2005 MERCEDES-BENZ SPRINTER catalytic converter

Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on coolant
container until thermostat opens. Attach a Pressure
Tester to container. If pressure builds up quickly it
indicates a combustion leak exists. This is usually
the result of a cylinder head gasket leak or crack in
engine. Repair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean and suitably marked
container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN
WITH SYSTEM HOT AND UNDER PRESSURE. SERI-
OUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat removal.
Remove accessory drive belt.
Add coolant to pressure container to bring level to
within 6.3 mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
STANDARD PROCEDURE
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
VAENGINE 7 - 11
COOLANT (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Oil Outlet Line to
Turbo Charger9-80
Connection-Flange of
Exhaust Manifold to Turbo
Charger30 22 -
Connection-Turbo Charger
to Front Catalytic
Converter30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air
Distribution Pipe16 - 141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe9-80
Bolt-Support to Charge Air
Distribution Pipe20 - 177
Bolt-Support to Engine
Bracket40 30 -
Clamp-Charge Air
Pipes/Hoses3-27
Belt Tensioning Device
Bolt-Guide Pulley to
Coolant Pump35 26 -
Bolt-Guide Pulley to
Timing Case Cover35 26 -
Bolt-V-Belt Tensioning
Device to Tensioning
Pulley36 26.5 -
Bolt-V-Belt Tensioning
Device to Timing Case
Cover30 22 -
Exhaust Manifold
Nut-Exhaust Manifold at
Cylinder Head30 22 -
Position Sensor
Nut/Bolt-Camshaft
Position Sensor to
Cylinder Head Cover11 - 9 7
Nut/Bolt-Crankshaft
Position Sensor to Engine
Block8-70
Pre-Glow System
Cylinder Head to Glow
Plug12 - 106
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of Circuit
3014 - 124
9 - 10 ENGINEVA
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Engine Mount to
Engine Bracket55 40.5 -
Bolt-Front Engine Mount
to Front Axle Carrier35 26 -
Bolt-Rear Engine Cross
Member to Body40 30 -
Bolt-Rear Engine Mount to
Rear Engine Cross
Member35 26 -
Bolt/Nut- Rear Engine
Mount to Transmission40 26 -
Bolt-Shrowd to Engine
Bracket10 - 88.5
Nut-Front Engine Mount to
Engine Bracket65 48 -
Nut-Engine Mount to
Vehicle Frame35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
Bolt- Fuel Filter to Charge
Air Distribution Pipe14 - 124
Exhaust System
Bolt- Catalytic Converter
Bracket to Crankcase20 - 177
Bolt - Turbocharger Oil
Supply Line at
Turbocharger25 18 -
Bolt - Turbocharger Oil
Return Line at
Turbocharger10 - 89
Clamp-Connection
Between Front Exhaust
Pipe and Rear Exhaust
System55 41 -
Clip-Front Catalytic
Converter to Engine
Mount20 - 177
Exhaust Manifold to
Cylinder Head29 21 -
Nut-Bracket to Tail Pipe 55 40.5 -
Nut-Exhaust Bracket to
Threaded Plate of Center
Exhaust Pipe20 - 177
Support-Exhaust Bracket
on Transmission20 - 177
9 - 12 ENGINEVA
ENGINE (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION - 2.7L DIESEL...............1
DIAGNOSIS AND TESTING - DIESEL ENGINE . . 2
CATALYTIC CONVERTER
REMOVAL.............................3
INSTALLATION..........................3
EXHAUST PIPE
REMOVAL.............................3
INSTALLATION..........................3
TAILPIPE
REMOVAL.............................3
INSTALLATION..........................3
TURBOCHARGER SYSTEM
DESCRIPTION..........................3
OPERATION............................4
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION..........................4OPERATION............................4
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS...............4
REMOVAL.............................5
CLEANING.............................5
INSPECTION...........................5
INSTALLATION..........................5
TURBOCHARGER
DESCRIPTION..........................6
OPERATION............................6
REMOVAL
REMOVAL............................7
REMOVAL - VACUUM TRANSDUCER.......7
INSTALLATION
INSTALLATION........................8
INSTALLATION - VACUUM TRANSDUCER . . . 8
EXHAUST SYSTEM
DESCRIPTION - 2.7L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe (Fig. 1).The exhaust system must be properly aligned and
secured to prevent stress, leakage and body contact.
The exhaust components should be kept a minimum
of 25.4 mm (1.0 in.) away from the body and frame.
If the system contacts any body panel, it may amplify
objectionable noises from the engine or body.
VAEXHAUST SYSTEM 11 - 1

DIAGNOSIS AND TESTING - DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten/replace clamps/bolts at
leaking joints.
2. Rusted or expanded muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten/replace exhaust manifold
to cylinder head bolts.
7. Turbocharger mounting flange
cracked.7. Remove turbocharger and
inspect.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
Fig. 1 Exhaust System
1 - TURBOCHARGER
2 - HEAT SHIELD
3 - CLAMP
4 - EXHAUST PIPE
5 - FRONT INSULATOR
6 - NUT7 - WASHER
8 - INSULATOR
9 - BOLT
10 - MUFFLER/CATALYTIC CONVERTER ASSEMBLY
11 - TAILPIPE
11 - 2 EXHAUST SYSTEMVA
EXHAUST SYSTEM (Continued)

CATALYTIC CONVERTER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
rear clamp. (Fig. 1)
(3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front clamp.
(4) Remove the cataylic converter and muffler
assembly from the isolators.
(5) Seperat the cataylic converter and muffler
assembly from the tailpipe and the exhaust pipe.
(6) Remove the cataylic converter and muffler
assembly and isolators from the vehicle.
(7) Remove the bolt, nut and front isolator from
the cataylic converter and muffler assembly.
(8) Remove the rear isolator from the cataylic con-
verter and muffler assembly.
(9)
INSTALLATION
(1) Install bolt, front isolator and nut (Fig. 1).
(2) Install rear insulator onto the cataylic con-
verter and muffler assembly
(3) Position the cataylic conveter and muffler
assembly into the exhaust pipe and tailpipe until
alignment tab is inserted into the alignment slot.
(4) Install the front and rear insulators.
(5) Install the real clamp.
(6) Install the front clamp.
(7) Lower vehicle.
(8) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(9) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
EXHAUST PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front and rear clamp (Fig. 1).
(3) Remove the mounting bracket nuts.
(4) Remove the exhaust pipe.
INSTALLATION
(1) Position the exhaust pipe into the exhaust pipe
into the cataylic converter and muffler assembly
until alignment tab is inserted into the alignment
slot.
(2) Install mounting bracket and nuts (Fig. 1).(3) Install clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TAILPIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration (Fig. 1).
(3) Remove the clamp.
(4) Remove the tailpipe and insulator form the
vehicle
(5) Remove the insulator from the tailpipe.
INSTALLATION
(1) Position the tail pipe into the cataylic converter
and muffler assembly until alignment tab is inserted
into the alignment slot.
(2) Install the insulator.
(3) Install the clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The boost pressure
bracket is an integral part of the turbocharger. Tam-
pering with the boost pressure components can
reduce durability by increasing cylinder pressure
and thermal loading due to incorrect inlet and
exhaust manifold pressure. Poor fuel economy and
failure to meet regulatory emissions laws may
result. Increasing the turbocharger boost WILL NOT
increase engine power.
The turbocharger used on this vehicle is of the
variable turbine type. These turbochargers use the
entire exhaust energy to boost efficiency of the turbo-
charger and the engine.
The advantages of a turbocharger with variable
turbine geometry are:
²Higher charge pressure already in the lower and
in upper engine speed ranges.
VAEXHAUST SYSTEM 11 - 3

BRAKE/PARK BRAKE INDICATOR -
OPERATION.........................8J-12
BRAKE/PARK LAMP BULB -
INSTALLATION........................8L-7
BRAKE/PARK LAMP BULB - REMOVAL.....8L-7
BRAKES, SPECIAL TOOLS................5-7
BREAKER - DESCRIPTION, CIRCUIT....8W-97-2
BREAKER - DIAGNOSIS AND TESTING,
CIRCUIT.........................8W-97-2
BREAKER - OPERATION, CIRCUIT.....8W-97-2
BREAK-IN - STANDARD PROCEDURE,
COMPRESSOR CLUTCH................24-9
BUCKLE - INSTALLATION, FRONT SEAT
BELT ..............................8O-23
BUCKLE - REMOVAL, FRONT SEAT BELT . . 8O-22
BULB - INSTALLATION, BACKUP LAMP....8L-6
BULB - INSTALLATION, BRAKE/PARK
LAMP...............................8L-7
BULB - INSTALLATION, CARGO/DOME
LAMP..............................8L-27
BULB - INSTALLATION, CENTER HIGH
MOUNTED STOP LAMP.................8L-7
BULB - INSTALLATION, CLEARANCE
LAMP...............................8L-8
BULB - INSTALLATION, DOME
LAMP/INTRUSION SENSOR.............8L-30
BULB - INSTALLATION, DOME/READING
LAMP..............................8L-29
BULB - INSTALLATION, ENTRY/EXIT
LAMP..............................8L-32
BULB - INSTALLATION, FOG LAMP.......8L-10
BULB - INSTALLATION, FRONT POSITION
LAMP..............................8L-14
BULB - INSTALLATION, FRONT
TURN/PARK/SIDE MARKER LAMP.......8L-15
BULB - INSTALLATION, HIGH BEAM
HEADLAMP.........................8L-17
BULB - INSTALLATION, LICENSE PLATE
LAMP..............................8L-18
BULB - INSTALLATION, LOW BEAM
HEADLAMP.........................8L-19
BULB - INSTALLATION, REAR SIDE
MARKER LAMP......................8L-21
BULB - INSTALLATION, REAR TURN
LAMP..............................8L-22
BULB - INSTALLATION, REPEATER LAMP . . 8L-22
BULB - REMOVAL, BACKUP LAMP........8L-5
BULB - REMOVAL, BRAKE/PARK LAMP....8L-7
BULB - REMOVAL, CARGO/DOME LAMP . . 8L-27
BULB - REMOVAL, CENTER HIGH
MOUNTED STOP LAMP.................8L-7
BULB - REMOVAL, CLEARANCE LAMP.....8L-8
BULB - REMOVAL, DOME LAMP/
INTRUSION SENSOR..................8L-30
BULB - REMOVAL, DOME/READING
LAMP..............................8L-29
BULB - REMOVAL, ENTRY/EXIT LAMP....8L-31
BULB - REMOVAL, FOG LAMP..........8L-10
BULB - REMOVAL, FRONT POSITION
LAMP..............................8L-14
BULB - REMOVAL, FRONT TURN/PARK/
SIDE MARKER LAMP.................8L-14
BULB - REMOVAL, HIGH BEAM
HEADLAMP.........................8L-17
BULB - REMOVAL, LICENSE PLATE
LAMP..............................8L-17
BULB - REMOVAL, LOW BEAM
HEADLAMP.........................8L-18
BULB - REMOVAL, REAR SIDE MARKER
LAMP..............................8L-21
BULB - REMOVAL, REAR TURN LAMP....8L-21
BULB - REMOVAL, REPEATER LAMP.....8L-22
BULKHEAD - INSTALLATION............8L-29
BULKHEAD - REMOVAL................8L-28
BULKHEAD TRIM PANEL -
INSTALLATION.......................23-69
BULKHEAD TRIM PANEL -
INSTALLATION, BACKLITE..............23-81
BULKHEAD TRIM PANEL - REMOVAL.....23-69
BULKHEAD TRIM PANEL - REMOVAL,
BACKLITE..........................23-81
BUMPER - STEP - INSTALLATION, REAR
. . . 13-3
BUMPER - STEP - REMOVAL, REAR
.......13-3
BUMPER - STEPS - INSTALLATION,
FRONT
..............................13-2
BUMPER - STEPS - REMOVAL, FRONT
.....13-2
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF
................21-102BUSHINGS - INSTALLATION..............2-3
BUSHINGS - REMOVAL..................2-3
BUZZ, SQUEAK & RATTLE - STANDARD
PROCEDURE........................23-10
CABIN HEATER - DESCRIPTION.........24-72
CABIN HEATER - OPERATION...........24-72
CABLE - DESCRIPTION.................8P-3
CABLE - DIAGNOSIS AND TESTING,
GEARSHIFT........................21-109
CABLE - INSTALLATION, ANTENNA BODY . . 8A-1
CABLE - INSTALLATION, GEARSHIFT....21-109
CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA......................8A-2
CABLE - INSTALLATION, LATCH RELEASE . 23-51
CABLE - INSTALLATION, PARK LOCK....21-126
CABLE - REMOVAL, ANTENNA BODY......8A-1
CABLE - REMOVAL, GEARSHIFT........21-109
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA...........................8A-1
CABLE - REMOVAL, LATCH RELEASE.....23-51
CABLE - REMOVAL, PARK LOCK........21-125
CABLE TENSIONER - INSTALLATION......5-23
CABLE TENSIONER - REMOVAL..........5-23
CABLES - ADJUSTMENT, PARKING
BRAKE..............................5-25
CABLES - DESCRIPTION, BATTERY.......8F-14
CABLES - DIAGNOSIS AND TESTING,
BATTERY...........................8F-14
CABLES - INSTALLATION, BATTERY......8F-16
CABLES - INSTALLATION, MODE DOOR . . . 24-19
CABLES - OPERATION, BATTERY........8F-14
CABLES - REMOVAL, BATTERY..........8F-16
CABLES - REMOVAL, MODE DOOR.......24-19
CAMSHAFT POSITION - STANDARD
PROCEDURE, CHECKING................9-27
CAMSHAFT POSITION SENSOR -
DESCRIPTION.......................14-19
CAMSHAFT POSITION SENSOR -
INSTALLATION.......................14-19
CAMSHAFT POSITION SENSOR -
OPERATION.........................14-19
CAMSHAFT POSITION SENSOR -
REMOVAL..........................14-19
CAMSHAFT(S) - INSTALLATION..........9-29
CAMSHAFT(S) - REMOVAL..............9-28
CAP - DESCRIPTION, RADIATOR
PRESSURE..........................7-18
CAP - DIAGNOSIS AND TESTING,
RADIATOR PRESSURE.................7-19
CAP - OPERATION, RADIATOR
PRESSURE..........................7-18
CAPACITIES - SPECIFICATIONS, FLUID......0-4
CAPACITY, SPECIFICATIONS - CHARGE . . . 24-49
CARGO/DOME LAMP BULB -
INSTALLATION.......................8L-27
CARGO/DOME LAMP BULB - REMOVAL . . . 8L-27
CARGO/DOME LAMP UNIT -
INSTALLATION.......................8L-28
CARGO/DOME LAMP UNIT - REMOVAL . . . 8L-28
CARPETS AND FLOOR MATS -
INSTALLATION.......................23-70
CARPETS AND FLOOR MATS - REMOVAL . 23-69
CARRIER - INSTALLATION, SPARE TIRE . . . 22-10
CARRIER - REMOVAL, SPARE TIRE......22-10
CATALYTIC CONVERTER - INSTALLATION . . . 11-3
CATALYTIC CONVERTER - REMOVAL......11-3
CAUSES OF BURNT FLUID - DIAGNOSIS
AND TESTING
......................21-102
CAUTION - CAUTION
..................24-45
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS
.................24-45
CAUTION, CAUTION
...................24-45
CAUTION, INTERIOR
..................23-67
CENTER - DESCRIPTION, POWER
DISTRIBUTION
....................8W-97-3
CENTER - OPERATION, POWER
DISTRIBUTION
....................8W-97-3
CENTER BEARING - INSTALLATION
........3-9
CENTER BEARING - REMOVAL
............3-8
CENTER BEZEL - INSTALLATION,
INSTRUMENT PANEL
..................23-55
CENTER BEZEL - REMOVAL,
INSTRUMENT PANEL
..................23-55
CENTER HIGH MOUNTED STOP LAMP
BULB - INSTALLATION
.................8L-7
CENTER HIGH MOUNTED STOP LAMP
BULB - REMOVAL
.....................8L-7CENTER HIGH MOUNTED STOP LAMP
UN - INSTALLATION...................8L-8
CENTER HIGH MOUNTED STOP LAMP
UN - REMOVAL.......................8L-8
CENTER ROLLER ARM - INSTALLATION . . . 23-38
CENTER ROLLER ARM - REMOVAL......23-37
CENTER TRACK - INSTALLATION........23-39
CENTER TRACK - REMOVAL............23-38
CENTERING - STANDARD PROCEDURE,
CLOCKSPRING......................8O-13
CENTRAL TIMER MODULE -
DESCRIPTION........................8E-1
CENTRAL TIMER MODULE - DIAGNOSIS
AND TESTING........................8E-2
CENTRAL TIMER MODULE -
INSTALLATION........................8E-2
CENTRAL TIMER MODULE - OPERATION . . . 8E-2
CENTRAL TIMER MODULE - REMOVAL....8E-2
CHAIN - INSTALLATION, OIL PUMP.......9-54
CHAIN - INSTALLATION, TIMING.........9-67
CHAIN - REMOVAL, OIL PUMP...........9-53
CHAIN - REMOVAL, TIMING.............9-63
CHAIN COVER - INSTALLATION, TIMING . . . 9-60
CHAIN COVER - REMOVAL, TIMING.......9-59
CHAIN TENSIONER - INSTALLATION,
TIMING.............................9-71
CHAIN TENSIONER - REMOVAL, TIMING . . . 9-70
CHAIN TENSIONING RAIL -
INSTALLATION, TIMING.................9-66
CHAIN TENSIONING RAIL - REMOVAL,
TIMING.............................9-63
CHARGE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM...............24-48
CHARGE AIR COOLER AND PLUMBING -
CLEANING...........................11-5
CHARGE AIR COOLER AND PLUMBING -
DESCRIPTION........................11-4
CHARGE AIR COOLER AND PLUMBING -
INSPECTION.........................11-5
CHARGE AIR COOLER AND PLUMBING -
INSTALLATION........................11-5
CHARGE AIR COOLER AND PLUMBING -
OPERATION..........................11-4
CHARGE AIR COOLER AND PLUMBING -
REMOVAL...........................11-5
CHARGE AIR COOLER SYSTEM - LEAKS
- DIAGNOSIS AND TESTING.............11-4
CHARGE CAPACITY, SPECIFICATIONS.....24-49
CHARGING - STANDARD PROCEDURE,
BATTERY............................8F-8
CHARGING INDICATOR - DESCRIPTION . . . 8J-13
CHARGING INDICATOR - OPERATION.....8J-13
CHART - SPECIFICATIONS, TORQUE....5-29,5-5
CHART - SPECIFICATIONS, TORQUE.....19-10,
19-14,19-5,19-9
CHART - SPECIFICATIONS, TORQUE....2-12,2-2
CHART, SPECIFICATIONS - TORQUE.......5-22
CHART, SPECIFICATIONS - TORQUE.......22-5
CHECK - INSTALLATION..........23-13,23-24
CHECK - REMOVAL..............23-13,23-24
CHECK OIL LEVEL - STANDARD
PROCEDURE.......................21-102
CHECK VALVE - DESCRIPTION...........8R-7
CHECK VALVE - INSTALLATION..........8R-7
CHECK VALVE - OPERATION.............8R-7
CHECK VALVE - REMOVAL..............8R-7
CHECKING AND REPAIRING
CONNECTING RODS - STANDARD
PROCEDURE.........................9-40
CHECKING BATTERY ELECTROLYTE
LEVEL - STANDARD PROCEDURE........8F-12
CHECKING CAMSHAFT POSITION -
STANDARD PROCEDURE................9-27
CHECKS - DIAGNOSIS AND TESTING,
PRELIMINARY.........................7-1
CHIME WARNING SYSTEM - DIAGNOSIS
AND TESTING........................8B-2
CHIME/BUZZER - DESCRIPTION..........8B-1
CHIME/BUZZER - OPERATION............8B-1
CIGAR LIGHTER OUTLET -
DESCRIPTION.....................8W-97-1
CIGAR LIGHTER OUTLET - DIAGNOSIS
AND TESTING
.....................8W-97-2
CIGAR LIGHTER OUTLET - OPERATION
. 8W-97-2
CIGAR LIGHTER OUTLET - REMOVAL
. . 8W-97-2
CIRCUIT BREAKER - DESCRIPTION
....8W-97-2
CIRCUIT BREAKER - DIAGNOSIS AND
TESTING
.........................8W-97-2
VAINDEX 3
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
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