2005 MERCEDES-BENZ SPRINTER air condition

(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)

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)

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

CIRCUIT BREAKER - OPERATION......8W-97-2
CIRCUIT INFORMATION - DESCRIPTION . 8W-01-5
CLAMP PLATES - INSTALLATION,
SPRING..............................2-8
CLAMP PLATES - REMOVAL, SPRING......2-8
CLASSIFICATION - STANDARD
PROCEDURE, INJECTOR...............14-22
CLEARANCE LAMP BULB -
INSTALLATION........................8L-8
CLEARANCE LAMP BULB - REMOVAL.....8L-8
CLEARANCE LAMP UNIT -
INSTALLATION........................8L-9
CLEARANCE LAMP UNIT - REMOVAL......8L-8
CLOCK - DESCRIPTION................8J-13
CLOCK - OPERATION..................8J-14
CLOCKSPRING - DESCRIPTION.........8O-12
CLOCKSPRING - INSTALLATION.........8O-15
CLOCKSPRING - OPERATION...........8O-13
CLOCKSPRING - REMOVAL............8O-14
CLOCKSPRING CENTERING - STANDARD
PROCEDURE........................8O-13
CLOGGED INDICATOR - DESCRIPTION,
FUEL FILTER........................8J-15
CLOGGED INDICATOR - OPERATION,
FUEL FILTER........................8J-15
CLUSTER - DESCRIPTION, INSTRUMENT . . . 8J-2
CLUSTER - DIAGNOSIS AND TESTING,
INSTRUMENT........................8J-7
CLUSTER - INSTALLATION, INSTRUMENT . . 8J-9
CLUSTER - INSTALLATION, TOP COVER . . . 23-62
CLUSTER - OPERATION, INSTRUMENT.....8J-5
CLUSTER - REMOVAL, INSTRUMENT......8J-7
CLUSTER - REMOVAL, TOP COVER......23-62
CLUSTER BEZEL - INSTALLATION........23-54
CLUSTER BEZEL - REMOVAL...........23-53
CLUTCH - ASSEMBLY, FREEWHEELING . . 21-107
CLUTCH - DESCRIPTION, A/C
COMPRESSOR........................24-8
CLUTCH - DESCRIPTION,
FREEWHEELING.....................21-105
CLUTCH - DISASSEMBLY,
FREEWHEELING.....................21-106
CLUTCH - INSTALLATION, FAN DRIVE
VISCOUS............................7-16
CLUTCH - OPERATION, A/C
COMPRESSOR........................24-8
CLUTCH - OPERATION, FREEWHEELING . . 21-105
CLUTCH - REMOVAL, FAN DRIVE
VISCOUS............................7-16
CLUTCH AIR GAP - STANDARD
PROCEDURE, COMPRESSOR............24-9
CLUTCH B1 - ASSEMBLY, HOLDING.....21-113
CLUTCH B1 - DISASSEMBLY, HOLDING . . 21-112
CLUTCH B2 - ASSEMBLY, HOLDING.....21-116
CLUTCH B2 - DISASSEMBLY, HOLDING . . 21-115
CLUTCH BREAK-IN - STANDARD
PROCEDURE, COMPRESSOR............24-9
CLUTCH COIL - DIAGNOSIS AND
TESTING, COMPRESSOR...............24-12
CLUTCH K1 - ASSEMBLY, DRIVING.......21-75
CLUTCH K1 - DISASSEMBLY, DRIVING....21-74
CLUTCH K2 - ASSEMBLY, DRIVING.......21-78
CLUTCH K2 - DISASSEMBLY, DRIVING....21-76
CLUTCH K3 - ASSEMBLY, DRIVING.......21-80
CLUTCH K3 - DISASSEMBLY, DRIVING....21-80
CLUTCH/COIL - INSPECTION,
COMPRESSOR.......................24-10
CLUTCHES - DESCRIPTION, DRIVING.....21-72
CLUTCHES - DESCRIPTION, HOLDING . . . 21-111
CLUTCHES - OPERATION, DRIVING......21-72
CLUTCHES - OPERATION, HOLDING.....21-112
CODES - SPECIFICATIONS, PAINT........23-74
COIL - DIAGNOSIS AND TESTING,
COMPRESSOR CLUTCH...............24-12
COLUMN OPENING COVER -
INSTALLATION, STEERING.............23-66
COLUMN OPENING COVER - REMOVAL,
STEERING..........................23-66
COMPRESSION TESTING ENGINE -
STANDARD PROCEDURE.................9-3
COMPRESSOR - DESCRIPTION, A/C......24-49
COMPRESSOR - INSTALLATION, A/C
.....24-51
COMPRESSOR - OPERATION, A/C
........24-49
COMPRESSOR - REMOVAL, A/C
.........24-50
COMPRESSOR CLUTCH - DESCRIPTION,
A/C
................................24-8
COMPRESSOR CLUTCH - OPERATION,
A/C
................................24-8COMPRESSOR CLUTCH AIR GAP -
STANDARD PROCEDURE................24-9
COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE................24-9
COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-12
COMPRESSOR CLUTCH/COIL -
INSPECTION........................24-10
COMPRESSOR NOISE - DIAGNOSIS AND
TESTING...........................24-49
CONDENSER - DESCRIPTION, A/C.......24-52
CONDENSER - INSTALLATION, A/C.......24-52
CONDENSER - OPERATION, A/C.........24-52
CONDENSER - REMOVAL, A/C..........24-52
CONDITIONER - DESCRIPTION, HEATER
AND AIR ............................24-1
CONDITIONER - OPERATION, HEATER
AND AIR ............................24-2
CONNECTING FUEL LINES - STANDARD
PROCEDURE, DISCONNECTING...........14-2
CONNECTING ROD - DESCRIPTION,
PISTON.............................9-40
CONNECTING RODS - STANDARD
PROCEDURE, CHECKING AND
REPAIRING..........................9-40
CONNECTOR - INSTALLATION........8W-01-9
CONNECTOR - REMOVAL............8W-01-8
CONNECTOR, GROUND AND SPLICE
INFORMATION - DESCRIPTION........8W-01-5
CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION....................8W-91-1
CONTACT - DESCRIPTION, PARK/
NEUTRAL..........................21-139
CONTACT - OPERATION, PARK/NEUTRAL . 21-140
CONTAMINATION - DIAGNOSIS AND
TESTING, BRAKE FLUID................5-14
CONTAMINATION - DIAGNOSIS AND
TESTING, FLUID....................21-102
CONTINUITY - STANDARD PROCEDURE,
TESTING.........................8W-01-8
CONTROL ARM - INSTALLATION, LOWER . . . 2-6
CONTROL ARM - REMOVAL, LOWER.......2-6
CONTROL INDICATOR - DESCRIPTION,
TRACTION..........................8J-24
CONTROL INDICATOR - OPERATION,
TRACTION..........................8J-24
CONTROL MALFUNCTION INDICATOR -
DESCRIPTION, TRACTION..............8J-25
CONTROL MALFUNCTION INDICATOR -
OPERATION, TRACTION................8J-25
CONTROL MODULE - DESCRIPTION......24-24
CONTROL MODULE - DESCRIPTION,
AIRBAG.............................8O-8
CONTROL MODULE - DESCRIPTION,
ENGINE.............................8E-3
CONTROL MODULE - DESCRIPTION,
TRANSMISSION.......................8E-5
CONTROL MODULE - DIAGNOSIS AND
TESTING...........................24-24
CONTROL MODULE - INSTALLATION.....24-25
CONTROL MODULE - INSTALLATION,
AIRBAG............................8O-11
CONTROL MODULE - INSTALLATION,
ENGINE.............................8E-4
CONTROL MODULE - OPERATION.......24-24
CONTROL MODULE - OPERATION,
AIRBAG.............................8O-9
CONTROL MODULE - OPERATION,
TRANSMISSION.......................8E-5
CONTROL MODULE - REMOVAL.........24-24
CONTROL MODULE - REMOVAL, AIRBAG . 8O-10
CONTROL MODULE - REMOVAL, ENGINE . . . 8E-4
CONTROLLER - INSTALLATION, ALB......5-15
CONTROLLER - REMOVAL, ALB..........5-15
CONTROLLER ANTILOCK BRAKE -
DESCRIPTION........................8E-3
CONTROLLER ANTILOCK BRAKE -
INSTALLATION........................8E-3
CONTROLLER ANTILOCK BRAKE -
REMOVAL...........................8E-3
CONVERTER - DESCRIPTION, TORQUE . . . 21-141
CONVERTER - INSTALLATION, CATALYTIC . . 11-3
CONVERTER - INSTALLATION, TORQUE
. . 21-146
CONVERTER - OPERATION, TORQUE
....21-143
CONVERTER - REMOVAL, CATALYTIC
......11-3
CONVERTER - REMOVAL, TORQUE
......21-146
CONVERTER HUB SEAL - INSTALLATION,
TORQUE
...........................21-147CONVERTER HUB SEAL - REMOVAL,
TORQUE...........................21-147
COOLANT - DESCRIPTION...............7-9
COOLANT - DESCRIPTION, ENGINE........0-1
COOLANT - DESCRIPTION, HOAT..........0-2
COOLANT - STANDARD PROCEDURE,
ADDING ADDITIONAL..................7-11
COOLANT LEVEL SENSOR -
INSTALLATION........................7-13
COOLANT LEVEL SENSOR - REMOVAL.....7-13
COOLANT LOW INDICATOR -
DESCRIPTION.......................8J-14
COOLANT LOW INDICATOR - OPERATION . 8J-14
COOLANT PUMP - DESCRIPTION,
ELECTRIC..........................24-57
COOLANT PUMP - INSTALLATION,
ELECTRIC..........................24-57
COOLANT PUMP - OPERATION,
ELECTRIC..........................24-57
COOLANT PUMP - REMOVAL, ELECTRIC . . 24-57
COOLANT TEMP SENSOR -
DESCRIPTION, ENGINE.................7-14
COOLANT TEMP SENSOR -
INSTALLATION, ENGINE................7-15
COOLANT TEMP SENSOR - REMOVAL,
ENGINE.............................7-14
COOLANT THERMOSTAT -
INSTALLATION, ENGINE................7-16
COOLANT THERMOSTAT - REMOVAL,
ENGINE.............................7-15
COOLER & LINES - INSTALLATION, OIL....9-50
COOLER & LINES - REMOVAL, OIL.......9-50
COOLER AND PLUMBING - CLEANING,
CHARGE AIR.........................11-5
COOLER AND PLUMBING -
DESCRIPTION, CHARGE AIR.............11-4
COOLER AND PLUMBING - INSPECTION,
CHARGE AIR.........................11-5
COOLER AND PLUMBING -
INSTALLATION, CHARGE AIR............11-5
COOLER AND PLUMBING - OPERATION,
CHARGE AIR.........................11-4
COOLER AND PLUMBING - REMOVAL,
CHARGE AIR.........................11-5
COOLER SYSTEM - LEAKS - DIAGNOSIS
AND TESTING, CHARGE AIR.............11-4
COOLER TUBE - INSTALLATION, FLUID . . . 19-14
COOLER TUBE - INSTALLATION, RETURN
HOSE FROM GEAR TO................19-15
COOLER TUBE - INSTALLATION, RETURN
LINE FROM PUMP TO.................19-15
COOLER TUBE - REMOVAL, FLUID.......19-14
COOLER TUBE - REMOVAL, RETURN
HOSE FROM GEAR TO................19-15
COOLER TUBE - REMOVAL, RETURN
LINE FROM PUMP TO.................19-15
COOLING SYSTEM - DIAGNOSIS AND
TESTING.............................7-2
COOLING SYSTEM - OPERATION..........7-1
COOLING SYSTEM - STANDARD
PROCEDURE, DRAINING................7-12
COOLING SYSTEM - STANDARD
PROCEDURE, REFILLING................7-12
COOLING SYSTEM LEAKS - DIAGNOSIS
AND TESTING........................7-10
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION........................24-1
CORE - DESCRIPTION, HEATER.........24-57
CORE - INSTALLATION, HEATER.........24-58
CORE - OPERATION, HEATER...........24-57
CORE - REMOVAL, HEATER............24-58
CORE AND OIL GALLERY PLUGS -
STANDARD PROCEDURE, REPLACING
ENGINE.............................9-34
COVER - CLUSTER - INSTALLATION, TOP . 23-62
COVER - CLUSTER - REMOVAL, TOP.....23-62
COVER - INSTALLATION, CYLINDER
HEAD FRONT.........................9-26
COVER - INSTALLATION, ENGINE..........9-7
COVER - INSTALLATION, STEERING
COLUMN OPENING...................23-66
COVER - INSTALLATION, TIMING CHAIN
. . . 9-60
COVER - INSTALLATION, TOP
...........23-65
COVER - REMOVAL, CYLINDER HEAD
FRONT
..............................9-23
COVER - REMOVAL, ENGINE
..............9-4
COVER - REMOVAL, STEERING COLUMN
OPENING
...........................23-66
4 INDEXVA
Description Group-Page Description Group-Page Description Group-Page

HAT BRAKE - CLEANING, REAR DRUM
IN .................................5-27
HCU (HYDRAULIC CONTROL UNIT) -
DESCRIPTION........................5-31
HCU (HYDRAULIC CONTROL UNIT) -
INSTALLATION........................5-32
HCU (HYDRAULIC CONTROL UNIT) -
REMOVAL...........................5-31
HEAD - INSTALLATION, CYLINDER........9-25
HEAD - REMOVAL, CYLINDER...........9-22
HEAD BOLT INSPECTION - STANDARD
PROCEDURE, CYLINDER................9-21
HEAD COVER(S) - INSTALLATION,
CYLINDER...........................9-30
HEAD COVER(S) - REMOVAL, CYLINDER . . . 9-30
HEAD FRONT COVER - INSTALLATION,
CYLINDER...........................9-26
HEAD FRONT COVER - REMOVAL,
CYLINDER...........................9-23
HEAD GUIDE RAIL - INSTALLATION,
CYLINDER...........................9-26
HEAD GUIDE RAIL - REMOVAL,
CYLINDER...........................9-24
HEAD SURFACE - STANDARD
PROCEDURE, MEASURE CYLINDER.......9-21
HEADLAMP BULB - INSTALLATION, HIGH
BEAM..............................8L-17
HEADLAMP BULB - INSTALLATION, LOW
BEAM..............................8L-19
HEADLAMP BULB - REMOVAL, HIGH
BEAM..............................8L-17
HEADLAMP BULB - REMOVAL, LOW
BEAM...............................8L-18
HEADLAMP LEVELING MOTOR -
INSTALLATION.......................8L-16
HEADLAMP LEVELING MOTOR -
REMOVAL..........................8L-15
HEADLAMP LEVELING SWITCH -
INSTALLATION.......................8L-17
HEADLAMP LEVELING SWITCH -
REMOVAL..........................8L-16
HEADLINER - INSTALLATION...........23-71
HEADLINER - REMOVAL...............23-70
HEADREST - INSTALLATION............23-76
HEADREST - REMOVAL................23-76
HEATED SEAT ELEMENT - DESCRIPTION . . . 8G-3
HEATED SEAT ELEMENT - DIAGNOSIS
AND TESTING........................8G-3
HEATED SEAT ELEMENT - OPERATION.....8G-3
HEATED SEAT RELAY - DESCRIPTION.....8G-4
HEATED SEAT RELAY - DIAGNOSIS AND
TESTING............................8G-4
HEATED SEAT RELAY - INSTALLATION.....8G-4
HEATED SEAT RELAY - OPERATION.......8G-4
HEATED SEAT RELAY - REMOVAL........8G-4
HEATED SEAT SENSOR - DESCRIPTION....8G-4
HEATED SEAT SENSOR - DIAGNOSIS
AND TESTING........................8G-4
HEATED SEAT SWITCH - DESCRIPTION,
DRIVER.............................8G-2
HEATED SEAT SWITCH - DESCRIPTION,
PASSENGER.........................8G-5
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING, DRIVER.................8G-2
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING, PASSENGER.............8G-5
HEATED SEAT SWITCH - INSTALLATION,
DRIVER.............................8G-3
HEATED SEAT SWITCH - INSTALLATION,
PASSENGER.........................8G-5
HEATED SEAT SWITCH - OPERATION,
DRIVER.............................8G-2
HEATED SEAT SWITCH - OPERATION,
PASSENGER.........................8G-5
HEATED SEAT SWITCH - REMOVAL,
DRIVER.............................8G-3
HEATED SEAT SWITCH - REMOVAL,
PASSENGER.........................8G-5
HEATED SEATS - DESCRIPTION..........8G-1
HEATED SEATS - DIAGNOSIS AND
TESTING............................8G-2
HEATED SEATS - OPERATION
............8G-2
HEATER - DCHA - DIAGNOSIS AND
TESTING, DIESEL SUPPLEMENTAL
.......24-72
HEATER - DESCRIPTION, CABIN
.........24-72
HEATER - INSTALLATION, ENGINE
BLOCK
..............................7-14
HEATER - OPERATION, CABIN
...........24-72HEATER - REMOVAL, ENGINE BLOCK......7-14
HEATER AND AIR CONDITIONER -
DESCRIPTION........................24-1
HEATER AND AIR CONDITIONER -
OPERATION..........................24-2
HEATER CONTROL - DESCRIPTION, A/C . . . 24-12
HEATER CONTROL - INSTALLATION, A/C . . 24-13
HEATER CONTROL - OPERATION, A/C....24-12
HEATER CONTROL - REMOVAL, A/C......24-12
HEATER CORE - DESCRIPTION..........24-57
HEATER CORE - INSTALLATION.........24-58
HEATER CORE - OPERATION............24-57
HEATER CORE - REMOVAL.............24-58
HEATER PERFORMANCE - DIAGNOSIS
AND TESTING........................24-4
HI PRESSURE FUEL SHUTOFF SOL -
DESCRIPTION.......................14-16
HI PRESSURE FUEL SHUTOFF SOL -
OPERATION.........................14-16
HIGH BEAM HEADLAMP BULB -
INSTALLATION.......................8L-17
HIGH BEAM HEADLAMP BULB -
REMOVAL..........................8L-17
HIGH BEAM INDICATOR - DESCRIPTION . . 8J-17
HIGH BEAM INDICATOR - OPERATION....8J-17
HIGH FUEL SYSTEM PRESSURE -
WARNING...........................14-1
HIGH MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER................8L-7
HIGH MOUNTED STOP LAMP BULB -
REMOVAL, CENTER....................8L-7
HIGH MOUNTED STOP LAMP UN -
INSTALLATION, CENTER................8L-8
HIGH MOUNTED STOP LAMP UN -
REMOVAL, CENTER....................8L-8
HIGH PRESSURE FUEL LINES -
DIAGNOSIS AND TESTING..............14-1
HIGH PRESSURE LINES - INSTALLATION . . . 14-7
HIGH PRESSURE LINES - REMOVAL......14-6
HIGH PRESSURE PUMP - DESCRIPTION . . . 14-7
HIGH PRESSURE PUMP - INSTALLATION . . 14-10
HIGH PRESSURE PUMP - REMOVAL......14-8
HIGH SPEEDS - DESCRIPTION, TIRE
PRESSURE..........................22-6
HINGE - INSTALLATION......23-17,23-34,23-50
HINGE - REMOVAL.........23-17,23-34,23-50
HITCH - INSTALLATION, TRAILER........13-10
HITCH - REMOVAL, TRAILER............13-9
HOAT COOLANT - DESCRIPTION..........0-2
HOISTING - STANDARD PROCEDURE.......0-5
HOLDDOWN - DESCRIPTION, BATTERY . . . 8F-14
HOLDDOWN - INSTALLATION, BATTERY . . . 8F-14
HOLDDOWN - REMOVAL, BATTERY......8F-14
HOLDER - INSTALLATION, CUP.........23-56
HOLDER - REMOVAL, CUP.............23-55
HOLDING CLUTCH B1 - ASSEMBLY.....21-113
HOLDING CLUTCH B1 - DISASSEMBLY . . 21-112
HOLDING CLUTCH B2 - ASSEMBLY.....21-116
HOLDING CLUTCH B2 - DISASSEMBLY . . 21-115
HOLDING CLUTCHES - DESCRIPTION....21-111
HOLDING CLUTCHES - OPERATION.....21-112
HOLE REPAIR - DESCRIPTION,
THREADED........................Intro.-5
HOOD - INSTALLATION................23-50
HOOD - REMOVAL....................23-50
HOOD BATTERY INSTALLATION,
INSTALLATION - UNDER...............8F-13
HOOD BATTERY REMOVAL, REMOVAL -
UNDER.............................8F-12
HORN - INSTALLATION.................8H-1
HORN - REMOVAL....................8H-1
HORN SWITCH - INSTALLATION
..........8H-1
HORN SWITCH - REMOVAL
.............8H-1
HOSE - INSTALLATION, INLET
..........24-78
HOSE - INSTALLATION, PRESSURE
......19-15
HOSE - REMOVAL, INLET
..............24-78
HOSE - REMOVAL, PRESSURE
..........19-15
HOSE FROM GEAR TO COOLER TUBE -
INSTALLATION, RETURN
...............19-15
HOSE FROM GEAR TO COOLER TUBE -
REMOVAL, RETURN
..................19-15
HOSES/LINES/TUBES PRECAUTIONS,
CAUTION - REFRIGERANT
..............24-45
HOSES/TUBES - DESCRIPTION, WASHER
. . 8R-8
HOSES/TUBES - OPERATION, WASHER
....8R-9
HOUSING - ASSEMBLY, HVAC
...........24-36
HOUSING - DISASSEMBLY, HVAC
........24-36HOUSING - INSTALLATION, AIR
CLEANER............................9-20
HOUSING - INSTALLATION, HVAC........24-36
HOUSING - INSTALLATION, REAR A/C....24-41
HOUSING - REMOVAL, AIR CLEANER......9-20
HOUSING - REMOVAL, HVAC...........24-34
HOUSING - REMOVAL, REAR A/C........24-40
HOW TO USE WIRING DIAGRAMS -
DESCRIPTION.....................8W-01-1
HUB / BEARING - INSTALLATION..........2-5
HUB / BEARING - REMOVAL..............2-4
HUB BEARINGS/SEALS - INSTALLATION,
AXLE...............................3-20
HUB BEARINGS/SEALS - REMOVAL,
AXLE...............................3-20
HUB SEAL - INSTALLATION, TORQUE
CONVERTER.......................21-147
HUB SEAL - REMOVAL, TORQUE
CONVERTER.......................21-147
HVAC HOUSING - ASSEMBLY...........24-36
HVAC HOUSING - DISASSEMBLY........24-36
HVAC HOUSING - INSTALLATION........24-36
HVAC HOUSING - REMOVAL............24-34
IDENTIFICATION - DESCRIPTION,
FASTENER.........................Intro.-2
IDENTIFICATION AND INFORMATION -
DESCRIPTION, SECTION.............8W-01-5
IDENTIFICATION NUMBER -
DESCRIPTION, VEHICLE..............Intro.-1
IGNITION CONTROL - SPECIAL TOOLS......8I-1
IGNITION-OFF DRAW TEST - STANDARD
PROCEDURE........................8F-10
INBOARD - INSTALLATION.............8O-30
INBOARD - REMOVAL.................8O-29
IN-CAR TEMPERATURE SENSOR -
DESCRIPTION.......................24-19
IN-CAR TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING.............24-19
IN-CAR TEMPERATURE SENSOR -
OPERATION.........................24-19
IN-CAR TEMPERATURE SENSOR -
REMOVAL..........................24-19
INCORRECT FLUID LEVEL - DIAGNOSIS
AND TESTING, EFFECTS OF............21-102
INDICATOR - DESCRIPTION, ABS.........8J-9
INDICATOR - DESCRIPTION, AIRBAG.....8J-10
INDICATOR - DESCRIPTION, AMBIENT
TEMPERATURE......................8J-11
INDICATOR - DESCRIPTION, BRAKE
WEAR.............................8J-12
INDICATOR - DESCRIPTION, BRAKE/
PARK BRAKE........................8J-11
INDICATOR - DESCRIPTION, CHARGING . . . 8J-13
INDICATOR - DESCRIPTION, COOLANT
LOW...............................8J-14
INDICATOR - DESCRIPTION, FUEL
FILTER CLOGGED.....................8J-15
INDICATOR - DESCRIPTION, GEAR
SELECTOR..........................8J-17
INDICATOR - DESCRIPTION, HIGH BEAM . . 8J-17
INDICATOR - DESCRIPTION, LOW FUEL . . . 8J-18
INDICATOR - DESCRIPTION, LOW OIL
LEVEL.............................8J-18
INDICATOR - DESCRIPTION,
MAINTENANCE.......................8J-19
INDICATOR - DESCRIPTION, MULTI-
FUNCTION..........................8J-20
INDICATOR - DESCRIPTION, SEATBELT . . . 8J-22
INDICATOR - DESCRIPTION, TRACTION
CONTROL...........................8J-24
INDICATOR - DESCRIPTION, TRACTION
CONTROL MALFUNCTION..............8J-25
INDICATOR - DESCRIPTION, TURN
SIGNAL............................8J-25
INDICATOR - DESCRIPTION, WAIT-TO-
START .............................8J-26
INDICATOR - DESCRIPTION, WASHER
FLUID..............................8J-27
INDICATOR - DESCRIPTION, WATER-IN-
FUEL..............................8J-27
INDICATOR - OPERATION, ABS...........8J-9
INDICATOR - OPERATION, AIRBAG
.......8J-10
INDICATOR - OPERATION, AMBIENT
TEMPERATURE
......................8J-11
INDICATOR - OPERATION, BRAKE WEAR
. . 8J-12
INDICATOR - OPERATION, BRAKE/PARK
BRAKE
.............................8J-12
INDICATOR - OPERATION, CHARGING
....8J-13
8 INDEXVA
Description Group-Page Description Group-Page Description Group-Page