NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
*1 Bumper to grille 19.0 3.0 Ð
*2 Hood to grille 1.5 1.0
Parallel within 2.0U/F 0.75 1.75
*3 Fender to hood 6.0 2.0
Parallel within 1.0U/F 3.2 1.5
(Underflush from front of
hood to start of hockey
stick area only)
*4 Fender to hood
(Up/Down surface only)6.0 1.5
Parallel within 1.00.0 1.5
*5 Front door to windshield Ð O/F 20.5 1.5
(Base of windshield)
O/F 9.0 1.5
(Top of windshield)
*6 Roof to front door Ð U/F 6.0 1.5
Parallel within 1.5
7 Quarter to front door 5.0 1.5
Parallel within 1.00.0 1.5
8 Front door to quarter character line
alignmentÐ Up/Down 0.0 1.5
*9 Front door to fender character line
alignmentÐ Up/Down 0.0 1.5
*10 Front door to fender 5.0 1.5
Parallel within 1.00.0 1.5
*11 Bumper to fender 19.0 3.0
Parallel within 3.0O/F 5.0 5.0 (SLT)
O/F 14.0 5.0 (SPORT)
*12 Bumper to headlamp 19.0 4.0 Ð
* ALL MODELS
Fig. 1 GAP & FLUSH - STANDARD CAB
23 - 96 BODY STRUCTUREDR
GAP AND FLUSH (Continued)
²Faulty A/C-heater control.
²Faulty related wiring harness or connectors.
²Improper engine coolant temperature.
SPECIFICATIONS - A/C SYSTEM
The R-134a refrigerant system charge capacity for
this vehicle can be found on the underhood Specifica-
tion Label.
A/C SYSTEM SPECIFICATION CHART
Item Description Notes
Compressor Saden SD-7
(5.9L engine)SP-15 PAG oil
Denso 10S17
(3.7L/4.7L/5.7L
engines)ND-8 PAG oil
Freeze±up
ControlEvaporator
Temperature
SensorEvaporator coil
mounted
High psi Control A/C pressure
transducerDischarge line
mounted
Compressor
Clutch Coil
Draw2 - 3.9 amps @
12V 0.5V @
21É C (70É F)5.9L engine
2.2 amps @
12V 0.5V @
21É C (70É F)3.7L/4.7L/5.7L
engines
Compressor
Clutch Air Gap0.41 - 0.79 mm
(0.016 - 0.031
in.)5.9L engine
0.35 - 0.65 mm
(0.013 - 0.025
in.)3.7L/4.7L/5.7L
engines
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A/C Compressor Shaft Nut 15-20 11-15 ±
A/C Compressor Bolt-Inner
Front-3.7L,4.7L40 30 ±
A/C Compressor Bolt-Inner
Rear-3.7L,4.7L55 41 ±
A/C Compressor Rear Bolt-
3.7L,4.7L55 41 ±
A/C Compressor Lower Bolts-5.7L 40 30 ±
A/C Compressor Rear Bolt-5.7L 55 41 ±
A/C Compressor Bolts-5.9L Diesel 24 17 ±
A/C Compressor Clutch Coil Wire
Retainer Screw2.2 ± 20
A/C-Heater Control Screws 2.2 ± 20
Accumulator Bracket Bolts 4.5 ± 40
Blower Motor Screws 2.2 ± 20
Blower Motor Resistor Block
Screws2.2 ± 20
Center Distribution Duct Screws 2.2 ± 20
DRHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)
HEATED SEAT MODULE - INSTALLATION . . . 8E-7
HEATED SEAT MODULE - INSTALLATION . . 8G-15
HEATED SEAT MODULE - OPERATION.....8E-6
HEATED SEAT MODULE - OPERATION....8G-14
HEATED SEAT MODULE - REMOVAL.......8E-7
HEATED SEAT MODULE - REMOVAL.....8G-15
HEATED SEAT SENSOR - DESCRIPTION . . . 8G-11
HEATED SEAT SENSOR - DIAGNOSIS
AND TESTING.......................8G-11
HEATED SEAT SENSOR - OPERATION....8G-11
HEATED SEAT SENSOR - REMOVAL......8G-11
HEATED SEAT SWITCH - DESCRIPTION . . . 8G-11
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING.......................8G-12
HEATED SEAT SWITCH - INSTALLATION . . 8G-13
HEATED SEAT SWITCH - OPERATION.....8G-12
HEATED SEAT SWITCH - REMOVAL......8G-13
HEATED SEAT SYSTEM - DESCRIPTION....8G-7
HEATED SEAT SYSTEM - DIAGNOSIS
AND TESTING........................8G-8
HEATED SEAT SYSTEM - OPERATION.....8G-8
HEATER - 5.9L DIESEL - DESCRIPTION,
ENGINE BLOCK.......................7-37
HEATER - 5.9L DIESEL - INSTALLATION,
ENGINE BLOCK.......................7-38
HEATER - 5.9L DIESEL - OPERATION,
ENGINE BLOCK.......................7-38
HEATER - 5.9L DIESEL - REMOVAL,
ENGINE BLOCK.........................7-38
HEATER - DESCRIPTION, ENGINE BLOCK . . . 7-36
HEATER - DESCRIPTION, FUEL..........14-51
HEATER - DESCRIPTION, INTAKE AIR.....14-80
HEATER - DIAGNOSIS AND TESTING,
ENGINE BLOCK.......................7-36
HEATER - DIAGNOSIS AND TESTING,
FUEL..............................14-52
HEATER - INSTALLATION, ENGINE
BLOCK..............................7-37
HEATER - INSTALLATION, INTAKE AIR....14-80
HEATER - OPERATION, ENGINE BLOCK....7-36
HEATER - OPERATION, FUEL............14-51
HEATER - OPERATION, INTAKE AIR......14-80
HEATER - REMOVAL, ENGINE BLOCK......7-37
HEATER - REMOVAL, INTAKE AIR........14-80
HEATER AND AIR CONDITIONER -
DESCRIPTION........................24-1
HEATER AND AIR CONDITIONER -
OPERATION..........................24-1
HEATER CONTROL - DESCRIPTION, A/C . . . 24-14
HEATER CONTROL - INSTALLATION, A/C . . 24-15
HEATER CONTROL - REMOVAL, A/C......24-15
HEATER CORE - DESCRIPTION..........24-63
HEATER CORE - INSTALLATION.........24-63
HEATER CORE - OPERATION............24-63
HEATER CORE - REMOVAL.............24-63
HEATER INLET HOSE - INSTALLATION....24-64
HEATER INLET HOSE - REMOVAL........24-64
HEATER PERFORMANCE TEST -
DIAGNOSIS AND TESTING..............24-6
HEATER RELAY - DESCRIPTION, FUEL....14-52
HEATER RELAY - DESCRIPTION, INTAKE
AIR ...............................14-82
HEATER RELAY - INSTALLATION, FUEL . . . 14-53
HEATER RELAY - INSTALLATION, INTAKE
AIR ...............................14-82
HEATER RELAY - OPERATION, FUEL......14-52
HEATER RELAY - OPERATION, INTAKE
AIR ...............................14-82
HEATER RELAY - REMOVAL, FUEL.......14-52
HEATER RELAY - REMOVAL, INTAKE AIR . . 14-82
HEATER RETURN HOSE - INSTALLATION . . 24-65
HEATER RETURN HOSE - REMOVAL......24-64
HEIGHT ADJUSTMENT - 4WD (LD) -
STANDARD PROCEDURE.................2-3
HEIGHT MEASUREMENT - 4WD (LD) -
STANDARD PROCEDURE.................2-3
HEMI ENGINE - INSTALLATION, 3.7L/4.7L
AND 5.7L......................24-59,24-73
HEMI ENGINE - REMOVAL, 3.7L/4.7L
AND 5.7L......................24-57,24-71
HIGH BEAM INDICATOR - DESCRIPTION
. . 8J-28
HIGH BEAM INDICATOR - OPERATION
....8J-28
HIGH MOUNTED STOP LAMP -
INSTALLATION, CENTER
...............8L-11
HIGH MOUNTED STOP LAMP -
REMOVAL, CENTER
...................8L-11
HIGH MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER
...............8L-11HIGH MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER...................8L-11
HIGH PRESSURE RELIEF VALVE -
DESCRIPTION.......................24-48
HIGH PRESSURE RELIEF VALVE -
OPERATION.........................24-48
HIGH SPEEDS - DESCRIPTION, TIRE
PRESSURE..........................22-7
HIGH/LOW RELAY - DESCRIPTION,
WIPER.............................8R-20
HIGH/LOW RELAY - DIAGNOSIS AND
TESTING, WIPER.....................8R-21
HIGH/LOW RELAY - INSTALLATION,
WIPER.............................8R-22
HIGH/LOW RELAY - OPERATION, WIPER . . 8R-20
HIGH/LOW RELAY - REMOVAL, WIPER . . . 8R-21
HIGH-PRESSURE FUEL LINE LEAKS -
DIAGNOSIS AND TESTING.............14-58
HINGE - INSTALLATION.....23-16,23-22,23-31,
23-46
HINGE - INSTALLATION, CENTER SEAT
BACK..............................23-79
HINGE - REMOVAL....23-16,23-22,23-31,23-46
HINGE - REMOVAL, CENTER SEAT BACK . . 23-78
HINGE COVER - INSTALLATION, CENTER
SEAT BACK INERTIA..................23-77
HINGE COVER - REMOVAL, CENTER
SEAT BACK INERTIA..................23-77
HITCH - INSTALLATION, TRAILER........13-25
HITCH - REMOVAL, TRAILER...........13-25
HOAT COOLANT - DESCRIPTION..........7-32
HOISTING - STANDARD PROCEDURE......0-20
HOLDDOWN - DESCRIPTION, BATTERY . . . 8F-14
HOLDDOWN - INSTALLATION, BATTERY . . . 8F-14
HOLDDOWN - OPERATION, BATTERY.....8F-14
HOLDDOWN - REMOVAL, BATTERY......8F-14
HOLDER - INSTALLATION, CUP.........23-51
HOLDER - REMOVAL, CUP.............23-51
HOLDING CLUTCHES - DESCRIPTION....21-371
HOLDING CLUTCHES - OPERATION.....21-372
HOLE PLUG - INSTALLATION, CAMSHAFT
CORE..............................9-206
HOLE PLUG - REMOVAL, CAMSHAFT
CORE..............................9-205
HOLE REPAIR - DESCRIPTION,
THREADED........................Intro.-8
HONING - STANDARD PROCEDURE,
CYLINDER BORE.................9-128,9-38
HOOD - INSTALLATION................23-47
HOOD - REMOVAL....................23-46
HOOK - INSTALLATION, COAT...........23-66
HOOK - REMOVAL, COAT..............23-66
HOOK ASSEMBLY - INSTALLATION,
FRONT TOW........................13-23
HOOK ASSEMBLY - REMOVAL, FRONT
TOW ..............................13-23
HORN - DIAGNOSIS AND TESTING.......8H-1
HORN - INSTALLATION.................8H-2
HORN - REMOVAL....................8H-2
HORN SWITCH - DESCRIPTION..........8H-2
HORN SWITCH - DIAGNOSIS AND
TESTING............................8H-2
HORN SYSTEM - DESCRIPTION..........8H-1
HORN SYSTEM - DIAGNOSIS AND
TESTING............................8H-1
HORN SYSTEM - OPERATION............8H-1
HOSE - GEAR TO COOLER -
INSTALLATION, RETURN..........19-44,19-45
HOSE - GEAR TO COOLER - REMOVAL,
RETURN......................19-44,19-45
HOSE - INSTALLATION, FRONT BRAKE.....5-13
HOSE - INSTALLATION, HEATER INLET....24-64
HOSE - INSTALLATION, HEATER RETURN . 24-65
HOSE - INSTALLATION, PRESSURE . 19-44,19-45
HOSE - INSTALLATION, REAR BRAKE......5-12
HOSE - REMOVAL, FRONT..............5-12
HOSE - REMOVAL, HEATER INLET.......24-64
HOSE - REMOVAL, HEATER RETURN.....24-64
HOSE - REMOVAL, PRESSURE.....19-44,19-45
HOSE - REMOVAL, REAR BRAKE
.........5-11
HOSE - RESERVOIR TO COOLER -
INSTALLATION, RETURN
..........19-44,19-45
HOSE - RESERVOIR TO COOLER -
REMOVAL, RETURN
.............19-44,19-45
HOSE ASSEMBLY - INSTALLATION, REAR
TUBE
...............................5-13
HOSE ASSEMBLY - REMOVAL, REAR
TUBE
...............................5-12HOSE CLAMPS - DESCRIPTION...........7-3
HOSE CLAMPS - OPERATION.............7-5
HOSES/TUBES - DESCRIPTION, WASHER . 8R-11
HOSES/TUBES - OPERATION, WASHER . . . 8R-11
HOUSING - ASSEMBLY, HVAC...........24-35
HOUSING - DIAGNOSIS AND TESTING,
CLUTCH..............................6-7
HOUSING - DISASSEMBLY, HVAC........24-35
HOUSING - INSTALLATION, CLUTCH.......6-9
HOUSING - INSTALLATION, GEAR........9-300
HOUSING - INSTALLATION, HVAC........24-36
HOUSING - INSTALLATION, ROCKER.....9-255
HOUSING - REMOVAL, CLUTCH...........6-9
HOUSING - REMOVAL, GEAR...........9-299
HOUSING - REMOVAL, HVAC...........24-34
HOUSING - REMOVAL, ROCKER.........9-255
HOUSING BUSHING AND SEAL -
INSTALLATION, EXTENSION...........21-440
HOUSING BUSHING AND SEAL -
REMOVAL, EXTENSION...............21-440
HOUSING COVER - INSTALLATION, GEAR . 9-301
HOUSING COVER - REMOVAL, GEAR.....9-301
HOUSING FLUID LEAK - DIAGNOSIS AND
TESTING, CONVERTER.........21-144,21-318
HOUSING SEAL - INSTALLATION,
ADAPTER...............21-128,21-364,21-85
HOUSING SEAL - INSTALLATION,
EXTENSION . 21-128,21-201,21-507,21-536,21-85
HOUSING SEAL - REMOVAL, ADAPTER . . 21-128,
21-364,21-85
HOUSING SEAL - REMOVAL,
EXTENSION . 21-128,21-201,21-507,21-536,21-85
HOUSING SEAL AND DUST BOOT -
INSTALLATION, EXTENSION.....21-476,21-571
HOUSING SEAL AND DUST BOOT -
REMOVAL, EXTENSION.........21-476,21-571
HOW TO USE WIRING DIAGRAMS -
DESCRIPTION.....................8W-01-1
H-SECTION REPLACEMENT - STANDARD
PROCEDURE, REAR FRAME............13-13
HUB / BEARING - INSTALLATION.........2-32
HUB / BEARING - REMOVAL.............2-31
HVAC HOUSING - ASSEMBLY...........24-35
HVAC HOUSING - DISASSEMBLY........24-35
HVAC HOUSING - INSTALLATION........24-36
HVAC HOUSING - REMOVAL............24-34
HYDRAULIC BOOSTER - DIAGNOSIS
AND TESTING........................5-30
HYDRAULIC LASH ADJUSTER -
DIAGNOSIS AND TESTING.........9-125,9-32
HYDRAULIC PRESSURE TEST -
DIAGNOSIS AND TESTING......21-141,21-316
HYDRAULIC SCHEMATICS, SCHEMATICS
AND DIAGRAMS..............21-176,21-337
HYDRAULIC TAPPETS - DIAGNOSIS AND
TESTING...........................9-210
HYDRAULIC TAPPETS - INSTALLATION . . . 9-211
HYDRAULIC TAPPETS - REMOVAL.......9-211
HYDROBOOST - INSTALLATION..........5-27
HYDROBOOST - INSTALLATION, ALL
EXCEPT.............................5-27
HYDROBOOST - REMOVAL..............5-26
HYDROBOOST - REMOVAL, ALL EXCEPT . . . 5-26
HYDRO-BOOST BRAKE BOOSTER -
INSTALLATION........................5-32
HYDRO-BOOST BRAKE BOOSTER -
REMOVAL
...........................5-31
HYDROFORM FENDER RAIL REPAIR -
STANDARD PROCEDURE
...............13-11
HYDROSTATIC LOCK - STANDARD
PROCEDURE
...................9-190,9-240
IDENTIFICATION - DESCRIPTION,
FASTENER
.........................Intro.-5
IDENTIFICATION AND INFORMATION -
DESCRIPTION, SECTION
.............8W-01-6
IDENTIFICATION NUMBER -
DESCRIPTION, VEHICLE
..............Intro.-1
IDLE AIR CONTROL MOTOR -
DESCRIPTION
.......................14-28
IDLE AIR CONTROL MOTOR -
INSTALLATION
.......................14-29
IDLE AIR CONTROL MOTOR -
OPERATION
.........................14-28
IDLE AIR CONTROL MOTOR - REMOVAL
. . 14-29
IDLER SHAFT - INSTALLATION
......9-179,9-81
IDLER SHAFT - REMOVAL
..........9-179,9-81
IGNITION - SPECIFICATIONS, TORQUE
.....8I-3
16 INDEXDR
Description Group-Page Description Group-Page Description Group-Page