2005 MERCEDES-BENZ SPRINTER heater

FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the supple-
mental heater from the vehicle fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental heater control module. The pump supplies
diesel fuel from the vehicle fuel tank to the supple-
mental heater.
REMOVAL
NOTE: The dosing pump is serviceable without
removing the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line (Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 2).(2) Disconnect the fuel line between the dosing
pump and the heater unit.
NOTE: Position and retain the heater fuel line to
prevent fuel leakage while servicing the dosing
pump.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(3) Disconnect the wiring harness connector to the
fuel pump by depressing the integral spring and pull-
ing the connector away from the pump.
(4) Remove the dosing pump from the rubber iso-
lator.INSTALLATION
(1) Install the dosing pump onto the rubber isola-
tor.
(2) Connect the fuel lines to the dosing pump and
the heater unit.
NOTE: The connectors should point towards the
heater fuel line.
Fig. 1 Diesel Cabin Heater Exhaust System
1 - MOUNTING SCREW (3)
2 - STEEL HEATER EXHAUST PIPE
3 - EXHAUST CLAMP (2)4 - FLEXIBLE HEATER EXHAUST PIPE
5 - HEATER SHIELD
6 - EXHAUST PIPE MOUNTING CLIP (3)
24 - 74 CABIN HEATERVA
EXHAUST TUBE (Continued)

(3) Use aviation style clamps to attach the hose to
the fuel pump nipples (Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/FUEL LINE
- INSTALLATION).
(4) Connect the wire harness connector to the fuel
pump by depressing the integral spring and pushing
the connector towards the dosing pump. Pull the con-
nector towards the heater to verify the installation.
(5) Verify function of the supplemental heater.
FUEL LINE
STANDARD PROCEDURE - CLEANING
(1) Remove the cabin heater fuel line (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - REMOVAL).
(2) With the cabin heater line removed from the
vehicle, place a shop cloth on the fuel tank end of the
fuel line to catch any residue, then apply a small
amount of air pressure to the other end of the fuel
line.
(3) Check to see if air pressure is coming from the
tank end of the line. If pressure is flowing unre-
stricted the line is clean.(4) If the line shows any signs of being restricted
after air pressure is applied, the fuel line should be
replaced.
(5) Install the cabin heater line (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - INSTALLATION).
(6) Verify function of the heater.
REMOVAL
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Remove clamps on dosing pump end of fuel line
and separate line from the pump (Fig. 3).
NOTE: Have an approved fuel holding device ready
to capture any diesel fuel that drains from the fuel
line or heater unit.
(3) Remove clamp from the fuel line at the fuel
tank connection and separate the line from the tank.
(4) Remove any retaining clips and remove the
fuel line from vehicle.
Fig. 2 Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
VACABIN HEATER 24 - 75
FUEL DOSING PUMP (Continued)

INSTALLATION
WARNING: DO NOT OPERATE THE DCHA IN AN
ENCLOSED AREA SUCH AS A GARAGE THAT
DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA'S EXHAUST WHEN
OPERATING THE DCHA. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING: VERIFY THAT ALL DCHA FUEL LINES
ARE SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING THIS PRO-
CEDURE.
NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle's fuel tank before performing this
procedure. Add fuel, if necessary.(1) Install the heater fuel supply line into vehicle
and fuel line retainers.
(2) Install the fuel line connection at the fuel tank
and tighten the connection securely.
(3) Install the fuel line at the dosing pump and
tighten the connection securely.
(4) Lower the vehicle.
NOTE: Failure to prime the dosing pump after drain-
ing the DCHA fuel line will prevent DCHA heater
activation during the first attempt to start the
heater. This will also set a Diagnostic Trouble Code
(DCT) in the DCHA Control's memory. Do not per-
form the Dosing Pump Priming procedure if an
attempt was made to start the DCHA without prim-
ing the dosing pump first. This will put excess fuel
in the DCHA Heater Module and cause smoke to
emit from the DCHA exhaust pipe when heater acti-
vation occurs.
(5) Connect the DRBIIItscan tool to the Diagnos-
tic Link Connector.
(6) Turn the ignition to the ON position.
Fig. 3 Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
24 - 76 CABIN HEATERVA
FUEL LINE (Continued)

NOTE: Do not activate the Dosing Pump Prime
more than one time. This will put excess fuel in the
DCHA Heater Module an cause smoke to emit from
the DCHA exhaust pipe when heater activation
occurs.
NOTE: A clicking noise heard coming from the dos-
ing pump indicates that the pump is operational.
(7) With the DRBIIItscan tool in Cabin Heater,
select System Tests and Dosing Pump Prime. Allow
the dosing pump to run for the full 45 second cycle
time. When the 45 second cycle is complete, press
Page Back on the DRBIIItscan tool key pad to exit
the Dosing Pump Prime. The Dosing Pump Priming
procedure is now complete.
HEATER UNIT
REMOVAL
REMOVAL
WARNING: ALLOW THE SUPPLEMENTAL HEATER
TO COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR OR REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT
IN PERSONAL INJURY.
WARNING: ALLOW THE EXHAUST SYSTEM TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR OR REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
(1) Raise and support the vehicle. Take note of the
location of the flexible exhaust tube section.
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the heater and the hose and
tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board cross member at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe-board cross member and
rail.(7) Remove the wiring harness from the toe-board
cross member (Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel filler cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(9) Loosen the two fasteners at the rail. Take care
to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the heater exhaust tube flex section
from the exhaust tube by loosening the bolt of the
clamp assembly. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to cross member.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable cabin heater support device
under the cabin heater and secure the cabin heater
to the device.
(13) Loosen the remaining three fasteners to the
cross members.
(14) Remove the loosened fasteners that support
the heater while supporting the weight of the heater.
(15) Swing the unit mounting bracket from
between the exhaust bracket and rail mounting loca-
tion. Drain any residual coolant from the heater unit.
(16) Lower the cabin heater and remove from the
supporting device and place on a suitable work area.
REMOVAL
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Unplug the wire harness connector from vehi-
cle wiring harness to cabin heater harness.
(3) Unplug the wire harness connector from cabin
heater harness to dosing pump connector.
(4) Unplug the two wire harness connectors from
cabin heater harness to cabin heater controller con-
nectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
VACABIN HEATER 24 - 77
FUEL LINE (Continued)

INSTALLATION
INSTALLATION
(1) Install the unit mounting bracket between the
exhaust bracket and the rail mounting location.
(2) Install the fasteners that support the heater
while supporting the weight of the heater.
(3) Install the three fasteners to the cross mem-
bers. Tighten the M6 fasteners to 7 N´m (62 in. lbs.).
(4) Position the two spacer washers between the
body and the rubber grommets for the two mounting
points on the rail.
(5) Tighten the remaining M6 fasteners to 7 N´m
(62 in. lbs.) and the M8 fasteners to 23 N´m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.
(6) Install the seat hex nut at the heater mounting
flange to the cross members. Tighten the nut to 60
N´m (44 ft. lbs.)
(7) Install the heater exhaust tube flex section to
the exhaust tube by tightening the M6 bolt of the
clamp assembly. Install the hose to the exhaust tube.
(8) Tighten the two M8 fasteners at the rail to 23
N´m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.
(9) Install the wiring harness (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
(10) Tighten the hose and tube assembly to the
toe-board cross member at two locations.
(11) Install the second hose to the underbody hose
and tube assembly.
(12) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(13) Remove the heater unit support device from
under the vehicle.
(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Verify function of the cabin heater.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
INLET HOSE
REMOVAL
NOTE: Heater air intake tube is part of an assembly
that includes the heater cooling intake and return
pipes. If heater air intake tube requires removal or
replacement the entire assembly will require remov-
al/replacement.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(2) Remove clamps from the heater tubes at the
lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the heater air
intake muffler connection (Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/INLET
MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 4).
(5) Remove the two retaining screws and remove
pipe assembly (Fig. 5).
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N´m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the heater air intake
muffler and install and tighten the retaining clamp
securely.
24 - 78 CABIN HEATERVA
HEATER UNIT (Continued)

(4) Install the heater tubes to the lower heater
connection and the lower EGR cooler connection and
tighten the retaining clamps.(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(7) Verify function of the heater unit.
Fig. 4 Flexible Air Intake Line
1 - HEATER UNIT AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
Fig. 5 Air Intake And Heater Pipe Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
VACABIN HEATER 24 - 79
INLET HOSE (Continued)

INDEX
ABS INDICATOR - DESCRIPTION..........8J-9
ABS INDICATOR - OPERATION...........8J-9
A/C COMPRESSOR - DESCRIPTION......24-49
A/C COMPRESSOR - INSTALLATION......24-51
A/C COMPRESSOR - OPERATION........24-49
A/C COMPRESSOR - REMOVAL.........24-50
A/C COMPRESSOR CLUTCH -
DESCRIPTION........................24-8
A/C COMPRESSOR CLUTCH -
OPERATION..........................24-8
A/C CONDENSER - DESCRIPTION........24-52
A/C CONDENSER - INSTALLATION.......24-52
A/C CONDENSER - OPERATION..........24-52
A/C CONDENSER - REMOVAL...........24-52
A/C DISCHARGE LINE - INSTALLATION . . . 24-54
A/C DISCHARGE LINE - REMOVAL.......24-53
A/C EVAPORATOR - DESCRIPTION.......24-54
A/C EVAPORATOR - INSTALLATION......24-55
A/C EVAPORATOR - OPERATION.........24-54
A/C EVAPORATOR - REMOVAL..........24-55
A/C EXPANSION VALVE - DESCRIPTION . . . 24-55
A/C EXPANSION VALVE - DIAGNOSIS
AND TESTING.......................24-56
A/C EXPANSION VALVE - INSTALLATION . . 24-56
A/C EXPANSION VALVE - OPERATION.....24-55
A/C EXPANSION VALVE - REMOVAL.......24-56
A/C HEATER CONTROL - DESCRIPTION . . . 24-12
A/C HEATER CONTROL - INSTALLATION . . . 24-13
A/C HEATER CONTROL - OPERATION.....24-12
A/C HEATER CONTROL - REMOVAL......24-12
A/C HOUSING - INSTALLATION, REAR....24-41
A/C HOUSING - REMOVAL, REAR........24-40
A/C PERFORMANCE TEST - DIAGNOSIS
AND TESTING........................24-3
A/C PRESSURE TRANSDUCER -
DESCRIPTION.......................24-13
A/C PRESSURE TRANSDUCER -
DIAGNOSIS AND TESTING.............24-13
A/C PRESSURE TRANSDUCER -
INSTALLATION.......................24-14
A/C PRESSURE TRANSDUCER -
OPERATION.........................24-13
A/C PRESSURE TRANSDUCER -
REMOVAL..........................24-14
A/C SYSTEM, SPECIFICATIONS...........24-5
ACCELERATOR PEDAL POSITION
SENSOR - DESCRIPTION...............14-17
ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING.........................7-5
ACCESSORY SWITCH BEZEL -
INSTALLATION.......................23-54
ACCESSORY SWITCH BEZEL - REMOVAL . . 23-54
ACTUATOR - DESCRIPTION,
RECIRCULATION DOOR................24-20
ACTUATOR - INSTALLATION, INSIDE
HANDLE.......................23-34,23-37
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR................24-21
ACTUATOR - OPERATION,
RECIRCULATION DOOR................24-20
ACTUATOR - REMOVAL, INSIDE HANDLE . 23-34,
23-37
ACTUATOR - REMOVAL, RECIRCULATION
DOOR.............................24-21
ADAPTATION - STANDARD PROCEDURE,
TCM................................8E-8
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE................7-11
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING..................7-11
ADJUSTER - INSTALLATION, SEAT BELT
TURNING LOOP.....................8O-34
ADJUSTER - REMOVAL, SEAT BELT
TURNING LOOP.....................8O-33
ADJUSTERS - FRONT - INSTALLATION,
SEAT ..............................23-78
ADJUSTERS - FRONT - REMOVAL, SEAT . . 23-78
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE.................8O-6
AIR CLEANER ELEMENT - INSTALLATION . . 9-20
AIR CLEANER ELEMENT - REMOVAL
......9-20
AIR CLEANER HOUSING - INSTALLATION
. . 9-20
AIR CLEANER HOUSING - REMOVAL
......9-20
AIR CONDITIONER - DESCRIPTION,
HEATER
.............................24-1
AIR CONDITIONER - OPERATION,
HEATER
.............................24-2AIR COOLER AND PLUMBING -
CLEANING, CHARGE...................11-5
AIR COOLER AND PLUMBING -
DESCRIPTION, CHARGE................11-4
AIR COOLER AND PLUMBING -
INSPECTION, CHARGE.................11-5
AIR COOLER AND PLUMBING -
INSTALLATION, CHARGE................11-5
AIR COOLER AND PLUMBING -
OPERATION, CHARGE..................11-4
AIR COOLER AND PLUMBING -
REMOVAL, CHARGE...................11-5
AIR COOLER SYSTEM - LEAKS -
DIAGNOSIS AND TESTING, CHARGE.......11-4
AIR FILTER - INSTALLATION.......24-31,24-39
AIR FILTER - REMOVAL..........24-31,24-39
AIR FLOW (MAF) SENSOR -
DESCRIPTION, MANIFOLD.............14-30
AIR FLOW (MAF) SENSOR -
INSTALLATION, MANIFOLD.............14-31
AIR FLOW (MAF) SENSOR - OPERATION,
MANIFOLD..........................14-30
AIR FLOW (MAF) SENSOR - REMOVAL,
MANIFOLD..........................14-31
AIR GAP - STANDARD PROCEDURE,
COMPRESSOR CLUTCH................24-9
AIR IN FUEL SYSTEM - DIAGNOSIS AND
TESTING............................14-2
AIR OUTLET TEMPERATURE SENSOR -
DESCRIPTION.......................24-14
AIR OUTLET TEMPERATURE SENSOR -
INSTALLATION.......................24-15
AIR OUTLET TEMPERATURE SENSOR -
OPERATION.........................24-15
AIR OUTLET TEMPERATURE SENSOR -
REMOVAL..........................24-15
AIR OUTLETS - INSTALLATION..........24-32
AIR OUTLETS - REMOVAL.............24-31
AIR TEMPERATURE SENSOR -
DESCRIPTION, INLET.................14-29
AIR TEMPERATURE SENSOR -
INSTALLATION, INLET.................14-30
AIR TEMPERATURE SENSOR -
OPERATION, INLET...................14-29
AIR TEMPERATURE SENSOR -
REMOVAL, INLET....................14-30
AIRBAG - DESCRIPTION, DRIVER........8O-16
AIRBAG - DESCRIPTION, PASSENGER....8O-23
AIRBAG - INSTALLATION, DRIVER.......8O-18
AIRBAG - INSTALLATION, PASSENGER . . . 8O-26
AIRBAG - OPERATION, DRIVER.........8O-17
AIRBAG - OPERATION, PASSENGER......8O-24
AIRBAG - REMOVAL, DRIVER...........8O-17
AIRBAG - REMOVAL, PASSENGER.......8O-24
AIRBAG BRACKET - INSTALLATION,
PASSENGER........................8O-27
AIRBAG BRACKET - REMOVAL,
PASSENGER........................8O-27
AIRBAG CONTROL MODULE -
DESCRIPTION........................8O-8
AIRBAG CONTROL MODULE -
INSTALLATION......................8O-11
AIRBAG CONTROL MODULE -
OPERATION..........................8O-9
AIRBAG CONTROL MODULE - REMOVAL . . 8O-10
AIRBAG INDICATOR - DESCRIPTION......8J-10
AIRBAG INDICATOR - OPERATION.......8J-10
ALB CONTROLLER - INSTALLATION
.......5-15
ALB CONTROLLER - REMOVAL
...........5-15
ALB LEVER - INSTALLATION
.............5-15
ALB LEVER - REMOVAL
................5-15
ALIGNMENT - DESCRIPTION, WHEEL
......2-17
ALIGNMENT - SPECIFICATIONS, WHEEL
....2-19
ALUMINUM THREAD REPAIR -
STANDARD PROCEDURE
...............21-27
AMBIENT TEMPERATURE INDICATOR -
DESCRIPTION
.......................8J-11
AMBIENT TEMPERATURE INDICATOR -
OPERATION
.........................8J-11
AMBIENT TEMPERATURE SENSOR -
DESCRIPTION
.......................24-15
AMBIENT TEMPERATURE SENSOR -
INSTALLATION
.......................24-16
AMBIENT TEMPERATURE SENSOR -
OPERATION
.........................24-15
AMBIENT TEMPERATURE SENSOR -
REMOVAL
..........................24-15ANTENNA BODY & CABLE -
INSTALLATION.......................8A-1
ANTENNA BODY & CABLE - REMOVAL.....8A-1
ANTENNA CABLE - INSTALLATION,
INSTRUMENT PANEL..................8A-2
ANTENNA CABLE - REMOVAL,
INSTRUMENT PANEL..................8A-1
ANTILOCK BRAKE - DESCRIPTION,
CONTROLLER........................8E-3
ANTILOCK BRAKE - INSTALLATION,
CONTROLLER........................8E-3
ANTILOCK BRAKE - REMOVAL,
CONTROLLER........................8E-3
A-PILLAR TRIM - INSTALLATION........23-68
A-PILLAR TRIM - REMOVAL............23-67
ARM - DESCRIPTION, WIPER...........8R-13
ARM - INSTALLATION, CENTER ROLLER . . 23-38
ARM - INSTALLATION, LOWER CONTROL . . . 2-6
ARM - INSTALLATION, LOWER ROLLER . . . 23-38
ARM - INSTALLATION, UPPER ROLLER . . . 23-37
ARM - INSTALLATION, WIPER..........8R-14
ARM - OPERATION, WIPER............8R-14
ARM - REMOVAL, CENTER ROLLER......23-37
ARM - REMOVAL, LOWER CONTROL.......2-6
ARM - REMOVAL, LOWER ROLLER......23-38
ARM - REMOVAL, UPPER ROLLER.......23-37
ARM - REMOVAL, WIPER..............8R-14
ARMREST - INSTALLATION.............23-76
ARMREST - REMOVAL................23-76
ASH RECEIVER - INSTALLATION.........23-55
ASH RECEIVER - REMOVAL............23-55
ASH RECEIVER/CIGAR LIGHTER LAMP
UNIT - INSTALLATION.................8L-27
ASH RECEIVER/CIGAR LIGHTER LAMP
UNIT - REMOVAL....................8L-27
ASSIST HANDLE - INSTALLATION........23-68
ASSIST HANDLE - REMOVAL...........23-68
AUDIO, SPECIAL TOOLS................8A-1
AUTOMATIC TRANSMISSION -
DIAGNOSIS AND TESTING........21-23,21-24
AUTOMATIC TRANSMISSION - NAG1 -
DESCRIPTION........................21-2
AUTOMATIC TRANSMISSION - NAG1 -
OPERATION..........................21-4
AUTOMATIC TRANSMISSION - SPECIAL
TOOLS, NAG1.......................21-69
AUTOMATIC TRANSMISSION -
SPECIFICATIONS, NAG1...............21-68
AUTOMATIC TRANSMISSION FLUID -
NAG1 - DESCRIPTION...................0-4
AUTOMATIC TRANSMISSION FLUID -
OPERATION...........................0-4
AUXILIARY BATTERY INSTALLATION,
INSTALLATION.......................8F-13
AUXILIARY BATTERY REMOVAL,
REMOVAL..........................8F-13
AXLE - DESCRIPTION...................0-3
AXLE - DESCRIPTION, REAR.............3-10
AXLE - DIAGNOSIS AND TESTING, REAR . . . 3-10
AXLE - INSTALLATION, REAR............3-12
AXLE - OPERATION, REAR..............3-10
AXLE - REMOVAL, REAR................3-11
AXLE - SPECIAL TOOLS, REAR...........3-14
AXLE - SPECIFICATIONS, REAR..........3-13
AXLE BEARINGS/SEALS - INSTALLATION . . . 3-17
AXLE BEARINGS/SEALS - REMOVAL......3-17
AXLE HUB BEARINGS/SEALS -
INSTALLATION........................3-20
AXLE HUB BEARINGS/SEALS - REMOVAL . . 3-20
AXLE SHAFTS - DUAL REAR WHEELS -
INSTALLATION........................3-19
AXLE SHAFTS - DUAL REAR WHEELS -
REMOVAL...........................3-19
AXLE SHAFTS - INSTALLATION...........3-15
AXLE SHAFTS - REMOVAL..............3-15
B1 - ASSEMBLY, HOLDING CLUTCH.....21-113
B1 - DISASSEMBLY, HOLDING CLUTCH . . 21-112
B2 - ASSEMBLY, HOLDING CLUTCH.....21-116
B2 - DISASSEMBLY, HOLDING CLUTCH . . 21-115
BACK - FRONT - INSTALLATION, SEAT....23-77
BACK - FRONT - REMOVAL, SEAT
.......23-77
BACK CUSHION/COVER - REAR -
INSTALLATION, SEAT
.................23-80
BACK CUSHION/COVER - REAR -
REMOVAL, SEAT
.....................23-80
BACK SHIELD - INSTALLATION, REAR
SEAT
..............................23-79
BACK SHIELD - REMOVAL, REAR SEAT
. . . 23-79
VAINDEX 1
Description Group-Page Description Group-Page Description Group-Page

BACKLITE - BULKHEAD TRIM PANEL -
INSTALLATION.......................23-81
BACKLITE - BULKHEAD TRIM PANEL -
REMOVAL..........................23-81
BACKUP LAMP BULB - INSTALLATION.....8L-6
BACKUP LAMP BULB - REMOVAL........8L-5
BALANCE - STANDARD PROCEDURE,
TIRE AND WHEEL.....................22-3
BALL JOINT - INSTALLATION, LOWER......2-6
BALL JOINT - REMOVAL, LOWER..........2-6
BAR - DESCRIPTION, STABILIZER.........2-9
BAR - INSTALLATION, STABILIZER.....2-15,2-9
BAR - OPERATION, STABILIZER...........2-9
BAR - REMOVAL, STABILIZER........2-15,2-9
BASE BRAKE, SPECIFICATIONS............5-6
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING.............................5-2
BASECOAT/CLEARCOAT FINISH -
DESCRIPTION.......................23-74
BATTERY - DESCRIPTION...............8F-6
BATTERY - DIAGNOSIS AND TESTING.....8F-7
BATTERY - OPERATION.................8F-7
BATTERY CABLES - DESCRIPTION.......8F-14
BATTERY CABLES - DIAGNOSIS AND
TESTING...........................8F-14
BATTERY CABLES - INSTALLATION.......8F-16
BATTERY CABLES - OPERATION.........8F-14
BATTERY CABLES - REMOVAL..........8F-16
BATTERY CHARGING - STANDARD
PROCEDURE.........................8F-8
BATTERY ELECTROLYTE LEVEL -
STANDARD PROCEDURE, CHECKING.....8F-12
BATTERY HOLDDOWN - DESCRIPTION....8F-14
BATTERY HOLDDOWN - INSTALLATION . . . 8F-14
BATTERY HOLDDOWN - REMOVAL.......8F-14
BATTERY INSTALLATION, INSTALLATION
- AUXILIARY........................8F-13
BATTERY INSTALLATION, INSTALLATION
- UNDER HOOD......................8F-13
BATTERY REMOVAL, REMOVAL -
AUXILIARY..........................8F-13
BATTERY REMOVAL, REMOVAL - UNDER
HOOD..............................8F-12
BATTERY SYSTEM - CLEANING...........8F-5
BATTERY SYSTEM - DESCRIPTION........8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING............................8F-2
BATTERY SYSTEM - INSPECTION.........8F-6
BATTERY SYSTEM - OPERATION.........8F-2
BATTERY SYSTEM SPECIAL TOOLS,
SPECIAL TOOLS......................8F-6
BATTERY TESTER - STANDARD
PROCEDURE, USING MICRO 420........8F-11
BATTERY TRAY - DESCRIPTION.........8F-16
BATTERY TRAY - INSTALLATION.........8F-16
BATTERY TRAY - OPERATION...........8F-16
BATTERY TRAY - REMOVAL............8F-16
BEAM HEADLAMP BULB -
INSTALLATION, HIGH.................8L-17
BEAM HEADLAMP BULB -
INSTALLATION, LOW..................8L-19
BEAM HEADLAMP BULB - REMOVAL,
HIGH..............................8L-17
BEAM HEADLAMP BULB - REMOVAL,
LOW ..............................8L-18
BEAM INDICATOR - DESCRIPTION, HIGH . . 8J-17
BEAM INDICATOR - OPERATION, HIGH....8J-17
BEARING - INSTALLATION, CENTER........3-9
BEARING - INSTALLATION, HUB...........2-5
BEARING - INSTALLATION, OUTPUT
SHAFT............................21-122
BEARING - REMOVAL, CENTER...........3-8
BEARING - REMOVAL, HUB..............2-4
BEARING - REMOVAL, OUTPUT SHAFT . . . 21-122
BEARINGS/SEALS - INSTALLATION, AXLE . . 3-17
BEARINGS/SEALS - INSTALLATION, AXLE
HUB................................3-20
BEARINGS/SEALS - REMOVAL, AXLE......3-17
BEARINGS/SEALS - REMOVAL, AXLE
HUB
................................3-20
BELT - DIAGNOSIS AND TESTING,
ACCESSORY DRIVE
.....................7-5
BELT & RETRACTOR - INSTALLATION,
FRONT SEAT
........................8O-21
BELT & RETRACTOR - INSTALLATION,
REAR SEAT
.........................8O-29
BELT & RETRACTOR - REMOVAL, FRONT
SEAT
..............................8O-19BELT & RETRACTOR - REMOVAL, REAR
SEAT ..............................8O-27
BELT BUCKLE - INSTALLATION, FRONT
SEAT ..............................8O-23
BELT BUCKLE - REMOVAL, FRONT SEAT . . 8O-22
BELT SWITCH - DESCRIPTION, SEAT.....8O-31
BELT SWITCH - OPERATION, SEAT.......8O-31
BELT TENSIONER - DESCRIPTION, SEAT . . 8O-31
BELT TENSIONER - OPERATION, SEAT....8O-32
BELT TENSIONERS - DESCRIPTION........7-5
BELT TENSIONERS - OPERATION..........7-5
BELT TURNING LOOP ADJUSTER -
INSTALLATION, SEAT.................8O-34
BELT TURNING LOOP ADJUSTER -
REMOVAL, SEAT.....................8O-33
BELT WEATHERSTRIP - INSTALLATION,
FRONT DOOR INNER..................23-87
BELT WEATHERSTRIP - INSTALLATION,
FRONT DOOR OUTER.................23-87
BELT WEATHERSTRIP - REMOVAL,
FRONT DOOR INNER..................23-87
BELT WEATHERSTRIP - REMOVAL,
FRONT DOOR OUTER.................23-87
BELTS - INSTALLATION, DRIVE............7-8
BELTS - REMOVAL, DRIVE...............7-8
BEZEL - INSTALLATION, ACCESSORY
SWITCH............................23-54
BEZEL - INSTALLATION, CLUSTER.......23-54
BEZEL - INSTALLATION, INSTRUMENT
PANEL CENTER......................23-55
BEZEL - REMOVAL, ACCESSORY SWITCH . 23-54
BEZEL - REMOVAL, CLUSTER...........23-53
BEZEL - REMOVAL, INSTRUMENT PANEL
CENTER............................23-55
BLADE - DESCRIPTION, WIPER.........8R-15
BLADE - INSTALLATION, WIPER.........8R-16
BLADE - OPERATION, WIPER...........8R-15
BLADE - REMOVAL, WIPER............8R-16
BLEED PROCEDURE, STANDARD
PROCEDURE - POWER STEERING
PUMP FILL.........................19-14
BLEEDING - STANDARD PROCEDURE,
MANUAL.............................5-4
BLEEDING - STANDARD PROCEDURE,
MASTER CYLINDER...................5-17
BLEEDING - STANDARD PROCEDURE,
PRESSURE...........................5-5
BLOCK - DESCRIPTION, BLOWER
MOTOR RESISTOR...................24-16
BLOCK - DIAGNOSIS AND TESTING,
BLOWER MOTOR RESISTOR............24-16
BLOCK - INSTALLATION, BLOWER
MOTOR RESISTOR...................24-17
BLOCK - OPERATION, BLOWER MOTOR
RESISTOR..........................24-16
BLOCK - REMOVAL, BLOWER MOTOR
RESISTOR..........................24-16
BLOCK #1 - DESCRIPTION, FUSE......8W-97-2
BLOCK #1 - INSTALLATION, FUSE.....8W-97-3
BLOCK #1 - OPERATION, FUSE.......8W-97-2
BLOCK #1 - REMOVAL, FUSE.........8W-97-3
BLOCK #2 - DESCRIPTION, FUSE......8W-97-3
BLOCK #2 - OPERATION, FUSE.......8W-97-3
BLOCK HEATER - INSTALLATION,
ENGINE.............................7-14
BLOCK HEATER - REMOVAL, ENGINE......7-14
BLOCK JOURNALS - STANDARD
PROCEDURE, MEASURE CRANKSHAFT
....9-35
BLOWER MOTOR - INSTALLATION
. . 24-33,24-40
BLOWER MOTOR - REMOVAL
......24-32,24-39
BLOWER MOTOR RELAY - DESCRIPTION
. . 24-23
BLOWER MOTOR RELAY - DIAGNOSIS
AND TESTING
.......................24-24
BLOWER MOTOR RELAY -
INSTALLATION
.......................24-24
BLOWER MOTOR RELAY - OPERATION
. . . 24-23
BLOWER MOTOR RELAY - REMOVAL
.....24-24
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION
.......................24-16
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING
.............24-16
BLOWER MOTOR RESISTOR BLOCK -
INSTALLATION
.......................24-17
BLOWER MOTOR RESISTOR BLOCK -
OPERATION
.........................24-16
BLOWER MOTOR RESISTOR BLOCK -
REMOVAL
..........................24-16BLOWER MOTOR SWITCH -
DESCRIPTION..................24-17,24-22
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING..................24-17,24-23
BLOWER MOTOR SWITCH -
INSTALLATION.......................24-23
BLOWER MOTOR SWITCH - OPERATION . . 24-17,
24-22
BLOWER MOTOR SWITCH - REMOVAL . . . 24-17,
24-23
BODY & CABLE - INSTALLATION,
ANTENNA...........................8A-1
BODY & CABLE - REMOVAL, ANTENNA....8A-1
BODY PANEL REPAIR - STANDARD
PROCEDURE, PLASTIC.................23-3
BOLT INSPECTION - STANDARD
PROCEDURE, CYLINDER HEAD...........9-21
BOOST PRESSURE SENSOR -
DESCRIPTION.......................14-17
BOOST PRESSURE SENSOR -
DIAGNOSIS AND TESTING.............14-18
BOOST PRESSURE SENSOR -
INSTALLATION.......................14-18
BOOST PRESSURE SENSOR -
OPERATION.........................14-18
BOOST PRESSURE SENSOR - REMOVAL . . 14-18
BOOSTER - DESCRIPTION, POWER
BRAKE..............................5-19
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER.............5-16
BOOSTER - INSTALLATION, POWER
BRAKE..............................5-19
BOOSTER - OPERATION, POWER BRAKE....5-19
BOOSTER - REMOVAL, POWER BRAKE....5-19
BORES - STANDARD PROCEDURE,
MEASURING CYLINDER................9-34
BOX - INSTALLATION, GLOVE...........23-56
BOX - REMOVAL, GLOVE..............23-56
B-PILLAR TRIM - INSTALLATION........23-69
B-PILLAR TRIM - REMOVAL............23-68
BRACKET - INSTALLATION, LICENSE
PLATE .............................23-47
BRACKET - INSTALLATION, PASSENGER
AIRBAG............................8O-27
BRACKET - INSTALLATION, REAR VIEW
MIRROR SUPPORT...................23-72
BRACKET - REMOVAL, LICENSE PLATE . . . 23-47
BRACKET - REMOVAL, PASSENGER
AIRBAG............................8O-27
BRAKE - CLEANING, REAR DRUM IN
HAT ................................5-27
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK...........................8E-3
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK...........................8E-3
BRAKE - REMOVAL, CONTROLLER
ANTILOCK...........................8E-3
BRAKE BOOSTER - DESCRIPTION,
POWER.............................5-19
BRAKE BOOSTER - INSTALLATION,
POWER.............................5-19
BRAKE BOOSTER - OPERATION, POWER . . . 5-19
BRAKE BOOSTER - REMOVAL, POWER....5-19
BRAKE CABLES - ADJUSTMENT,
PARKING............................5-25
BRAKE FLUID - DESCRIPTION............0-3
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING..............5-14
BRAKE FLUID LEVEL - STANDARD
PROCEDURE.........................5-14
BRAKE FLUID, SPECIFICATIONS..........5-14
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK........................8J-11
BRAKE INDICATOR - OPERATION,
BRAKE/PARK........................8J-12
BRAKE LAMP SWITCH - INSTALLATION....8L-6
BRAKE LAMP SWITCH - REMOVAL.......8L-6
BRAKE, SPECIAL TOOLS - PARK.........5-23
BRAKE, SPECIFICATIONS - BASE..........5-6
BRAKE SWITCH - INSTALLATION, PARK . . . 8L-20
BRAKE SWITCH - REMOVAL, PARK
......8L-20
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE
........................5-2
BRAKE WEAR INDICATOR -
DESCRIPTION
.......................8J-12
BRAKE WEAR INDICATOR - OPERATION
. . . 8J-12
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION
.......................8J-11
2 INDEXVA
Description Group-Page Description Group-Page Description Group-Page