2003 DODGE RAM cooling system flow

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................1
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................1
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................5
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................7
SPECIFICATIONS
A/C APPLICATION TABLE................7
SPECIFICATIONS......................8
CONTROLS.............................9
DISTRIBUTION..........................24
PLUMBING.............................31
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Engine Cooling for
more information before the opening of, or attempt-
ing any service to the engine cooling system.
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system, toensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
OPERATION
OPERATION - HEATER AND AIR CONDITIONER
The heater air conditioner are blend-air type sys-
tems. In a blend-air system, a blend door controls the
amount of unconditioned air (or cooled air from the
evaporator on models with air conditioning) that is
allowed to flow through, or around, the heater core. A
temperature control knob on the A/C Heater control
panel determines the discharge air temperature by
controlling an electric actuator, which moves the
blend door. This allows an almost immediate control
of the output air temperature of the system.
The mode control knob on the A/C Heater control
panel is used to direct the conditioned air to the
selected system outlets. Both mode control switches
use electric actuators to control the mode doors.
On all vehicles, the outside air intake can be shut
off by selecting the Recirculation Mode with the
mode control knob. This will operate a electric actu-
ated recirculation door that closes off the outside
fresh air intake and recirculates the air that is
already inside the vehicle.
The air conditioner for all models is designed for
the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
heated air. This air conditioning system uses a fixed
orifice tube in the liquid line near the condenser out-
let tube to meter refrigerant flow to the evaporator
DRHEATING & AIR CONDITIONING 24 - 1

Pressure Diagnosis
Condition Possible Causes Correction
4. Faulty a/c compressor
clutch relay.4. See A/C Compressor Clutch Relay/Diagnosis
and Testing - Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty Fin Sensor.5. See Fin Sensor/Diagnosis and Testing in this
group. Reinstall or replace the Fin Sensor as
required.
6. Faulty a/c high pressure
transducer.6. See A/C High Pressure Transducer/Diagnosis
and Testing in this group. Test the a/c high
pressure transducer and replace, if required.
7. Faulty Powertrain Control
Module (PCM).7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil/Standard Procedure -
Refrigerant Oil Level in this group. Recover the
refrigerant from the refrigerant system and
inspect the refrigerant oil content. Restore the
refrigerant oil to the proper level, if required.
2. Blend door inoperative or
sealing improperly.2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.3. Perform blend door actuator diagnosis, replace
if faulty.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Refrigerant flow through
the accumulator is restricted.2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.1. Condenser air flow
restricted.1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Cooling for more information on air
seals. Clean, repair, or replace components as
required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.3. See Plumbing/Standard Procedure -
Refrigerant System Charge in this group. Recover
the refrigerant from the refrigerant system.
Charge the refrigerant system to the proper level,
if required.
24 - 4 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

Pressure Diagnosis
Condition Possible Causes Correction
4. Air in the refrigerant
system.4. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.1. Accessory drive belt
slipping.1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Fixed orifice tube not
installed.2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Faulty compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
2. Restricted refrigerant flow
through the fixed orifice tube.2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Restricted refrigerant flow
through the condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performing the following tests, refer to Cool-
ing for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery sys-
tem operation, accessory drive belt condition and ten-
sion, radiator air flow and the fan drive operation.
Also be certain that the accessory vacuum supply
line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core
through two heater hoses. With the engine idling at
normal operating temperature, set the temperature
control knob in the full hot position, the mode control
switch knob in the floor position, and the blower
motor switch knob in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged at the HVAC housing floor
outlets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
DRHEATING & AIR CONDITIONING 24 - 5
HEATING & AIR CONDITIONING (Continued)

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)

STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect the battery negative cable and iso-
late it. If vehicle has a dual batterys remove both
negative cables.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 2).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connections together using rosin
core type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery negative cable(s), and
test affected systems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle DR- Ram Truck
System R134a w/ fixed
orifice tube
Compressor Saden SD-7 SP-15 PAG oil
Freeze±up
ControlA/C Fin Sensor Evaporator
mounted
High psi Control 475 psi A/C cut
outdischarge line
Control Head electronic Software -
J2190
Mode Door electric
Blend Door electric
Recirculation
Doorelectric
Blower Motor hardwired to
control headresistor block
Cooling Fan Viscous for
cooling with a
single speed
electric for A/C
for 3.7, 4.7 and
5.7L gas
engines.
Viscous for
both cooling
and A/C with
5.9L diesel
engine and
8.0L gas
engine.
Clutch Electro-
mechanical
Control relay PCM
Draw 2 - 3.7 amps @
12V  0.5V @ 70É F
Gap 0.0169- 0.0319
DRB IIIT
Reads TPS, RPM, A/C
switch test
Actuators clutch and fan
relay
Fig. 2 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
DRHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

nents, caused by condenser air flow restriction or an
overcharge of refrigerant.
OPERATION
OPERATION
The compressor is driven by the engine through an
electric clutch, drive rotor and belt arrangement. The
compressor is lubricated by refrigerant oil that is cir-
culated throughout the refrigerant system with the
refrigerant.
The compressor draws in low-pressure refrigerant
vapor from the evaporator through its suction port. It
then compresses the refrigerant into a high-pressure,
high-temperature refrigerant vapor, which is then
pumped to the condenser through the compressor dis-
charge port.
The compressor cannot be repaired. If faulty or
damaged, the entire compressor assembly must be
replaced. The compressor clutch, pulley and clutch
coil are available for service.
OPERATION - HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents the system
when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes
when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
NOISE
When investigating an air conditioning related
noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation can often be misleading.
For example: What sounds like a failed front bearing
or connecting rod, may be caused by loose bolts, nuts,
mounting brackets, or a loose compressor clutch
assembly.
Drive belts are speed sensitive. At different engine
speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressornoise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and rotor are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH - INSTALLATION)
(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAU-
TION)
(5) If the noise is from opening and closing of the
high pressure relief valve, evacuate and recharge the
refrigerant system. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM CHARGE) If the high pressure
relief valve still does not seat properly, replace the
compressor.
(6) If the noise is from liquid slugging on the suc-
tion line. Check the refrigerant oil level and the
refrigerant system charge. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT OIL - STANDARD PROCEDURE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
SPECIFICATIONS - CHARGE CAPACITY) If either
is out of specification range reclaim, evacuate and
recharge the refrigerent system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
24 - 36 PLUMBINGDR
A/C COMPRESSOR (Continued)

(7) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
INSTALLATION - 5.9L DIESEL ENGINE
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)
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - STANDARD PRO-
CEDURE) Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket.
Tighten the four mounting bolts to 24 N´m (210 in.
lbs.).
(2) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C SUCTION AND DISCHARGE LINE -
INSTALLATION)
(3) Install the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(4) Plug in the compressor clutch coil wire harness
connector.
(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)
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow next to the
engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.
The condenser cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
REMOVAL - 3.7, 4.7 and 5.7L ENGINES
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)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Disconnect the discharge line refrigerant line
fitting at the condenser inlet. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(4) Disconnect the liquid line refrigerant line fit-
ting at the condenser outlet. (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 fit-
tings.
DRPLUMBING 24 - 39
A/C COMPRESSOR (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