2003 DODGE RAM Heater core

If the floor outlet air temperature is too low, refer
to Cooling to check the engine coolant temperature
specifications. Both of the heater hoses should be hot
to the touch. The coolant return heater hose should
be slightly cooler than the coolant supply heater
hose. If the return hose is much cooler than the sup-
ply hose, locate and repair the engine coolant flow
obstruction in the cooling system. Refer to Cooling
for the procedures.
An alternate method of checking heater perfor-
mance is to use a DRBIIItscan tool to monitor the
engine coolant temperature. The floor outlet air tem-
perature reading should be no more than 4.5É C (40É
F) lower than the engine coolant temperature read-
ing.
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow:
²Faulty water pump.
²Faulty thermostat.
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²A plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is still
low, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible locations or
causes of insufficient heat:
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²A faulty, obstructed or improperly installed
blend door.
²A faulty blower system.
²A faulty a/c heater control.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
a/c heater control panel, the following could require
service:
²A faulty a/c heater control.
²A faulty blend door actuator.
²A faulty, obstructed or improperly installed
blend door.
²An obstructed cowl air intake.
²The engine cooling system.
Heater Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT HEATER
OUTPUT.1. Incorrect engine
coolant level.1. Check the engine coolant level. Refer to Cooling for
the procedures.
2. Air trapped in engine
cooling system.2. Check the operation of the coolant reserve/recovery
system. Refer to Cooling for the procedures.
3. Incorrect engine
coolant temperature.3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Cooling for the procedures.
4. Blend door actuator
inoperative or defective.4. (Refer to Controls/Blend Door Actuator) in this group.
5. Blend door not
operating properly.5. Check for a damaged, obstructed or improperly
installed blend door or seals. (Refer to Controls/Blend
Door Actuator) in this group.
6. Insufficient air flow
through heater housing.6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.7. (Refer to Distribution/Blower Motor/ Diagnosis and
Testing) in this group.
24 - 6 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

(3) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube (Fig. 4). (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - A/C LINE COU-
PLERS)
(5) Disconnect the accumulator inlet tube refriger-
ant line fitting from the evaporator outlet tube.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS) Install plugs in, or tape over all of the
opened refrigerant line fittings.
(6) Drain the engine cooling system(Refer to 7 -
COOLING - STANDARD PROCEDURE).(7) Disconnect the heater hoses from the heater
core tubes. Install plugs in, or tape over the opened
heater core tubes.
(8) Unplug all electrical connectors from the actua-
tors and blower motor.
(9) Remove the nuts from the HVAC housing
mounting studs.
(10) Remove the HVAC housing from inside the
vehicle taking care not to allow any remaining cool-
ant to drain on the vehicles interior.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on the workbench. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - REMOVAL)
(2) Unplug the electrical connectors from each
actuator.
(3) Remove the HVAC assembly wiring harness
from the HVAC case.
(4) Remove the blower motor and blower wheel
unit from the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/
BLOWER MOTOR - REMOVAL)
(5) Remove the heater core mounting screws and
carefully remove the heater core assembly(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
(6) Carefully remove the foam seals from the
heater core and evaporator coil tube mounting flange
of the HVAC housing. If the either seal is deformed
or damaged it must be replaced.
(7) Use a screwdriver to pry off the four snap clips
that help secure the upper and lower HVAC housing
halves together.
(8) Remove the screws that secure the upper and
lower HVAC housing halves together.
(9) Carefully separate the upper HVAC housing
from the lower half.
ASSEMBLY
(1) Assemble the upper HVAC housing half to the
lower half. During assembly, be certain of the follow-
ing.
(a) That each of the mode door pivot shaft ends
and the temperature blend door shafts are properly
engaged in there pivot holes.
(b) That the blower motor is properly indexed
and installed.
(c) If the unit is equipped with air conditioning,
that the evaporator coil tube rubber seal is prop-
erly positioned in the grooves in both the upper
and lower HVAC housing halves.
(d) That the evaporator drain opening is clean.
(e) That the evaporator drain shield is installed
correctly.
Fig. 4 HVAC Housing - Dual Zone Shown (Typical -
Single Zone)
1 - Mounting Nut
2 - Passenger Blend Door Actuator (dual zone)
3 - Mounting Nut
4 - Air Intake Spacer
5 - Recirculation Door Actuator
6 - Recirculation Door Assembly
7 - Driver Side Blend Door Actuator
8 - HVAC Housing
9 - Mounting Screw
10 - Defroster Door Actuator
11 - Panel Actuator
24 - 28 DISTRIBUTIONDR
HVAC HOUSING (Continued)

(2) Install the screws and snap clips that secure
the upper and lower HVAC housing halves to each
other. Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Install the blower motor and wheel unit in the
HVAC housing. (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/BLOWER MOTOR -
INSTALLATION)
(4) Install the foam seals on the flanges around
the heater core and evaporator coil tube mounting
flange of the HVAC housing. Repair or replace any
seals as required.
(5) Install the electrical wiring harness for the
acutators. Make sure the wires are routed through
all wiring retainers, replace any retainers that are
damaged or missing.
(6) Connect the wiring harness to each actuator,
making sure each connector is securely attached.
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION -
REFRIGERANT HOSES/LINES/TUBES PRECAU-
TIONS)
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct mounting holes.
(2) Install and tighten the nuts onto the HVAC
housing mounting studs. Tighten the nuts to 6.2 N´m
(55 in.lbs.).
(3) Connect the HVAC system electrical connec-
tors.
(4) Unplug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fill the engine cooling system(Refer to
7 - COOLING/ENGINE - STANDARD PROCE-
DURE).
(5) Unplug or remove the tape from the liquid line
and the evaporator inlet tube fittings. Connect the
liquid line coupler to the evaporator inlet tube. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLERS)(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(8) Install the instrument panel in the vehicle(Re-
fer to 23 - BODY/INSTRUMENT PANEL - INSTAL-
LATION).
(9) Connect the battery negative cable.
(10) Start the engine and check for proper opera-
tion of the heating and air conditioning systems.
(11) Run the calibration procedure.
INSTRUMENT PANEL DUCTS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the HVAC assembly from the vehi-
cle(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(3) Disasemble the HVAC housing(Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - DISASSEMBLY).
(4) Remove the panel door actuator from the hous-
ing if not already removed.
(5) With the actuator removed you can take the
door and shift it so that one pivot point will clear the
housing. You can then tilt the door and remove it
from the housing.
INSTALLATION
(1) Take the door and tilt it so one pivot point is
installed. The carfully install the second pivot point.
Check to be sure no binding of the door is occuring,
repair as required.
(2) Reassemble the HVAC housing(Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC assembly into the vehicle(Re-
fer to 24 - HEATING & AIR CONDITIONING/DIS-
TRIBUTION/INSTRUMENT PANEL DUCTS -
INSTALLATION).
(4) Connect the battery negative cable.
DRDISTRIBUTION 24 - 29
HVAC HOUSING (Continued)

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE.......32
OPERATION- REFRIGERANT LINES........32
WARNING
SERVICE WARNINGS..................32
CAUTION
SERVICE CAUTIONS..................33
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS.................33
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........34
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................34
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................35
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................35
SPECIFICATIONS - CHARGE CAPACITY.....35
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION........................35
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE..............................35
OPERATION
OPERATION.........................36
OPERATION - HIGH PRESSURE RELIEF
VALVE..............................36
DIAGNOSIS AND TESTING - A/C
COMPRESSOR NOISE.................36
REMOVAL
REMOVAL...........................37
REMOVAL - 5.9L DIESEL ENGINE.........37
INSTALLATION
INSTALLATION.......................38
INSTALLATION - 5.9L DIESEL ENGINE.....39
A/C CONDENSER
DESCRIPTION.........................39
OPERATION...........................39
REMOVAL
REMOVAL - 3.7, 4.7 and 5.7L ENGINES....39
REMOVAL - 5.9L DIESEL ENGINE.........40
REMOVAL - 8.0L Engine................40
INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES . 41
INSTALLATION - 5.9L DIESEL ENGINE.....42
INSTALLATION - 8.0L Engine.............42A/C CONDENSER FAN
REMOVAL - CONDENSER FAN (GAS ENGINE
ONLY - 3.7, 4.7 & 5.7L).................43
INSTALLATION - CONDENSER FAN (GAS
ENGINE ONLY - 3.7, 4.7 & 5.7L)..........43
A/C DISCHARGE LINE
REMOVAL
REMOVAL...........................43
REMOVAL - 5.9L DIESEL ENGINE.........43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - 5.9L DIESEL ENGINE.....44
LIQUID LINE
REMOVAL.............................45
INSTALLATION.........................45
SUCTION LINE
REMOVAL
REMOVAL...........................46
REMOVAL - 5.9L DIESEL ENGINE.........46
INSTALLATION
INSTALLATION.......................46
INSTALLATION.......................47
A/C EVAPORATOR
DESCRIPTION.........................47
OPERATION...........................47
REMOVAL.............................47
INSTALLATION.........................47
A/C ORIFICE TUBE
DESCRIPTION.........................48
OPERATION...........................48
DIAGNOSIS AND TESTING - FIXED ORIFICE
TUBE...............................48
REMOVAL.............................49
INSTALLATION.........................49
ACCUMULATOR
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................49
INSTALLATION.........................50
HEATER CORE
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
REFRIGERANT
DESCRIPTION.........................50
OPERATION...........................50
DIAGNOSIS AND TESTING- REFRIGERANT
SYSTEM LEAKS......................51
DRPLUMBING 24 - 31

INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the accumulator to the bulkhead but do
not tighten yet.
(2) Remove the tape or plugs from the refrigerant
line fittings on the accumulator inlet and the evapo-
rator outlet. Connect the accumulator inlet refriger-
ant line coupler to the evaporator outlet. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(3) Remove the tape or plugs from the refrigerant
line fittings on the suction line and the accumulator
outlet. Connect the suction line refrigerant line cou-
pler to the accumulator outlet. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(4) Tighten the accumulator fasteners to 4.5 N´m
(40 in. lbs.).
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the accumulator is replaced, add 60 milli-
liters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing,
under the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
The heater core is not repairable and if damaged it
must be replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flowsthrough the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the HVAC housing is directed through the heater
core. The blower motor speed controls the volume of
air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
NOTE: Disassembly of the HVAC housing is not
required to remove heater core.
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the screws and retainers that secure
the heater core to the HVAC housing.
(3) Lift the heater core out of the heater-A/C hous-
ing.
(4) Inspect all seals and repair or replace as
required.
INSTALLATION
(1) Place the heater core into the HVAC housing.
(2) Snap the retainers for the heater core to the
housing. Install and tighten the screws that secure
the heater core to the HVAC housing (if equipped).
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Reinstall the HVAC housing in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - INSTALLA-
TION)
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
24 - 50 PLUMBINGDR
ACCUMULATOR (Continued)

COOLER - 5.9L DIESEL - DESCRIPTION,
TRANS..............................7-73
COOLER - 5.9L DIESEL - OPERATION,
TRANS..............................7-74
COOLER - INSTALLATION, AIR TO OIL.....7-75
COOLER - INSTALLATION, FLUID........19-42
COOLER - INSTALLATION, RETURN
HOSE - GEAR TO................19-43,19-44
COOLER - INSTALLATION, RETURN
HOSE - RESERVOIR TO...........19-43,19-44
COOLER - REMOVAL, AIR TO OIL.........7-74
COOLER - REMOVAL, FLUID............19-42
COOLER - REMOVAL, RETURN HOSE -
GEAR TO...........................19-43
COOLER - REMOVAL, RETURN HOSE -
RESERVOIR TO.................19-43,19-44
COOLER - REMOVAL, WATER TO OIL......7-74
COOLER AND PLUMBING - CLEANING,
CHARGE AIR........................11-16
COOLER AND PLUMBING -
DESCRIPTION, CHARGE AIR............11-15
COOLER AND PLUMBING - INSPECTION,
CHARGE AIR........................11-16
COOLER AND PLUMBING -
INSTALLATION, CHARGE AIR...........11-16
COOLER AND PLUMBING - OPERATION,
CHARGE AIR........................11-15
COOLER AND PLUMBING - REMOVAL,
CHARGE AIR........................11-15
COOLER SYSTEM - LEAKS - DIAGNOSIS
AND TESTING, CHARGE AIR............11-15
COOLING, SPECIAL TOOLS...............7-20
COOLING SYSTEM - OPERATION..........7-3
COOLING SYSTEM - TESTING FOR
LEAKS - DIAGNOSIS AND TESTING........7-5
COOLING SYSTEM 3.7L/4.7L/5.7L
ENGINE - STANDARD PROCEDURE,
DRAINING...........................7-18
COOLING SYSTEM 3.7L/4.7L/5.7L
ENGINE - STANDARD PROCEDURE,
REFILLING...........................7-18
COOLING SYSTEM 5.9L DIESEL ENGINE
- STANDARD PROCEDURE, DRAINING.....7-19
COOLING SYSTEM 5.9L DIESEL ENGINE
- STANDARD PROCEDURE, REFILLING.....7-19
COOLING SYSTEM 5.9L/8.0L ENGINE -
STANDARD PROCEDURE, DRAINING......7-18
COOLING SYSTEM 5.9L/8.0L ENGINE -
STANDARD PROCEDURE, REFILLING......7-18
COOLING SYSTEM CLEANING/REVERSE
FLUSHING - STANDARD PROCEDURE.....7-17
COOLING SYSTEM DIESEL ENGINE -
DIAGNOSIS AND TESTING...............7-7
COOLING SYSTEM FLOW - 5.9L DIESEL
- DESCRIPTION........................7-2
COOLING SYSTEM FLOW - 5.9L ENGINE
- DESCRIPTION........................7-1
COOLING SYSTEM FLOW 3.7L/4.7L
ENGINE - DESCRIPTION.................7-1
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION........................24-1
CORE - DESCRIPTION, HEATER.........24-50
CORE - INSTALLATION, HEATER.........24-50
CORE - OPERATION, HEATER...........24-50
CORE - REMOVAL, HEATER
............24-50
CORE HOLE PLUG - INSTALLATION,
CAMSHAFT
.........................9-201
CORE HOLE PLUG - REMOVAL,
CAMSHAFT
.........................9-200
CORE PLUGS - INSTALLATION
..........9-130
CORE PLUGS - REMOVAL
..............9-129
COUPLER - DESCRIPTION,
REFRIGERANT LINE
...................24-52
COUPLER - INSTALLATION,
REFRIGERANT LINE
...................24-53
COUPLER - OPERATION, REFRIGERANT
LINE
...............................24-52
COUPLER - REMOVAL, REFRIGERANT
LINE
...............................24-52
COUPLING - INSTALLATION, UPPER
STEERING
..........................19-14
COUPLING - REMOVAL, UPPER
STEERING
..........................19-13
COVER - DESCRIPTION, STRUCTURAL
. . . 9-143,
9-210,9-56
COVER - FRONT - INSTALLATION, SEAT
BACK CUSHION
......................23-83COVER - FRONT - INSTALLATION, SEAT
CUSHION...........................23-83
COVER - FRONT - REMOVAL, SEAT BACK
CUSHION...........................23-83
COVER - FRONT - REMOVAL, SEAT
CUSHION...........................23-83
COVER - INSTALLATION...............23-16
COVER - INSTALLATION, ACM...........8O-9
COVER - INSTALLATION, CENTER SEAT
BACK INERTIA HINGE.................23-78
COVER - INSTALLATION, CENTER SEAT
CUSHION...........................23-81
COVER - INSTALLATION, CYLINDER
HEAD..............................9-304
COVER - INSTALLATION, GEAR HOUSING . 9-350
COVER - INSTALLATION, INSTRUMENT
PANEL TOP.........................23-60
COVER - INSTALLATION, REAR DOOR
SILL TRIM..........................23-72
COVER - INSTALLATION, SHIFT . . . 21-128,21-86
COVER - INSTALLATION, STEERING
COLUMN OPENING...................23-61
COVER - INSTALLATION, STRUCTURAL . . . 9-143,
9-210,9-56
COVER - INSTALLATION, TIMING/CHAIN . . 9-221
COVER - OPERATION, STRUCTURAL.....9-143,
9-210,9-56
COVER - REAR - INSTALLATION, SEAT
BACK CUSHION......................23-85
COVER - REAR - INSTALLATION, SEAT
CUSHION...........................23-85
COVER - REAR - REMOVAL, SEAT BACK
CUSHION...........................23-85
COVER - REAR - REMOVAL, SEAT
CUSHION...........................23-85
COVER - REMOVAL...................23-16
COVER - REMOVAL, ACM...............8O-9
COVER - REMOVAL, CENTER SEAT BACK
INERTIA HINGE......................23-78
COVER - REMOVAL, CENTER SEAT
CUSHION...........................23-81
COVER - REMOVAL, CYLINDER HEAD....9-304
COVER - REMOVAL, GEAR HOUSING.....9-349
COVER - REMOVAL, INSTRUMENT
PANEL TOP.........................23-59
COVER - REMOVAL, REAR DOOR SILL
TRIM..............................23-72
COVER - REMOVAL, SHIFT.......21-128,21-86
COVER - REMOVAL, STEERING COLUMN
OPENING...........................23-61
COVER - REMOVAL, STRUCTURAL . 9-143,9-210,
9-56
COVER - REMOVAL, TIMING/CHAIN......9-220
COVER - REMOVAL, WHEEL............22-14
COVER GASKET - DESCRIPTION,
CYLINDER HEAD.....................9-243
COVER GASKET - OPERATION,
CYLINDER HEAD.....................9-243
COVER INSTALLED - INSTALLATION,
FRONT OIL SEAL - FRONT.............9-384
COVER INSTALLED - REMOVAL, FRONT
OIL SEAL - FRONT...................9-384
COVER REMOVED - INSTALLATION,
FRONT OIL SEAL - FRONT.............9-384
COVER REMOVED - REMOVAL, FRONT
OIL SEAL - FRONT...................9-384
COVERING - INSTALLATION, UNDER
SEAT STORAGE BIN..................23-81
COVERING - REMOVAL, UNDER SEAT
STORAGE BIN.......................23-81
COVER(S) - CLEANING, CYLINDER HEAD . 9-245,
9-374
COVER(S) - DESCRIPTION, CYLINDER
HEAD.....................9-121,9-26,9-373
COVER(S) - INSPECTION, CYLINDER
HEAD.........................9-245,9-374
COVER(S) - INSTALLATION, CYLINDER
HEAD............9-196,9-245,9-27,9-36,9-374
COVER(S) - INSTALLATION, TIMING
BELT / CHAIN.........9-169,9-278,9-404,9-81
COVER(S) - REMOVAL, CYLINDER HEAD . 9-196,
9-245,9-26,9-35,9-373
COVER(S) - REMOVAL, TIMING BELT /
CHAIN
...............9-168,9-278,9-404,9-80
COWL GRILLE - INSTALLATION
.........23-38
COWL GRILLE - REMOVAL
.............23-38
COWL TRIM - INSTALLATION
...........23-67
COWL TRIM - REMOVAL
...............23-67C-PILLAR LOWER TRIM - INSTALLATION . . 23-68
C-PILLAR LOWER TRIM - REMOVAL.....23-67
C-PILLAR UPPER TRIM - INSTALLATION . . 23-68
C-PILLAR UPPER TRIM - REMOVAL......23-68
CRANKCASE BREATHER - INSTALLATION . . 9-292
CRANKCASE BREATHER - REMOVAL.....9-291
CRANKSHAFT - DESCRIPTION . 9-130,9-252,9-39
CRANKSHAFT - INSPECTION........9-131,9-40
CRANKSHAFT - INSTALLATION....9-131,9-202,
9-252,9-383,9-41
CRANKSHAFT - OPERATION............9-252
CRANKSHAFT - REMOVAL . . . 9-130,9-201,9-252,
9-382,9-39
CRANKSHAFT AND GEAR -
DESCRIPTION.......................9-322
CRANKSHAFT JOURNAL CLEARANCE -
STANDARD PROCEDURE, CONNECTING
ROD BEARING.......................9-321
CRANKSHAFT MAIN BEARING - FITTING
- STANDARD PROCEDURE........9-133,9-202
CRANKSHAFT MAIN BEARING FITTING -
STANDARD PROCEDURE...............9-253
CRANKSHAFT MAIN BEARINGS -
DESCRIPTION.......................9-253
CRANKSHAFT MAIN BEARINGS -
INSPECTION...................9-133,9-203
CRANKSHAFT MAIN BEARINGS -
INSTALLATION..................9-254,9-383
CRANKSHAFT MAIN BEARINGS -
OPERATION.........................9-253
CRANKSHAFT MAIN BEARINGS -
REMOVAL.....................9-254,9-383
CRANKSHAFT MAIN BEARINGS -
STANDARD PROCEDURE, FITTING.......9-383
CRANKSHAFT OIL SEAL - FRONT -
DESCRIPTION.......................9-254
CRANKSHAFT OIL SEAL - FRONT -
INSTALLATION . . . 9-134,9-203,9-255,9-324,9-45
CRANKSHAFT OIL SEAL - FRONT -
OPERATION.........................9-254
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL.......9-134,9-203,9-254,9-323,9-44
CRANKSHAFT OIL SEAL - REAR -
DESCRIPTION.......................9-255
CRANKSHAFT OIL SEAL - REAR -
INSTALLATION . . 9-136,9-204,9-256,9-325,9-385,
9-46
CRANKSHAFT OIL SEAL - REAR -
OPERATION.........................9-255
CRANKSHAFT OIL SEAL - REAR -
REMOVAL . . 9-135,9-204,9-255,9-325,9-385,9-45
CRANKSHAFT POSITION SENSOR -
DESCRIPTION..................14-26,14-83
CRANKSHAFT POSITION SENSOR -
INSTALLATION..................14-30,14-84
CRANKSHAFT POSITION SENSOR -
OPERATION....................14-26,14-83
CRANKSHAFT POSITION SENSOR -
REMOVAL.....................14-29,14-84
CRANKSHAFT REAR OIL SEAL RETAINER
- INSTALLATION...........9-205,9-326,9-386
CRANKSHAFT REAR OIL SEAL RETAINER
- REMOVAL...............9-204,9-326,9-386
CROSS MEMBER BUSHING -
INSTALLATION, TORSION BAR...........2-14
CROSSHEADS - CLEANING.............9-300
CROSSHEADS - INSPECTION...........9-301
CROSSMEMBER - INSTALLATION, FRONT . 13-23
CROSSMEMBER - INSTALLATION,
TRANSMISSION......................13-25
CROSSMEMBER - INSTALLATION,
UPPER RADIATOR
....................23-42
CROSSMEMBER - REMOVAL, FRONT
.....13-23
CROSSMEMBER - REMOVAL,
TRANSMISSION
......................13-24
CROSSMEMBER - REMOVAL, UPPER
RADIATOR
..........................23-42
CROSSMEMBER BUSHING - REMOVAL,
TORSION BAR
........................2-12
CRUISE INDICATOR - DESCRIPTION
......8J-22
CRUISE INDICATOR - OPERATION
.......8J-22
CUP HOLDER - INSTALLATION
..........23-52
CUP HOLDER - REMOVAL
..............23-52
CURTAIN AIRBAG - DESCRIPTION, SIDE
. . 8O-51
CURTAIN AIRBAG - INSTALLATION, SIDE
. . 8O-53
CURTAIN AIRBAG - OPERATION, SIDE
....8O-51
CURTAIN AIRBAG - REMOVAL, SIDE
.....8O-52
DRINDEX 9
Description Group-Page Description Group-Page Description Group-Page

GOVERNOR - REMOVAL, ELECTRONIC . . 21-198,
21-378
GRAB HANDLE - INSTALLATION,
B-PILLAR...........................23-69
GRAB HANDLE - REMOVAL, B-PILLAR....23-69
GRILLE - INSTALLATION...............23-40
GRILLE - INSTALLATION, COWL.........23-38
GRILLE - REMOVAL..................23-39
GRILLE - REMOVAL, COWL............23-38
GRILLE FRAME - INSTALLATION.........23-40
GRILLE FRAME - REMOVAL............23-40
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO..........8W-01-9
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR..........8W-01-7
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO.............................8W-01-10
GROUND STRAP - DESCRIPTION, RADIO
NOISE SUPPRESSION..................8A-8
GROUND STRAP - INSTALLATION,
RADIO NOISE SUPPRESSION...........8A-10
GROUND STRAP - OPERATION, RADIO
NOISE SUPPRESSION..................8A-8
GROUND STRAP - REMOVAL, RADIO
NOISE SUPPRESSION..................8A-9
GROUNDS - DESCRIPTION, POWER......8E-10
GUIDE SEALS - DESCRIPTION, VALVE . 9-31,9-36
GUIDES - DESCRIPTION, VALVE....9-106,9-197
GUIDES AND SPRINGS - STANDARD
PROCEDURE, VALVES............9-246,9-305
HALF SHAFT - CAUTION................3-11
HALF SHAFT - DIAGNOSIS AND TESTING . . 3-11
HALF SHAFT - INSTALLATION............3-12
HALF SHAFT - REMOVAL...............3-11
HALF SHAFT - SPECIAL TOOLS..........3-12
HALF SHAFT - SPECIFICATIONS..........3-12
HANDLE - INSTALLATION, A-PILLAR
TRIM/GRAB.........................23-64
HANDLE - INSTALLATION, B-PILLAR
GRAB..............................23-69
HANDLE - INSTALLATION, EXTERIOR....23-20,
23-30
HANDLE - INSTALLATION, RELEASE.......5-38
HANDLE - REMOVAL, A-PILLAR
TRIM/GRAB.........................23-64
HANDLE - REMOVAL, B-PILLAR GRAB....23-69
HANDLE - REMOVAL, EXTERIOR . . . 23-20,23-30
HANDLE - REMOVAL, RELEASE..........5-38
HANDLE ACTUATOR - INSTALLATION,
INSIDE........................23-22,23-32
HANDLE ACTUATOR - REMOVAL, INSIDE . 23-22,
23-31
HANDLE/LATCH REMOTE -
INSTALLATION, RELEASE..............23-17
HANDLE/LATCH REMOTE - REMOVAL,
RELEASE...........................23-17
HANDLING NON-DEPLOYED
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE...............8O-6
HARNESS - DIAGNOSIS AND TESTING,
WIRING..........................8W-01-7
HAT BRAKE - CLEANING, REAR DRUM
IN .................................5-33
HAT BRAKE - INSPECTION, REAR DRUM
IN .................................5-33
HAZARD SWITCH - DESCRIPTION.......8L-13
HAZARD SWITCH - OPERATION.........8L-13
HCU (HYDRAULIC CONTROL UNIT) -
DESCRIPTION........................5-43
HCU (HYDRAULIC CONTROL UNIT) -
INSTALLATION........................5-44
HCU (HYDRAULIC CONTROL UNIT) -
OPERATION..........................5-43
HCU (HYDRAULIC CONTROL UNIT) -
REMOVAL...........................5-44
HD - INSTALLATION, 4X4..............19-15
HD - INSTALLATION, ALL LD & HD
EXCEPT 4X4........................19-15
HD - REMOVAL, 4X4
..................19-14
HD - REMOVAL, ALL LD & HD EXCEPT
4X4
...............................19-14
HD EXCEPT 4X4 HD - INSTALLATION,
ALL LD
............................19-15
HD EXCEPT 4X4 HD - REMOVAL, ALL LD
. 19-14
HEAD - CLEANING, CYLINDER
.....9-195,9-300,
9-372HEAD - DESCRIPTION, CYLINDER . . 9-106,9-243,
9-298,9-370
HEAD - INSPECTION, CYLINDER . . . 9-195,9-301,
9-372
HEAD - INSTALLATION, CYLINDER . . 9-195,9-372
HEAD - INSTALLATION, LEFT CYLINDER . . 9-110
HEAD - INSTALLATION, RIGHT
CYLINDER..........................9-111
HEAD - LEFT - INSTALLATION,
CYLINDER...........................9-23
HEAD - LEFT - REMOVAL, CYLINDER......9-21
HEAD - OPERATION, CYLINDER....9-194,9-243
HEAD - REMOVAL, CYLINDER.....9-195,9-298,
9-371
HEAD - REMOVAL, LEFT CYLINDER......9-106
HEAD - REMOVAL, RIGHT CYLINDER.....9-108
HEAD - RIGHT - INSTALLATION,
CYLINDER...........................9-32
HEAD - RIGHT - REMOVAL, CYLINDER....9-32
HEAD COVER - INSTALLATION,
CYLINDER..........................9-304
HEAD COVER - REMOVAL, CYLINDER....9-304
HEAD COVER GASKET - DESCRIPTION,
CYLINDER..........................9-243
HEAD COVER GASKET - OPERATION,
CYLINDER..........................9-243
HEAD COVER(S) - CLEANING, CYLINDER . 9-245,
9-374
HEAD COVER(S) - DESCRIPTION,
CYLINDER.................9-121,9-26,9-373
HEAD COVER(S) - INSPECTION,
CYLINDER.....................9-245,9-374
HEAD COVER(S) - INSTALLATION,
CYLINDER........9-196,9-245,9-27,9-36,9-374
HEAD COVER(S) - REMOVAL, CYLINDER . 9-196,
9-245,9-26,9-35,9-373
HEAD GASKET - DIAGNOSIS AND
TESTING, CYLINDER...................9-20
HEAD GASKET FAILURE - DIAGNOSIS
AND TESTING, CYLINDER....9-194,9-243,9-370
HEAD GASKET SELECTION - STANDARD
PROCEDURE........................9-330
HEADLAMP - INSTALLATION............8L-13
HEADLAMP - REMOVAL...............8L-13
HEADLAMP ALIGNMENT - SPECIAL
TOOLS..............................8L-7
HEADLAMP SWITCH - DESCRIPTION.....8L-14
HEADLAMP SWITCH - INSTALLATION....8L-14
HEADLAMP SWITCH - OPERATION.......8L-14
HEADLAMP SWITCH - REMOVAL........8L-14
HEADLAMP SWITCH BEZEL -
INSTALLATION, INSTRUMENT PANEL.....23-57
HEADLAMP SWITCH BEZEL - REMOVAL,
INSTRUMENT PANEL..................23-57
HEADLAMP UNIT - ADJUSTMENTS......8L-15
HEADLAMP UNIT - INSTALLATION.......8L-15
HEADLAMP UNIT - REMOVAL...........8L-15
HEADLINER - INSTALLATION...........23-69
HEADLINER - REMOVAL...............23-69
HEADREST - INSTALLATION............23-82
HEADREST - REMOVAL................23-82
HEADREST SLEEVE - INSTALLATION.....23-82
HEADREST SLEEVE - REMOVAL.........23-82
HEAT SHIELDS - DESCRIPTION..........11-7
HEAT SHIELDS - INSTALLATION..........11-8
HEAT SHIELDS - REMOVAL.............11-7
HEAT STAKING - STANDARD
PROCEDURE.........................23-3
HEATED MIRROR SYSTEM -
DESCRIPTION........................8G-1
HEATED MIRROR SYSTEM - DIAGNOSIS
AND TESTING........................8G-2
HEATED MIRROR SYSTEM - OPERATION . . . 8G-1
HEATED SEAT ELEMENT - DESCRIPTION . . . 8G-5
HEATED SEAT ELEMENT - DIAGNOSIS
AND TESTING........................8G-6
HEATED SEAT ELEMENT - INSTALLATION . . 8G-6
HEATED SEAT ELEMENT - OPERATION.....8G-6
HEATED SEAT ELEMENT - REMOVAL......8G-6
HEATED SEAT MODULE - DESCRIPTION....8E-6
HEATED SEAT MODULE - DIAGNOSIS
AND TESTING........................8E-7
HEATED SEAT MODULE - INSTALLATION
. . . 8E-7
HEATED SEAT MODULE - OPERATION
.....8E-6
HEATED SEAT MODULE - REMOVAL
.......8E-7
HEATED SEAT SENSOR - DESCRIPTION
....8G-7
HEATED SEAT SENSOR - DIAGNOSIS
AND TESTING
........................8G-7HEATED SEAT SENSOR - OPERATION.....8G-7
HEATED SEAT SENSOR - REMOVAL.......8G-7
HEATED SEAT SWITCH - DESCRIPTION....8G-7
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING........................8G-8
HEATED SEAT SWITCH - INSTALLATION . . . 8G-9
HEATED SEAT SWITCH - OPERATION......8G-8
HEATED SEAT SWITCH - REMOVAL.......8G-9
HEATED SEAT SYSTEM - DESCRIPTION....8G-3
HEATED SEAT SYSTEM - DIAGNOSIS
AND TESTING........................8G-4
HEATED SEAT SYSTEM - OPERATION.....8G-4
HEATER - 5.9L DIESEL - DESCRIPTION,
ENGINE BLOCK.......................7-43
HEATER - 5.9L DIESEL - INSTALLATION,
ENGINE BLOCK.......................7-44
HEATER - 5.9L DIESEL - OPERATION,
ENGINE BLOCK.......................7-43
HEATER - 5.9L DIESEL - REMOVAL,
ENGINE BLOCK.......................7-43
HEATER - DESCRIPTION, ENGINE BLOCK . . . 7-42
HEATER - DESCRIPTION, FUEL..........14-63
HEATER - DESCRIPTION, INTAKE AIR.....14-91
HEATER - DIAGNOSIS AND TESTING,
ENGINE BLOCK.......................7-42
HEATER - DIAGNOSIS AND TESTING,
FUEL..............................14-63
HEATER - INSTALLATION, ENGINE
BLOCK..............................7-43
HEATER - INSTALLATION, INTAKE AIR......14-91
HEATER - OPERATION, ENGINE BLOCK....7-42
HEATER - OPERATION, FUEL............14-63
HEATER - OPERATION, INTAKE AIR......14-91
HEATER - REMOVAL, ENGINE BLOCK......7-43
HEATER - REMOVAL, INTAKE AIR........14-91
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......24-14
HEATER CORE - DESCRIPTION..........24-50
HEATER CORE - INSTALLATION.........24-50
HEATER CORE - OPERATION............24-50
HEATER CORE - REMOVAL.............24-50
HEATER PERFORMANCE - DIAGNOSIS
AND TESTING........................24-5
HEATER RELAY - DESCRIPTION, FUEL....14-64
HEATER RELAY - DESCRIPTION, INTAKE
AIR ...............................14-92
HEATER RELAY - INSTALLATION, FUEL . . . 14-64
HEATER RELAY - INSTALLATION, INTAKE
AIR ...............................14-93
HEATER RELAY - OPERATION, FUEL......14-64
HEATER RELAY - OPERATION, INTAKE
AIR ...............................14-92
HEATER RELAY - REMOVAL, FUEL.......14-64
HEATER RELAY - REMOVAL, INTAKE AIR . . 14-93
HEIGHT ADJUSTMENT - 4WD (LD) -
STANDARD PROCEDURE.................2-3
HEIGHT MEASUREMENT - 4WD (LD) -
STANDARD PROCEDURE.................2-3
HIGH BEAM INDICATOR - DESCRIPTION . . 8J-27
HIGH BEAM INDICATOR - OPERATION
....8J-28
HIGH MOUNTED STOP LAMP -
INSTALLATION, CENTER
...............8L-10
HIGH MOUNTED STOP LAMP -
REMOVAL, CENTER
...................8L-10
HIGH MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER
...............8L-10
HIGH MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER
...................8L-10
HIGH PRESSURE RELIEF VALVE -
DESCRIPTION
.......................24-35
HIGH PRESSURE RELIEF VALVE -
OPERATION
.........................24-36
HIGH SPEEDS - DESCRIPTION, TIRE
PRESSURE
..........................22-6
HIGH/LOW RELAY - DESCRIPTION,
WIPER
.............................8R-20
HIGH/LOW RELAY - DIAGNOSIS AND
TESTING, WIPER
.....................8R-21
HIGH/LOW RELAY - INSTALLATION,
WIPER
.............................8R-21
HIGH/LOW RELAY - OPERATION, WIPER
. . 8R-20
HIGH/LOW RELAY - REMOVAL, WIPER
. . . 8R-21
16 INDEXDR
Description Group-Page Description Group-Page Description Group-Page