fuel pump MERCEDES-BENZ SPRINTER 2005 Service Workshop Manual

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

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

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

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

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

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

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

COVER - REMOVAL, TIMING CHAIN.......9-59
COVER - REMOVAL, TOP..............23-64
COVER - TRAY - INSTALLATION, TOP.....23-64
COVER - TRAY - REMOVAL, TOP........23-63
COVER(S) - INSTALLATION, CYLINDER
HEAD...............................9-30
COVER(S) - REMOVAL, CYLINDER HEAD . . . 9-30
COWL TRIM - INSTALLATION...........23-70
COWL TRIM - REMOVAL...............23-70
CRADLE CROSSMEMBER -
INSTALLATION, ENGINE................13-8
CRADLE CROSSMEMBER - REMOVAL,
ENGINE.............................13-6
CRANKSHAFT - INSTALLATION...........9-36
CRANKSHAFT - REMOVAL..............9-35
CRANKSHAFT AND BLOCK JOURNALS -
STANDARD PROCEDURE, MEASURE......9-35
CRANKSHAFT OIL SEAL - FRONT -
INSTALLATION........................9-38
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL...........................9-38
CRANKSHAFT OIL SEAL - REAR -
INSTALLATION........................9-37
CRANKSHAFT OIL SEAL - REAR -
REMOVAL...........................9-37
CRANKSHAFT POSITION SENSOR -
DESCRIPTION.......................14-20
CRANKSHAFT POSITION SENSOR -
INSTALLATION.......................14-20
CRANKSHAFT POSITION SENSOR -
OPERATION..........................14-20
CRANKSHAFT POSITION SENSOR -
REMOVAL..........................14-20
CROSSMEMBER - INSTALLATION,
ENGINE CRADLE......................13-8
CROSSMEMBER - INSTALLATION,
RADIATOR..........................23-48
CROSSMEMBER - REMOVAL, ENGINE
CRADLE.............................13-6
CROSSMEMBER - REMOVAL, RADIATOR . . 23-47
CROSSMEMBER - TRANSMISSION -
INSTALLATION, REAR..................13-9
CROSSMEMBER - TRANSMISSION -
REMOVAL, REAR......................13-9
CUP HOLDER - INSTALLATION..........23-56
CUP HOLDER - REMOVAL..............23-55
CUSHION - FRONT - INSTALLATION,
SEAT ..............................23-78
CUSHION - FRONT - REMOVAL, SEAT....23-78
CUSHION/COVER - REAR -
INSTALLATION, SEAT.................23-80
CUSHION/COVER - REAR -
INSTALLATION, SEAT BACK............23-80
CUSHION/COVER - REAR - REMOVAL,
SEAT
..............................23-80
CUSHION/COVER - REAR - REMOVAL,
SEAT BACK
.........................23-80
CYLINDER - INSTALLATION, KEY/LOCK
....19-7
CYLINDER - INSTALLATION, LOCK
.......23-18
CYLINDER - INSTALLATION, MASTER
.....5-18
CYLINDER - REMOVAL, KEY/LOCK
........19-6
CYLINDER - REMOVAL, LOCK
...........23-18
CYLINDER - REMOVAL, MASTER
.........5-17
CYLINDER BLEEDING - STANDARD
PROCEDURE, MASTER
.................5-17
CYLINDER BORES - STANDARD
PROCEDURE, MEASURING
..............9-34
CYLINDER HEAD - INSTALLATION
........9-25
CYLINDER HEAD - REMOVAL
............9-22
CYLINDER HEAD BOLT INSPECTION -
STANDARD PROCEDURE
................9-21
CYLINDER HEAD COVER(S) -
INSTALLATION
........................9-30
CYLINDER HEAD COVER(S) - REMOVAL
. . . 9-30
CYLINDER HEAD FRONT COVER -
INSTALLATION
........................9-26
CYLINDER HEAD FRONT COVER -
REMOVAL
...........................9-23
CYLINDER HEAD GUIDE RAIL -
INSTALLATION
........................9-26
CYLINDER HEAD GUIDE RAIL -
REMOVAL
...........................9-24
CYLINDER HEAD SURFACE - STANDARD
PROCEDURE, MEASURE
................9-21
CYLINDER LEAK DOWN TEST -
STANDARD PROCEDURE
.................9-3CYLINDER PRESSURE LOSS -
STANDARD PROCEDURE,
DETERMINING.........................9-4
CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING, MASTER......5-16
DAMPER - INSTALLATION, VIBRATION.....9-48
DAMPER - REMOVAL, VIBRATION........9-47
DAYTIME RUNNING LAMP RELAY -
INSTALLATION........................8L-9
DAYTIME RUNNING LAMP RELAY -
REMOVAL...........................8L-9
DCHA - DIAGNOSIS AND TESTING,
DIESEL SUPPLEMENTAL HEATER........24-72
DECOUPLER - DIAGNOSIS AND
TESTING, GENERATOR................8F-19
DECOUPLER PULLEY - DESCRIPTION,
GENERATOR........................8F-19
DECOUPLER PULLEY - INSTALLATION,
GENERATOR........................8F-21
DECOUPLER PULLEY - OPERATION,
GENERATOR........................8F-19
DECOUPLER PULLEY - REMOVAL,
GENERATOR........................8F-20
DEFROSTER DUCTS - INSTALLATION.....24-33
DEFROSTER DUCTS - REMOVAL.........24-33
DELAY RELAY - INSTALLATION, TIME....8L-33
DELAY RELAY - REMOVAL, TIME........8L-32
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL RESTRAINT............8O-6
DETERMINING CYLINDER PRESSURE
LOSS - STANDARD PROCEDURE..........9-4
DEVICES - STANDARD PROCEDURE,
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE........................8W-01-7
DIAGRAMS - DESCRIPTION, HOW TO
USE WIRING......................8W-01-1
DIAGRAMS, DIAGNOSIS AND TESTING -
SCHEMATICS........................21-47
DIESEL - DESCRIPTION, 2.7L............11-1
DIESEL - SPECIFICATIONS, STARTER
MOTOR............................8F-29
DIESEL - TORQUE, 2.7L...............8F-17
DIESEL - TORQUE, STARTER...........8F-29
DIESEL ENGINE - DESCRIPTION, FUEL
REQUIREMENTS.......................0-1
DIESEL ENGINE - DIAGNOSIS AND
TESTING............................11-2
DIESEL ENGINES - DESCRIPTION,
ENGINE OIL...........................0-3
DIESEL SUPPLEMENTAL HEATER - DCHA
- DIAGNOSIS AND TESTING............24-72
DIMENSIONS - SPECIFICATIONS, FRAME . . . 13-4
DIMENSIONS - SPECIFICATIONS,
OPENING...........................23-90
DIODE - INSTALLATION.............8W-01-9
DIODE - REMOVAL.................8W-01-9
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC...................8W-01-7
DISCHARGE LINE - INSTALLATION, A/C . . . 24-54
DISCHARGE LINE - REMOVAL, A/C.......24-53
DISCONNECTING AND CONNECTING
FUEL LINES - STANDARD PROCEDURE....14-2
DISTRIBUTION - DESCRIPTION,
POWER..........................8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION CENTER - DESCRIPTION,
POWER..........................8W-97-3
DISTRIBUTION CENTER - OPERATION,
POWER..........................8W-97-3
DISTRIBUTION DUCTS - INSTALLATION,
FLOOR.............................24-34
DISTRIBUTION DUCTS - REMOVAL,
FLOOR.............................24-33
DOME LAMP/INTRUSION SENSOR -
INSTALLATION.......................8L-31
DOME LAMP/INTRUSION SENSOR -
REMOVAL..........................8L-31
DOME LAMP/INTRUSION SENSOR BULB
- INSTALLATION
.....................8L-30
DOME LAMP/INTRUSION SENSOR BULB
- REMOVAL
.........................8L-30
DOME/READING LAMP BULB -
INSTALLATION
.......................8L-29
DOME/READING LAMP BULB - REMOVAL
. 8L-29
DOME/READING LAMP UNIT -
INSTALLATION
.......................8L-30DOME/READING LAMP UNIT - REMOVAL . . 8L-30
DOOR - ASSEMBLY...................23-28
DOOR - ASSEMBLY, SLIDING...........23-43
DOOR - DISASSEMBLY................23-26
DOOR - DISASSEMBLY, SLIDING........23-42
DOOR - INSTALLATION...........23-14,23-30
DOOR - INSTALLATION, FUEL FILL.......23-47
DOOR - INSTALLATION, SLIDING........23-44
DOOR - REMOVAL...............23-14,23-25
DOOR - REMOVAL, FUEL FILL..........23-47
DOOR - REMOVAL, SLIDING............23-41
DOOR ACTUATOR - DESCRIPTION,
RECIRCULATION.....................24-20
DOOR ACTUATOR - INSTALLATION,
RECIRCULATION.....................24-21
DOOR ACTUATOR - OPERATION,
RECIRCULATION.....................24-20
DOOR ACTUATOR - REMOVAL,
RECIRCULATION.....................24-21
DOOR CABLES - INSTALLATION, MODE . . . 24-19
DOOR CABLES - REMOVAL, MODE.......24-19
DOOR GLASS - INSTALLATION....23-15,23-31,
23-46
DOOR GLASS - REMOVAL . . . 23-15,23-31,23-46
DOOR INNER BELT WEATHERSTRIP -
INSTALLATION, FRONT................23-87
DOOR INNER BELT WEATHERSTRIP -
REMOVAL, FRONT....................23-87
DOOR JAMB SWITCH - INSTALLATION.....8L-31
DOOR JAMB SWITCH - REMOVAL.......8L-31
DOOR LOCK MOTOR - INSTALLATION.....8N-1
DOOR LOCK MOTOR - REMOVAL.........8N-1
DOOR OPENING SEALS - INSTALLATION . . 23-87
DOOR OPENING SEALS - REMOVAL......23-87
DOOR OUTER BELT WEATHERSTRIP -
INSTALLATION, FRONT................23-87
DOOR OUTER BELT WEATHERSTRIP -
REMOVAL, FRONT....................23-87
DOSING PUMP - DESCRIPTION, FUEL....24-74
DOSING PUMP - INSTALLATION, FUEL....24-74
DOSING PUMP - OPERATION, FUEL......24-74
DOSING PUMP - REMOVAL, FUEL.......24-74
DOUBLE INVERTED FLARING -
STANDARD PROCEDURE.................5-8
D-PILLAR TRIM - INSTALLATION........23-70
D-PILLAR TRIM - REMOVAL............23-70
DRAIN AND FILL - STANDARD
PROCEDURE.........................3-11
DRAINING COOLING SYSTEM -
STANDARD PROCEDURE................7-12
DRAINING WATER FROM FUEL FILTER -
STANDARD PROCEDURES...............14-2
DRAW TEST - STANDARD PROCEDURE,
IGNITION-OFF.......................8F-10
DRIVE BELT - DIAGNOSIS AND TESTING,
ACCESSORY..........................7-5
DRIVE BELTS - INSTALLATION............7-8
DRIVE BELTS - REMOVAL................7-8
DRIVE VISCOUS CLUTCH -
INSTALLATION, FAN...................7-16
DRIVE VISCOUS CLUTCH - REMOVAL,
FAN ................................7-16
DRIVER AIRBAG - DESCRIPTION........8O-16
DRIVER AIRBAG - INSTALLATION.......8O-18
DRIVER AIRBAG - OPERATION..........8O-17
DRIVER AIRBAG - REMOVAL...........8O-17
DRIVER HEATED SEAT SWITCH -
DESCRIPTION........................8G-2
DRIVER HEATED SEAT SWITCH -
DIAGNOSIS AND TESTING..............8G-2
DRIVER HEATED SEAT SWITCH -
INSTALLATION.......................8G-3
DRIVER HEATED SEAT SWITCH -
OPERATION..........................8G-2
DRIVER HEATED SEAT SWITCH -
REMOVAL...........................8G-3
DRIVING CLUTCH K1 - ASSEMBLY.......21-75
DRIVING CLUTCH K1 - DISASSEMBLY....21-74
DRIVING CLUTCH K2 - ASSEMBLY.......21-78
DRIVING CLUTCH K2 - DISASSEMBLY....21-76
DRIVING CLUTCH K3 - ASSEMBLY.......21-80
DRIVING CLUTCH K3 - DISASSEMBLY
....21-80
DRIVING CLUTCHES - DESCRIPTION
.....21-72
DRIVING CLUTCHES - OPERATION
.......21-72
DROP - STANDARD PROCEDURE,
TESTING FOR A VOLTAGE
............8W-01-8
DRUM IN HAT BRAKE - CLEANING,
REAR
...............................5-27
VAINDEX 5
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

FREEWHEELING CLUTCH -
DISASSEMBLY......................21-106
FREEWHEELING CLUTCH - OPERATION . . 21-105
FROM FUEL FILTER - STANDARD
PROCEDURES, DRAINING WATER........14-2
FROM GEAR TO COOLER TUBE -
INSTALLATION, RETURN HOSE..........19-15
FROM GEAR TO COOLER TUBE -
REMOVAL, RETURN HOSE.............19-15
FROM PUMP TO COOLER TUBE -
INSTALLATION, RETURN LINE..........19-15
FROM PUMP TO COOLER TUBE -
REMOVAL, RETURN LINE..............19-15
FRONT - INSTALLATION............5-14,5-24
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL............................9-38
FRONT - INSTALLATION, SEAT..........23-77
FRONT - INSTALLATION, SEAT
ADJUSTERS.........................23-78
FRONT - INSTALLATION, SEAT BACK.....23-77
FRONT - INSTALLATION, SEAT CUSHION . . 23-78
FRONT - REMOVAL................5-13,5-24
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL...............................9-38
FRONT - REMOVAL, SEAT..............23-77
FRONT - REMOVAL, SEAT ADJUSTERS . . . 23-78
FRONT - REMOVAL, SEAT BACK.........23-77
FRONT - REMOVAL, SEAT CUSHION......23-78
FRONT BUMPER - STEPS -
INSTALLATION........................13-2
FRONT BUMPER - STEPS - REMOVAL.....13-2
FRONT COVER - INSTALLATION,
CYLINDER HEAD......................9-26
FRONT COVER - REMOVAL, CYLINDER
HEAD...............................9-23
FRONT DOOR INNER BELT
WEATHERSTRIP - INSTALLATION........23-87
FRONT DOOR INNER BELT
WEATHERSTRIP - REMOVAL............23-87
FRONT DOOR OUTER BELT
WEATHERSTRIP - INSTALLATION........23-87
FRONT DOOR OUTER BELT
WEATHERSTRIP - REMOVAL............23-87
FRONT (DRW) - INSTALLATION . . 5-11,5-13,5-21
FRONT (DRW) - REMOVAL.......5-12,5-20,5-9
FRONT FASCIA - INSTALLATION..........13-2
FRONT FASCIA - REMOVAL..............13-2
FRONT LAMP UNIT - ADJUSTMENT......8L-12
FRONT LAMP UNIT - INSTALLATION.....8L-12
FRONT LAMP UNIT - REMOVAL.........8L-12
FRONT POSITION LAMP BULB -
INSTALLATION.......................8L-14
FRONT POSITION LAMP BULB -
REMOVAL..........................8L-14
FRONT SEAT BELT & RETRACTOR -
INSTALLATION......................8O-21
FRONT SEAT BELT & RETRACTOR -
REMOVAL..........................8O-19
FRONT SEAT BELT BUCKLE -
INSTALLATION......................8O-23
FRONT SEAT BELT BUCKLE - REMOVAL . . 8O-22
FRONT (SRW) - INSTALLATION . . 5-10,5-12,5-21
FRONT (SRW) - REMOVAL.......5-11,5-19,5-9
FRONT SUSPENSION, SPECIAL TOOLS....19-11
FRONT SUSPENSION, SPECIAL TOOLS.....2-2
FRONT TURN/PARK/SIDE MARKER LAMP
BULB - INSTALLATION................8L-15
FRONT TURN/PARK/SIDE MARKER LAMP
BULB - REMOVAL....................8L-14
FRONT WHEEL SPEED SENSOR -
INSTALLATION........................5-30
FRONT WHEEL SPEED SENSOR -
REMOVAL...........................5-30
FUEL DOSING PUMP - DESCRIPTION.....24-74
FUEL DOSING PUMP - INSTALLATION....24-74
FUEL DOSING PUMP - OPERATION......24-74
FUEL DOSING PUMP - REMOVAL........24-74
FUEL FILL DOOR - INSTALLATION.......23-47
FUEL FILL DOOR - REMOVAL...........23-47
FUEL FILTER - DESCRIPTION............14-5
FUEL FILTER - INSTALLATION
............14-6
FUEL FILTER - OPERATION
..............14-5
FUEL FILTER - REMOVAL
...............14-5
FUEL FILTER - STANDARD
PROCEDURES, DRAINING WATER
FROM
..............................14-2
FUEL FILTER CLOGGED INDICATOR -
DESCRIPTION
.......................8J-15FUEL FILTER CLOGGED INDICATOR -
OPERATION.........................8J-15
FUEL GAUGE - DESCRIPTION...........8J-16
FUEL GAUGE - OPERATION.............8J-16
FUEL INDICATOR - DESCRIPTION, LOW . . . 8J-18
FUEL INDICATOR - OPERATION, LOW.....8J-18
FUEL INJECTOR, DESCRIPTION.........14-20
FUEL INJECTORS - STANDARD
PROCEDURE, CLEANING...............14-22
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION.......................14-15
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION.......................14-15
FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL..........................14-15
FUEL LINE - INSTALLATION............24-76
FUEL LINE - REMOVAL................24-75
FUEL LINES - DIAGNOSIS AND TESTING,
HIGH PRESSURE......................14-1
FUEL LINES - STANDARD PROCEDURE,
DISCONNECTING AND CONNECTING......14-2
FUEL PRESSURE SOLENOID -
DESCRIPTION.......................14-27
FUEL PRESSURE SOLENOID -
INSTALLATION.......................14-28
FUEL PRESSURE SOLENOID -
OPERATION.........................14-27
FUEL PRESSURE SOLENOID - REMOVAL . . 14-28
FUEL PUMP TEST - STANDARD
PROCEDURE, LOW PRESSURE...........14-3
FUEL RAIL - DESCRIPTION..............14-11
FUEL RAIL - INSTALLATION............14-11
FUEL RAIL - OPERATION...............14-11
FUEL RAIL - REMOVAL................14-11
FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION........................0-1
FUEL SENSOR - DESCRIPTION, WATER
IN ................................14-16
FUEL SENSOR - OPERATION, WATER IN . . 14-16
FUEL SHUTOFF SOL - DESCRIPTION, HI
PRESSURE.........................14-16
FUEL SHUTOFF SOL - OPERATION, HI
PRESSURE.........................14-16
FUEL SUPPLY RESTRICTIONS -
DIAGNOSIS AND TESTING..............14-5
FUEL SYSTEM - DIAGNOSIS AND
TESTING, AIR IN......................14-2
FUEL SYSTEM COMPONENTS -
STANDARD PROCEDURES, CLEANING.....14-2
FUEL SYSTEM PRESSURE - WARNING,
HIGH...............................14-1
FUEL SYSTEM, SPECIAL TOOLS..........14-5
FUEL TANK - DESCRIPTION............14-12
FUEL TANK - INSTALLATION............14-13
FUEL TANK - REMOVAL...............14-12
FUEL TANK MODULE - DESCRIPTION.....14-13
FUEL TANK MODULE - INSTALLATION....14-14
FUEL TANK MODULE - REMOVAL........14-13
FUEL TEMPERATURE SENSOR -
DESCRIPTION.......................14-29
FUEL TEMPERATURE SENSOR -
INSTALLATION.......................14-29
FUEL TEMPERATURE SENSOR -
OPERATION.........................14-29
FUEL TEMPERATURE SENSOR -
REMOVAL..........................14-29
FUNCTION TEST - DIAGNOSIS AND
TESTING............................24-3
FUSE BLOCK #1 - DESCRIPTION......8W-97-2
FUSE BLOCK #1 - INSTALLATION......8W-97-3
FUSE BLOCK #1 - OPERATION........8W-97-2
FUSE BLOCK #1 - REMOVAL.........8W-97-3
FUSE BLOCK #2 - DESCRIPTION......8W-97-3
FUSE BLOCK #2 - OPERATION........8W-97-3
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON.......8W-01-8
GALLERY PLUGS - STANDARD
PROCEDURE, REPLACING ENGINE
CORE AND OIL.......................9-34
GAP - STANDARD PROCEDURE,
COMPRESSOR CLUTCH AIR
.............24-9
GAP AND FLUSH - SPECIFICATIONS
......23-88
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE
......................8J-15
GAUGE - DESCRIPTION, FUEL
...........8J-16
GAUGE - OPERATION, ENGINE
TEMPERATURE
......................8J-15GAUGE - OPERATION, FUEL............8J-16
GAUGES - DIAGNOSIS AND TESTING,
PRESSURE..........................22-8
GEAR - DESCRIPTION..................19-8
GEAR - INSTALLATION.................19-8
GEAR - INSTALLATION, INTERMEDIATE....9-66
GEAR - REMOVAL.....................19-8
GEAR - REMOVAL, INTERMEDIATE........9-61
GEAR SELECTOR INDICATOR -
DESCRIPTION.......................8J-17
GEAR SELECTOR INDICATOR -
OPERATION.........................8J-17
GEAR TO COOLER TUBE -
INSTALLATION, RETURN HOSE FROM....19-15
GEAR TO COOLER TUBE - REMOVAL,
RETURN HOSE FROM.................19-15
GEARSHIFT CABLE - DIAGNOSIS AND
TESTING..........................21-109
GEARSHIFT CABLE - INSTALLATION.....21-109
GEARSHIFT CABLE - REMOVAL........21-109
GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-131
GEARTRAIN - DESCRIPTION,
PLANETARY........................21-130
GEARTRAIN - DISASSEMBLY,
PLANETARY........................21-131
GEARTRAIN - OPERATION, PLANETARY . . 21-130
GENERAL - WARNINGS.............8W-01-6
GENERATOR - DESCRIPTION...........8F-18
GENERATOR - INSTALLATION...........8F-18
GENERATOR - OPERATION.............8F-18
GENERATOR - REMOVAL...............8F-18
GENERATOR DECOUPLER - DIAGNOSIS
AND TESTING.......................8F-19
GENERATOR DECOUPLER PULLEY -
DESCRIPTION.......................8F-19
GENERATOR DECOUPLER PULLEY -
INSTALLATION.......................8F-21
GENERATOR DECOUPLER PULLEY -
OPERATION.........................8F-19
GENERATOR DECOUPLER PULLEY -
REMOVAL..........................8F-20
GLASS - INSTALLATION, DOOR....23-15,23-31,
23-46
GLASS - INSTALLATION, SIDE VIEW
MIRROR...........................23-49
GLASS - REMOVAL, DOOR . . . 23-15,23-31,23-46
GLASS - REMOVAL, SIDE VIEW MIRROR . . 23-49
GLOVE BOX - INSTALLATION...........23-56
GLOVE BOX - REMOVAL...............23-56
GLOW PLUG - INSTALLATION............8I-1
GLOW PLUG - REMOVAL................8I-1
GLOW PLUG RELAY - DESCRIPTION.......8I-2
GLOW PLUG RELAY - OPERATION........8I-2
GLOW PLUG RELAYS - DIAGNOSIS AND
TESTING.............................8I-2
GRILLE - INSTALLATION...............23-47
GRILLE - REMOVAL..................23-47
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO..........8W-01-8
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR..........8W-01-5
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO
..............................8W-01-8
GUIDE RAIL - INSTALLATION, CYLINDER
HEAD
...............................9-26
GUIDE RAIL - REMOVAL, CYLINDER
HEAD
...............................9-24
HANDLE - INSTALLATION, ASSIST
.......23-68
HANDLE - INSTALLATION, EXTERIOR
....23-16,
23-33,23-36
HANDLE - INSTALLATION, LATCH
RELEASE
...........................23-52
HANDLE - REMOVAL, ASSIST
...........23-68
HANDLE - REMOVAL, EXTERIOR
. . . 23-16,23-32,
23-36
HANDLE - REMOVAL, LATCH RELEASE
. . . 23-52
HANDLE ACTUATOR - INSTALLATION,
INSIDE
........................23-34,23-37
HANDLE ACTUATOR - REMOVAL, INSIDE
. 23-34,
23-37
HANDLING NON-DEPLOYED
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE
...............8O-6
HARNESS - DIAGNOSIS AND TESTING,
WIRING
..........................8W-01-6
VAINDEX 7
Description Group-Page Description Group-Page Description Group-Page