening Preparation
1123
Windshield Opening Primer
1123
Windshield Adhesive Overlap
1124
Door Opening Seals
1125
Front Door Inner Belt Weatherstrip
1125
Front Door Outer Belt Weatherstrip
1125
Weatherstrip/Seals
1125
Body Structure
1126
Gap & Flush Dimensions Index
1126
Gap and Flush
1126
Rear Door
1127
Opening Dimensions
1128
Description - Cooling System Requirements
1129
Description - Heater and Air Conditioner
1129
Heating & Air Conditioning
1129
Heater Booster
1130
Heater Housing
1130
Operation - Heater and Air Conditioner
1130
Diagnosis and Testing - A/C Performance Test
1131
Diagnosis and Testing - Function Test
1131
Diagnosis and Testing - Heater Performance
1132
Maximum Heater Output
1132
Temperature Reference Chart
1132
A/C Compressor Clutch
1136
Controls - Front
1136
Compressor Clutch — Typical
1137
Compressor Shaft Bolt and Clutch Plate
1137
Standard Procedure - Compressor Clutch Air Gap
1137
Standard Procedure - Compressor Clutch Break-In
1137
Clutch Coil Snap Ring
1138
Clutch Plate and Shim(S)
1138
Inspection - Compressor Clutch/Coil
1138
Pulley Snap Ring
1138
Pulley Assembly Install
1139
A/C Compressor Clutch Coil
1140
A/C Heater Control
1140
Diagnosis and Testing - Compressor Clutch Coil
1140
A/C Pressure Transducer
1141
Diagnosis and Testing - A/C Pressure Transducer
1141
A/C Pressure Transducer Voltage
1142
Blower Motor Switch
1150
Controls - Rear
1150
Blower Motor Relay
1151
Control Module
1152
Rear A/C Control Module
1153
Rear Evaporator Panel
1153
Rear Roof Duct Panel
1153
Rear Evaporator Temperature Sensor
1154
Solenoid Valve
1155
Temperature Control
1157
Air Filter
1159
Air Outlets
1159
Distribution - Front
1159
Blower Motor
1160
Instrument Panel Air Outlets
1160
Defroster Ducts
1161
Floor Distribution Ducts
1161
Hvac Housing
1162
Distribution - Rear
1167
Rear A/C Housing
1168
Plumbing
1171
Heater Core
1185
Water Valve
1195
Cabin Heater
1200
Fuel Line
1203
Heater Unit
1205
Emissions Control
1209
Exhaust Gas Recirculation
1209
4
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Mercedes-Benz 2005 Sprinter Specifications
General
Brand
Mercedes-Benz
Model
2005 Sprinter
Category
Automobile
Language
English
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