2005 MERCEDES-BENZ SPRINTER compression ratio

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................4
INSTALLATION
INSTALLATION - ENGINE COVER..........7
INSTALLATION........................7
SPECIFICATIONS - TORQUE
SPECIFICATIONS......................8
SPECIAL TOOLS.......................14
AIR CLEANER ELEMENT
REMOVAL.............................20
INSTALLATION.........................20
AIR CLEANER HOUSING
REMOVAL.............................20
INSTALLATION.........................20
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............21
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............21
REMOVAL
REMOVAL - CYLINDER HEAD............22
REMOVAL - CYLINDER HEAD FRONT
COVER.............................23
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 24
INSTALLATION
INSTALLATION - CYLINDER HEAD........25
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................26
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................26
CAMSHAFT(S)
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................27
REMOVAL.............................28
INSTALLATION.........................29
CYLINDER HEAD COVER(S)
REMOVAL.............................30
INSTALLATION.........................30VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............31
REMOVAL - VALVES...................31
INSTALLATION
INSTALLATION - VALVE SPRINGS........32
INSTALLATION - VALVES...............33
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 34
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................34
CRANKSHAFT
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....35
REMOVAL.............................35
INSTALLATION.........................36
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................37
INSTALLATION.........................37
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................38
INSTALLATION.........................38
FLYWHEEL
REMOVAL.............................39
INSTALLATION
INSTALLATION.......................39
INSTALLATION.......................39
PISTON & CONNECTING ROD
DESCRIPTION.........................40
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........40
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................42
REMOVAL.............................42
INSTALLATION.........................43
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................46
VIBRATION DAMPER
REMOVAL.............................47
INSTALLATION.........................48
VACUUM PUMP
DESCRIPTION.........................48
OPERATION...........................48
REMOVAL.............................48
INSTALLATION.........................49
VAENGINE 9 - 1

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line Engine
With 4-Valve Technology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System Common Rail Diesel
Injection (CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 125/4200 kW at RPM
Torque 400/1600-2400 Nm at
RPM
Maximum Speed 4800 RPM
Compression Ratio 19:1
Bore/Stroke 88.0/88.4 mm
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11)
Install glow plugs (Refer to 8 - ELECTRICAL/IG-
NITION CONTROL/GLOW PLUG - INSTALLATION).
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM UNLESS
COOLANT TEMPERATURE IS BELOW 90C (194ÉF).
RISK OF INJURY TO SKIN AND EYES AS A RESULT OF
SCALDING WITH HOT COOLANT WHICH SPLASHES
OUT. RISK OF POISONING FROM SWALLOWING
COOLANT. OPEN CAP SLOWLY AND RELEASE PRES-
SURE. STORE COOLANT IN PROPER CONTAINERS
ONLY. WEAR PROTECTIVE GLOVES, CLOTHING AND
EYE PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
VAENGINE 9 - 3
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Threaded Rail to Rail 22 16 -
Fuel Cooling System
Bolt-Fuel Cooler to
Charge Air Distribution
Pipe14 - 124
Heater Booster, Heater Unit
Bolt- Temperature
Controlled Cut Out to
Heater Booster Control
Module12 - 106
Nut-Threaded Stud to
Electronic Heater Booster18 - 159
SPECIAL TOOLS
SPECIAL TOOL CROSS REFERENCE CHART
MB
TOOL #MILLER
TOOL #DESCRIPTION
N/A 5069-2 FUEL GAUGE
611 589
04 63 008927 COMPRESSION TESTER
ADAPTER
611 589
03 15 008929 CANSHAFT LOCKING
PINS
611 589
00 40 008930 COUNTERHOLDER
N/A 8931 TIMING CHAIN
RETAINER
601 589
02 40 008932 CRANKSHAFT LOCK
603 589
00 40 008934 COUNTERHOLDER
N/A 8938A EXTRACTION CLAW
611 589
00 14 008936 FRONT CRANKSHAFT
SEAL INSTALLER
N/A 8938 EXTRACTION CLAW
613 589
00 33 008940 VIBRATION DAMPER
REMOVER
N/A 8941 SLIDE HAMMER
611 589
00 15 008942 OIL JET INSTALLER
611 589
01 14 008944 REAR MAIN SEAL
INSTALLER
MB
TOOL #MILLER
TOOL #DESCRIPTION
602 589
00 39 008947 RIVETING OPENER
602 589
02 33 008948 CHAIN SEPARATOR
TOOL
602 589
03 63 008949 THRUST PIECE
602 589
04 63 008950 PRESSING SCREW
602 589
02 40 008951 ASSEMBLY LINKS
602 589
02 40 008952 ASSEMBLY INSERTS
N/A 9285 FUEL LINE WRENCH
N/A 9286 GLOW PLUG PLIERS
N/A 9295 COMPRESSION HOSE
ADAPTER
111 5 8 9
25 61 009307 VAVLE SERVICE TOOLS
N/A 8534-16 ENGINE SUPPORT
FIXTURE ADAPTERS
N/A 9308 ENGINE LIFTING
FIXTURE
103 589
01 63 009310 ASSEMBLY INSERTS
602 589
05 63 009311 PRESSING SCREW
9 - 14 ENGINEVA
ENGINE (Continued)

²No. 1 Compression ring - Gap 120É from No. 2
compression ring gap.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Install retaining lock for crankshaft/ring gear
(Fig. 43).
(4) Remove crankshaft center bolt and washer
(Fig. 43).
NOTE: If hub of belt pulley/vibration damper is
tight, use puller # 8940 to remove. DO NOT tilt
puller when in use. Grooves of the puller must
mesh fully into the slots of the belt pulley.
(5) Remove the belt pulley/vibration damper (Fig.
43).
Fig. 41 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 42 Ring Gap Orientation
1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRTFig. 43 VIBRATION DAMPER/CRANKSHAFT PULLEY
1 - SPECIAL TOOL #8932
2 - RETAINING BOLTS
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY
4 - WASHER
5 - CRANKSHAFT BOLT
VAENGINE 9 - 47
PISTON RINGS (Continued)

INSTALLATION - HIGH PRESSURE LINES
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
(1) Loosen the fuel rail mounting bolts to install
lines free of stress.
CAUTION: Inspect sealing cone at lines. Replace if
compression points exist. Ensure lines are exactly
located.
(2) Position and install fuel lines (Fig. 2). Tighten
to 22N´m (195 lbs. in.) using a wrench to counterhold
at threaded connection.(3) Tighten fuel rail to 14N´m (124 lbs. in.).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(5) Start engine and inspect for leaks.
FUEL PUMP
DESCRIPTION
DESCRIPTION - HIGH PRESSURE PUMP
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
The high pressure pump is a radial piston pump
with three pistons arranged at an angle of 120É and
an internal shut off valve located in one of the ele-
ments to assist with fuel temperature regulation. The
high pressure pump is driven at about 1.3 times the
speed of the camshaft. The high pressure pump is
mounted to the front of the cylinder head and must
be replaced as an assembly should a failure occur
(Fig. 3).
DESCRIPTION - LOW PRESSURE PUMP
The low pressure pump (Fig. 4)supplies an ade-
quate quantity of filtered fuel in all operating condi-
tions from the fuel tank, at an adequate pressure, to
the high pressure pump.
OPERATION
OPERATION
LOW PRESSURE SIDE
The fuel supplied by the low pressure pump flows
through the fuel feed to the throttle valve. Any air
entrained by the fuel is directed through the restric-
tor to the return flow. The throttle valve opens
against the force of the spring at a pressure of
approx. 6 PSI (0.4 bar) and the fuel is able to flow
along a ring line to the individual pistons. The eccen-
tric shaft with its eccentric plate moves the pistons
up and down against the piston spring of the three
pump elements. The leak fuel from the pistons flows
along the return flow to the fuel tank. The fuel flow-
ing out of the throttle valve, also flows off along the
return flow.
Fig. 2 HIGH PRESSURE LINES AT INJECTORS
1 - HIGH PRESSURE LINE
2 - CYLINDER HEAD COVER
3 - FUEL RAIL
VAFUEL DELIVERY 14 - 7
FUEL LINES (Continued)

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

DUAL REAR WHEEL INSTALLATION -
STANDARD PROCEDURE...............22-12
DUAL REAR WHEELS - INSTALLATION,
AXLE SHAFTS........................3-19
DUAL REAR WHEELS - REMOVAL, AXLE
SHAFTS.............................3-19
DUCTS - INSTALLATION, DEFROSTER....24-33
DUCTS - INSTALLATION, FLOOR
DISTRIBUTION.......................24-34
DUCTS - INSTALLATION, INSTRUMENT
PANEL.............................24-38
DUCTS - REMOVAL, DEFROSTER........24-33
DUCTS - REMOVAL, FLOOR
DISTRIBUTION.......................24-33
DUCTS - REMOVAL, INSTRUMENT
PANEL.............................24-37
EFFECTS OF INCORRECT FLUID LEVEL -
DIAGNOSIS AND TESTING............21-102
ELECTRIC COOLANT PUMP -
DESCRIPTION.......................24-57
ELECTRIC COOLANT PUMP -
INSTALLATION.......................24-57
ELECTRIC COOLANT PUMP - OPERATION . 24-57
ELECTRIC COOLANT PUMP - REMOVAL . . . 24-57
ELECTRICAL - DESCRIPTION............5-29
ELECTRICAL - OPERATION..............5-29
ELECTROHYDRAULIC UNIT - ASSEMBLY . . 21-95
ELECTROHYDRAULIC UNIT -
DESCRIPTION.......................21-82
ELECTROHYDRAULIC UNIT -
DISASSEMBLY.......................21-92
ELECTROHYDRAULIC UNIT -
INSTALLATION......................21-100
ELECTROHYDRAULIC UNIT - OPERATION . . 21-87
ELECTROHYDRAULIC UNIT - REMOVAL . . . 21-92
ELECTROLYTE LEVEL - STANDARD
PROCEDURE, CHECKING BATTERY.......8F-12
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES - STANDARD
PROCEDURE......................8W-01-7
ELEMENT - DESCRIPTION, HEATED SEAT . . 8G-3
ELEMENT - DIAGNOSIS AND TESTING,
HEATED SEAT ........................8G-3
ELEMENT - INSTALLATION, AIR
CLEANER............................9-20
ELEMENT - OPERATION, HEATED SEAT....8G-3
ELEMENT - REMOVAL, AIR CLEANER......9-20
END - DIAGNOSIS AND TESTING, OUTER
TIE ROD............................19-10
END - INSTALLATION, TIE ROD.........19-11
END - REMOVAL, TIE ROD.............19-11
ENGINE - DESCRIPTION.................9-2
ENGINE - DESCRIPTION, FUEL
REQUIREMENTS - DIESEL...............0-1
ENGINE - DIAGNOSIS AND TESTING,
DIESEL.............................11-2
ENGINE - STANDARD PROCEDURE,
COMPRESSION TESTING................9-3
ENGINE BLOCK HEATER - INSTALLATION . . . 7-14
ENGINE BLOCK HEATER - REMOVAL......7-14
ENGINE CONTROL MODULE -
DESCRIPTION........................8E-3
ENGINE CONTROL MODULE -
INSTALLATION........................8E-4
ENGINE CONTROL MODULE - REMOVAL . . . 8E-4
ENGINE COOLANT - DESCRIPTION.........0-1
ENGINE COOLANT TEMP SENSOR -
DESCRIPTION........................7-14
ENGINE COOLANT TEMP SENSOR -
INSTALLATION........................7-15
ENGINE COOLANT TEMP SENSOR -
REMOVAL...........................7-14
ENGINE COOLANT THERMOSTAT -
INSTALLATION........................7-16
ENGINE COOLANT THERMOSTAT -
REMOVAL...........................7-15
ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE, REPLACING....9-34
ENGINE COVER - INSTALLATION..........9-7
ENGINE COVER - REMOVAL
..............9-4
ENGINE CRADLE CROSSMEMBER -
INSTALLATION
........................13-8
ENGINE CRADLE CROSSMEMBER -
REMOVAL
...........................13-6
ENGINE OIL - DIESEL ENGINES -
DESCRIPTION
.........................0-3
ENGINE TEMPERATURE GAUGE -
DESCRIPTION
.......................8J-15ENGINE TEMPERATURE GAUGE -
OPERATION.........................8J-15
ENGINES - DESCRIPTION, ENGINE OIL -
DIESEL..............................0-3
ENTRY MODULE - DESCRIPTION,
SENTRY KEY REMOTE.................8Q-2
ENTRY MODULE - INSTALLATION,
SENTRY KEY REMOTE.................8Q-4
ENTRY MODULE - OPERATION, SENTRY
KEY REMOTE........................8Q-3
ENTRY MODULE - REMOVAL, SENTRY
KEY REMOTE........................8Q-3
ENTRY TRANSMITTER - DESCRIPTION,
REMOTE KEYLESS....................8N-2
ENTRY/EXIT LAMP BULB -
INSTALLATION.......................8L-32
ENTRY/EXIT LAMP BULB - REMOVAL.....8L-31
ENTRY/EXIT LAMP UNIT - INSTALLATION . 8L-32
ENTRY/EXIT LAMP UNIT - REMOVAL.....8L-32
EQUIPMENT - STANDARD PROCEDURE,
REFRIGERANT SYSTEM SERVICE........24-46
EVACUATE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM...............24-47
EVAPORATOR - DESCRIPTION, A/C.......24-54
EVAPORATOR - INSTALLATION, A/C......24-55
EVAPORATOR - INSTALLATION, REAR....24-61
EVAPORATOR - OPERATION, A/C........24-54
EVAPORATOR - REMOVAL, A/C..........24-55
EVAPORATOR - REMOVAL, REAR........24-60
EVAPORATOR TEMPERATURE SENSOR -
DESCRIPTION....................24-17,24-25
EVAPORATOR TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING.............24-26
EVAPORATOR TEMPERATURE SENSOR -
INSTALLATION..................24-18,24-26
EVAPORATOR TEMPERATURE SENSOR -
OPERATION....................24-18,24-26
EVAPORATOR TEMPERATURE SENSOR -
REMOVAL.....................24-18,24-26
EXHAUST MANIFOLD - INSTALLATION.....9-59
EXHAUST MANIFOLD - REMOVAL.........9-59
EXHAUST PIPE - INSTALLATION..........11-3
EXHAUST PIPE - REMOVAL.............11-3
EXHAUST TUBE - INSTALLATION........24-73
EXHAUST TUBE - REMOVAL............24-73
EXPANSION VALVE - DESCRIPTION, A/C . . 24-55
EXPANSION VALVE - DIAGNOSIS AND
TESTING, A/C.......................24-56
EXPANSION VALVE - INSTALLATION, A/C . . 24-56
EXPANSION VALVE - INSTALLATION,
REAR..............................24-63
EXPANSION VALVE - OPERATION, A/C....24-55
EXPANSION VALVE - REMOVAL, A/C.....24-56
EXPANSION VALVE - REMOVAL, REAR....24-62
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR - OPERATION, LAMPS/
LIGHTING...........................8L-3
EXTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING.....................8L-5
EXTERIOR HANDLE - INSTALLATION.....23-16,
23-33,23-36
EXTERIOR HANDLE - REMOVAL . . . 23-16,23-32,
23-36
FAN - INSTALLATION, RADIATOR.........7-13
FAN - REMOVAL, RADIATOR.............7-13
FAN DRIVE VISCOUS CLUTCH -
INSTALLATION........................7-16
FAN DRIVE VISCOUS CLUTCH -
REMOVAL...........................7-16
FASCIA - INSTALLATION, FRONT.........13-2
FASCIA - INSTALLATION, REAR..........13-3
FASCIA - REMOVAL, FRONT.............13-2
FASCIA - REMOVAL, REAR..............13-3
FASTENER IDENTIFICATION -
DESCRIPTION......................Intro.-2
FASTENER USAGE - DESCRIPTION......Intro.-5
FILL - STANDARD PROCEDURE, DRAIN....3-11
FILL - STANDARD PROCEDURE,
TRANSMISSION.....................21-103
FILL AND BLEED PROCEDURE,
STANDARD PROCEDURE - POWER
STEERING PUMP
.....................19-14
FILL DOOR - INSTALLATION, FUEL
.......23-47
FILL DOOR - REMOVAL, FUEL
..........23-47
FILL/CHECK LOCATIONS - INSPECTION,
FLUID
...............................0-4
FILTER - DESCRIPTION, FLUID
.........21-101FILTER - DESCRIPTION, FUEL............14-5
FILTER - INSTALLATION, AIR......24-31,24-39
FILTER - INSTALLATION, FUEL...........14-6
FILTER - INSTALLATION, OIL............9-51
FILTER - OPERATION, FLUID...........21-101
FILTER - OPERATION, FUEL.............14-5
FILTER - REMOVAL, AIR..........24-31,24-39
FILTER - REMOVAL, FUEL...............14-5
FILTER - REMOVAL, OIL................9-51
FILTER - STANDARD PROCEDURES,
DRAINING WATER FROM FUEL...........14-2
FILTER CLOGGED INDICATOR -
DESCRIPTION, FUEL..................8J-15
FILTER CLOGGED INDICATOR -
OPERATION, FUEL....................8J-15
FINESSE SANDING/BUFFING & POLISH -
DESCRIPTION.......................23-75
FINISH - DESCRIPTION, BASECOAT/
CLEARCOAT.........................23-74
FITTING - STANDARD PROCEDURE,
PISTON RING........................9-46
FLARING - STANDARD PROCEDURE,
DOUBLE INVERTED.....................5-8
FLARING - STANDARD PROCEDURE, ISO....5-8
FLOOR DISTRIBUTION DUCTS -
INSTALLATION.......................24-34
FLOOR DISTRIBUTION DUCTS -
REMOVAL..........................24-33
FLOOR MATS - INSTALLATION, CARPETS . 23-70
FLOOR MATS - REMOVAL, CARPETS.......23-69
FLOW (MAF) SENSOR - DESCRIPTION,
MANIFOLD AIR......................14-30
FLOW (MAF) SENSOR - INSTALLATION,
MANIFOLD AIR......................14-31
FLOW (MAF) SENSOR - OPERATION,
MANIFOLD AIR......................14-30
FLOW (MAF) SENSOR - REMOVAL,
MANIFOLD AIR......................14-31
FLUID - DESCRIPTION, BRAKE............0-3
FLUID - DESCRIPTION, POWER
STEERING............................0-3
FLUID - DIAGNOSIS AND TESTING,
CAUSES OF BURNT..................21-102
FLUID - NAG1 - DESCRIPTION,
AUTOMATIC TRANSMISSION.............0-4
FLUID - OPERATION, AUTOMATIC
TRANSMISSION.......................0-4
FLUID AND FILTER - DESCRIPTION.....21-101
FLUID AND FILTER - OPERATION.......21-101
FLUID CAPACITIES - SPECIFICATIONS......0-4
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING......................21-102
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE..................5-14
FLUID COOLER TUBE - INSTALLATION....19-14
FLUID COOLER TUBE - REMOVAL.......19-14
FLUID FILL/CHECK LOCATIONS -
INSPECTION..........................0-4
FLUID INDICATOR - DESCRIPTION,
WASHER...........................8J-27
FLUID INDICATOR - OPERATION,
WASHER...........................8J-27
FLUID LEVEL - DIAGNOSIS AND
TESTING, EFFECTS OF INCORRECT......21-102
FLUID LEVEL - STANDARD PROCEDURE,
BRAKE..............................5-14
FLUID LEVEL SWITCH - DESCRIPTION,
WASHER............................8R-7
FLUID LEVEL SWITCH - OPERATION,
WASHER............................8R-8
FLUID RESERVOIR - INSTALLATION.......5-15
FLUID RESERVOIR - REMOVAL..........5-15
FLUID, SPECIFICATIONS - BRAKE.........5-14
FLUID/FILTER SERVICE - STANDARD
PROCEDURE.......................21-104
FLUSH - SPECIFICATIONS, GAP.........23-88
FLUSHING POWER STEERING SYSTEM -
STANDARD PROCEDURE...............19-13
FLYWHEEL - REMOVAL.................9-39
FOG LAMP BULB - INSTALLATION.......8L-10
FOG LAMP BULB - REMOVAL...........8L-10
FOG LAMP RELAY - INSTALLATION......8L-11
FOG LAMP RELAY - REMOVAL..........8L-10
FOG LAMP SWITCH - INSTALLATION
.....8L-12
FOG LAMP SWITCH - REMOVAL
.........8L-11
FRAME DIMENSIONS - SPECIFICATIONS
. . . 13-4
FREEWHEELING CLUTCH - ASSEMBLY
. . . 21-107
FREEWHEELING CLUTCH - DESCRIPTION
. 21-105
6 INDEXVA
Description Group-Page Description Group-Page Description Group-Page