service MERCEDES-BENZ SPRINTER 2006 Service Manual

CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Ensure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Reinstall the secondary retaining clip over the
spring-lock coupler cage.
(9) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(10) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
UNDERBODY LINES
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
NOTE: The underbody refrigerant lines for the
optional rear A/C system are serviced in five sec-
tions. Two sections are connected the A/C compres-
sor. Two sections of the underbody suction line
(low-side) are connected together by a tapping
block with an O-ring seal. The underbody A/C dis-
charge line uses a spring-lock type refrigerant line
coupler with an O-ring seal.
DISCHARGE LINE
(1) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - REMOVAL).
(2) Recover the refrigerant from the rear refriger-
ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Raise and support the vehicle.
(4) Using the proper A/C line disconnect tool, dis-
connect the underbody discharge line spring-lock cou-
pler from the compressor section of the underbody
discharge line and remove and discard the O-ring
seal (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL) (Fig. 39).
(5) Disconnect the underbody discharge line from
the rear A/C discharge line and remove and discard
the O-ring seal.
(6) Install plug in, or tape over all of the opened
discharge line fittings.
(7) Disengage the fuel lines from the retaining clip
located near the transmission and position the fuel
lines out of the way.
(8) Remove the screws and brackets that secure
the discharge line to the underneath of the vehicle.
(9) Support transmission with a suitable lifting
device and remove the rear transmission crossmem-
ber (Refer to 13 - FRAME & BUMPERS/FRAME/
REAR CROSSMEMBER-TRANSMISSION -
REMOVAL).
(10) Remove the underbody discharge line from
the vehicle. Push the discharge line forward and over
the transmission, then pull it rearward to remove.
(11) If necessary, remove the bolt that secures the
compressor section of the underbody discharge line to
the A/C compressor and remove and discard the
O-ring seal. Make sure to plug in, or tape over the
opened discharge line fitting and compressor port.
24 - 100 PLUMBINGVA

SYMPTOMS DIAGNOSIS
Symptom Possible Causes
Smell of diesel fuel. Check cabin heater system integration in vehicle's fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of exter-
nal fuel. If presence of external fuel is observed on the heater unit or
in the exhaust tube or after draining and testing. Remove the cabin
heater from vehicle and repair or replace components as required.
Heater does not achieve full load op-
eration.Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Continuous white smoke from heater
exhaust during combustion operation.Check cabin heater operation with DRBIIITscan tool and replace
components as required. White smoke is typical in extreme weather
conditions.
Heater can not be switched off. Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Heater does not operate. Diagnosis cabin heater control module using the DRBIIITscan tool
and the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.
Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an ex-
tremely sweet smell.Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is
an internal heater leak and cabin heater should be inspected and
components should be replaced as required.
Loss of fuel (dripping). Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.
EXHAUST TUBE
REMOVAL
WARNING: There is a potential danger of skin burns
as the supplemental cabin heater unit and its com-
ponents can become very hot. Make sure the heater
unit is allowed to cool down before any service
work on the cabin heater system is attempted. Fail-
ure to observe this warning may result in possible
personal injury.
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 1).
VACABIN HEATER 24 - 105

(3) Remove the clamp at the flexible pipe connec-
tion and the supplemental heater housing (if
required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
INSTALLATION
(1) Install the flexible exhaust pipe to the heater
unit. Tighten mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
exhaust and install and tighten the mounting clamp
securely.
(3) Install the three exhaust pipe screws, adjust
pipe placement as needed and tighten the screws
securely.
(4) Install the clamp to connect the steel exhaust
pipe to the flexible exhaust pipe and tighten clamp
securely.
(5) Check exhaust pipe exhaust end placement and
make any final adjustments.
(6) Lower the vehicle.
FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the supple-
mental cabin heater from the vehicle fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental cabin heater control module. The pump
supplies diesel fuel from the vehicle fuel tank to the
cabin 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 cabin heater unit.
Fig. 1 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 - 106 CABIN HEATERVA

(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.
INSTALLATION
WARNING: Do not operate the diesel supplemental
cabin heater in an enclosed area such as a garage
that does not have exhaust ventilation facilities.
Always vent the cabin heater exhaust when operat-
ing the cabin heater. Allow the diesel supplemental
cabin heater to cool before performing any service
procedures to the cabin heater. Verify that all diesel
supplemental cabin heater fuel lines are securely
fastened to their respective components before per-
forming any service procedures to the cabin heater.
Failure to follow these warnings may result in pos-
sible personal injury or death.
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 cabin 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 supplemental cabin fuel line will prevent
cabin heater activation during the first attempt to
start the cabin heater. This will also set a diagnostic
trouble code (DTC) in the cabin heater control's
memory. Do not perform the Dosing Pump Priming
procedure if an attempt was made to start the cabin
heater without priming the dosing pump first. This
will put excess fuel in the cabin heater and cause
smoke to emit from the cabin heater exhaust pipe
when cabin heater activation occurs.
(5) Connect the DRBIIItscan tool to the diagnos-
tic link connector.
(6) Turn the ignition to the ON position.
NOTE: Do not activate the dosing pump prime more
than one time. This will put excess fuel in the sup-
plemental cabin heater and cause smoke to emit
from the cabin heater exhaust pipe when cabin
heater activation occurs.
NOTE: A clicking noise heard coming from the dos-
ing pump indicates that the pump is operational.
Fig. 3 Cabin Heater Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
VACABIN HEATER 24 - 109

(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
HEATER UNIT
WARNING: Do not operate the diesel supplemental
cabin heater in an enclosed area such as a garage
that does not have exhaust ventilation facilities.
Always vent the cabin heater exhaust when operat-
ing the cabin heater. Allow the diesel supplemental
cabin heater to cool before performing any service
procedures to the cabin heater. Verify that all diesel
supplemental cabin heater fuel lines are securely
fastened to their respective components before per-
forming any service procedures to the cabin heater.
Failure to follow these warnings may result in pos-
sible personal injury or death.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
(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 cabin 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 crossmember at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe-board crossmember and
rail.
(7) Remove the wiring harness from the toe-board
crossmember (Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL - WIRE HARNESS).
(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 flexible section of the cabin
heater exhaust tube from the exhaust tube by loos-
ening the clamp. 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 crossmember.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable support device under the
cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the
crossmembers.
(14) Remove the loosened fasteners that support
the cabin heater while supporting the weight of the
heater.
(15) Swing the cabin heater mounting bracket
from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.
(16) Remove the cabin heater from the vehicle.
WIRE HARNESS
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Disconnect the cabin heater wire harness con-
nector from the vehicle wiring harness.
(3) Disconnect the cabin heater wire harness con-
nector from the dosing pump.
(4) Disconnect the two cabin heater wire harness
connectors from the cabin heater controller.
(5) Remove two wiring harness retainers from the
underbody.
(6) Remove two wiring harness retainers from the
cabin heater shield.
(7) Carefully route the cabin heater wire harness
out the left side between the heater unit and the
heater shield.
INSTALLATION
HEATER UNIT
(1) Install the cabin heater mounting bracket
between the exhaust bracket and the rail mounting
location.
(2) Support the cabin heater and install the fasten-
ers that secure the cabin heater to the mounting
bracket.
(3) Install the three fasteners to the crossmem-
bers. Tighten the M6 fasteners to 7 N´m (62 in. lbs.).
24 - 110 CABIN HEATERVA

(4) Connect the wiring harness connector to the
CCV heater (Fig. 1).
(5) Install the turbocharger heat shield.
(6) Connect the negative battery cable.
CRANKCASE VENTILATION
BREATHER
DESCRIPTION
The crankcase ventilation breather is a three
staged, filtered, oil separating breather with a oil
return passage into the cylinder head cover (Fig. 2).
The oil separator removes oil from the blow by gasses
to reduce MAF sensor contamination. For service
procedures refer to (Refer to 25 - EMISSIONS CON-
TROL/EVAPORATIVE EMISSIONS/CCV
RESTRICTER - REMOVAL).
REMOVAL
(1) Remove the engine cover.
(2) Disconnect the breather outlet hose at the
breather (Fig. 3).
(3) Remove the breather fasteners (Fig. 3).
(4) Wiggle the breather free from the cylinder head
cover (Fig. 3).
Fig. 2 CCV BREATHER
25 - 2 EVAPORATIVE EMISSIONSVA

OPERATION
The mass of the air supplied to the cylinders per
stroke is the decisive factor for determining the opti-
mum quantity of exhaust gas for the operating con-
dition. This is calculated from the Mass Air Flow
sensor information.
The ECM evaluates this signal as well as that
from the Charge Air Pressure sensor, and outputs a
PWM signal in accordance with one of the maps
stored in it. The signal is sent to the exhaust gas
recirculation valve. The map is formulated to keep
the NOx as low as possible. The EGR valve is actu-
ated by an electric positioning motor and has a self
cleaning function. Every time the ignition switch is
turned off, the valve rotates twice to eliminate any
carbon deposits.
REMOVAL
NOTE: The EGR and EGR Cooler are serviced as an
assembly.
(1) Disconnect the negative battery cable.
(2) Partailly drain the cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(3) Lift up on the charge air hose retaining clip at
the intake manifold and disconnect hose with seal
(4) Disconnect the electrical connector at the EGR
positioner (Fig. 3).(5) Disconnect the EGR cooler hose.
(6) Remove the EGR fasteners and EGR with
cooler assembly (Fig. 3).
INSTALLATION
(1) Clean all gasket mating surfaces.
(2) Position the EGR positioner to the intake man-
ifold with a new gasket, install bolts and tighten to
124 lbs.in (14 N´m) (Fig. 3).
(3) Connect the EGR positioner electrical connec-
tor (Fig. 3).
(4) Inspect the seal of the charge air inlet tube,
replace as necessary (Fig. 3).
(5) Seat the charge air tube with gasket into the
intake manifold and push down on the charge air
tube retaining clip.
(6) Refill the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(7) Connect negative battery cable.
VALVE COOLER
DESCRIPTION
The exhaust gas recirculation (EGR) cooler is an
integrated part of the EGR valve. Coolant flows
around the exhaust gasses, cooling them before they
are remixed with the incoming air and reburned in
the combustion chamber (Fig. 4).
Fig. 2 EXHAUST GAS RECIRCULATION
1 - E G R VA LV E
2 -CHARGE AIR PRESSURE SENSOR
3 - EXHAUST MANIFOLD
4 - EGR DUCT IN CYLINDER HEAD
5 - INTAKE MANIFOLD
Fig. 3 EGR VALVE
1 - E G R VA LV E
2 - INTAKE MANIFOLD
3 - EGR COOLER HOSE
4 - HARNESS CONNECTOR
25 - 6 EXHAUST GAS RECIRCULATIONVA

The EGR valve and Cooler are serviced as an
assembly, refer to (Refer to 25 - EMISSIONS CON-
TROL/EXHAUST GAS RECIRCULATION/VALVE -
REMOVAL).
Fig. 4 EGR AND COOLER
1 - E G R VA LV E
2 - EGR COOLER
3 - INTAKE MANIFOLD
VAEXHAUST GAS RECIRCULATION 25 - 7

INDEX
ABS INDICATOR.......................8J-9ACCELERATOR PEDAL POSITION SENSOR. . . 14-32
ACCESSORY SWITCH BEZEL............23-56
ADR INDICATOR.....................8J-10
AIR CLEANER ELEMENT................9-21
AIR CLEANER HOUSING................9-21
AIR FILTER ....................24-45, 24-58
AIR OUTLET TEMPERATURE SENSOR....24-16
AIR OUTLETS.......................24-45
AIRBAG CONTROL MODULE.............8O-8
AIRBAG INDICATOR...................8J-11
ALB CONTROLLER....................5-16
ALB LEVER..........................5-16
AMBIENT TEMPERATURE INDICATOR.....8J-11
AMBIENT TEMPERATURE SENSOR.......24-17
ANTENNA BODY & CABLE..............8A-1
ARMREST..........................23-79
ASH RECEIVER......................23-57
ASH RECEIVER / CIGAR LIGHTER LAMP
UNIT..............................8L-30
ASSIST HANDLE.....................23-71
AUDIO..............................8A-1
AUTOMATIC TRANSMISSION NAG1 -
SERVICE INFORMATION................21-3
A - PILLAR TRIM.....................23-70
A / C CLUTCH RELAY.................24-24
A / C COMPRESSOR CLUTCH COIL.......24-12
A / C COMPRESSOR CLUTCH............24-8
A / C COMPRESSOR..................24-66
A / C CONDENSER COVER.............24-52
A / C CONDENSER FAN RELAY..........24-26
A / C CONDENSER HOUSING...........24-52
A / C CONDENSER....................24-69
A / C CONTROL MODULE..............24-28
A / C DISCHARGE LINE................24-71
A / C EVAPORATOR COVER.............24-55
A / C EVAPORATOR HOUSING...........24-55
A / C EVAPORATOR...................24-72
A / C EXPANSION VALVE...............24-73
A / C HEATER CONTROL...............24-12
A / C HIGH PRESSURE SWITCH.........24-30
A / C LOW PRESSURE SWITCH.........24-32
A / C PRESSURE TRANSDUCER.........24-14
BACKLITE - BULKHEAD TRIM PANEL.....23-84
BACKUP LAMP BULB..................8L-5
BASECOAT / CLEARCOAT FINISH........23-77
BATTERY CABLES....................8F-14
BATTERY HOLDDOWN.................8F-13
BATTERY SYSTEM.....................8F-1
BATTERY TRAY......................8F-16
BATTERY............................8F-6
BEARINGS - DIFFERENTIAL CASE.........3-38
BEARING / SEAL - AXLE HUB............3-28
BEARING / SEAL - AXLE................3-24
BELT TENSIONERS.....................7-5
BLOWER MOTOR RELAY...............24-33
BLOWER MOTOR RESISTOR............24-17
BLOWER MOTOR SWITCH........24-19, 24-35
BLOWER MOTOR...............24-47, 24-58
BODY...............................23-1
BOOST PRESSURE SENSOR............14-33
BRAKE INDICATOR...................8J-12
BRAKE LAMP SWITCH.................8L-6
BRAKE LINES.........................5-8
BRAKE PADS / SHOES...................5-8
BRAKE WEAR INDICATOR..............8J-13
BRAKES - ABS........................5-30
BRAKES - BASE........................5-2
BRAKE / PARK LAMP BULB.............8L-7
BULKHEAD TRIM PANEL...............23-72
BUMPERS...........................13-1
BUSHINGS............................2-3
B - PILLAR TRIM.....................23-71
CABIN HEATER.....................24-104
CABLE TENSIONER....................5-24
CABLE..............................8P-2
CABLES.............................5-24
CAMSHAFT POSITION SENSOR..........14-33
CAMSHAFT(S)........................9-28
CARGO LAMP SWITCH................8L-31
CARGO / DOME LAMP BULB............8L-30
CARGO / DOME LAMP UNIT............8L-31
CARPETS AND FLOOR MATS...........23-72
CATALYTIC CONVERTER
................11-3
CENTER BEARING
......................3-9
CENTER HIGH MOUNTED STOP LAMP BULB. . . 8L-8CENTER HIGH MOUNTED STOP LAMP UN.....8L-8
CENTER ROLLER ARM
................23-36CENTER TRACK......................23-37
CENTRAL TIMER MODULE..............8E-1
CHARGE AIR COOLER AND PLUMBING....11-4
CHARGING INDICATOR................8J-14
CHARGING SYSTEM..................8F-17
CHECK VALVE.......................8R-11
CHECK.......................23-13, 23-23
CHIME / BUZZER......................8B-1
CIGAR LIGHTER OUTLET............8W-97-1
CIRCUIT BREAKER.................8W-97-2
CLEARANCE LAMP BULB...............8L-9
CLEARANCE LAMP UNIT................8L-9
CLOCK.............................8J-14
CLOCKSPRING......................8O-12
CLUSTER BEZEL.....................23-55
COLUMN............................19-4
CONNECTOR.......................Intro.-9
CONNECTOR/GROUND/SPLICE
LOCATION........................8W-91-1
CONTROLLER ANTILOCK BRAKE.........8E-3
COOLANT LEVEL SENSOR...............7-13
COOLANT LOW INDICATOR.............8J-15
COOLANT............................7-9
COOLING.............................7-1
COWL TRIM........................23-73
CRANKCASE VENTILATION BREATHER......25-2
CRANKCASE VENTILATION HEATER.......25-1
CRANKSHAFT OIL SEAL - FRONT.........9-42
CRANKSHAFT OIL SEAL - REAR..........9-41
CRANKSHAFT POSITION SENSOR........14-35
CRANKSHAFT........................9-39
CUP HOLDER........................23-57
CYLINDER HEAD COVER(S).............9-33
CYLINDER HEAD......................9-22
DAYTIME RUNNING LAMP RELAY.......8L-10
DEFROSTER DUCTS..................24-47
DIFFERENTIAL........................3-31
DIODE............................Intro.-9
DISC BRAKE CALIPER ADAPTER.........5-14
DISC BRAKE CALIPERS.................5-11
DOME LAMP / INTRUSION SENSOR
BULB..............................8L-33
DOME LAMP / INTRUSION SENSOR......8L-33
DOME / READING LAMP BULB..........8L-32
DOME / READING LAMP UNIT..........8L-32
DOOR GLASS............23-15, 23-30, 23-46
DOOR JAMB SWITCH.................8L-34
DOOR LOCK MOTOR...................8N-1
DOOR OPENING SEALS................23-90
DOOR........................23-14, 23-23
DRIVE BELTS..........................7-5
DRIVER AIRBAG.....................8O-16
DRIVER HEATED SEAT SWITCH.........8G-11
D - PILLAR TRIM.....................23-73
ELECTRIC COOLANT PUMP.............24-75
ELECTRICAL.........................5-30
ELECTROHYDRAULIC UNIT............21-105
ENGINE BLOCK HEATER................7-14
ENGINE BLOCK.......................9-37
ENGINE CONTROL MODULE.............8E-3
ENGINE COOLANT TEMP SENSOR........7-15
ENGINE COOLANT THERMOSTAT.........7-16
ENGINE CRADLE CROSSMEMBER........13-8
ENGINE TEMPERATURE GAUGE.........8J-15
ENGINE..............................9-2
ENTRY / EXIT LAMP BULB.............8L-34
ENTRY / EXIT LAMP UNIT..............8L-35
ESP INDICATOR......................8J-16
EVAPORATOR TEMPERATURE
SENSOR......................24-19, 24-37
EXHAUST GAS RECIRCULATION..........25-4
EXHAUST MANIFOLD..................9-68
EXHAUST PIPE.......................11-3
EXHAUST SYSTEM....................11-1
EXHAUST TUBE.....................24-105
EXTERIOR HANDLE.......23-16, 23-31, 23-35
FAN DRIVE VISCOUS CLUTCH...........7-17
FASTENER IDENTIFICATION...........Intro.-3
FASTENER USAGE...................Intro.-6
FINESSE SANDING / BUFFING & POLISH . . 23-78
FLOOR DISTRIBUTION DUCTS..........24-47
FLUID AND FILTER..................21-131
FLUID CAPACITIES.....................0-5
FLUID COOLER TUBE
.................19-13
FLUID FILL / CHECK LOCATIONS
..........0-5
FLUID RESERVOIR
....................5-15
FLUID TYPES
..........................0-1
FLYWHEEL
...........................9-43FOG LAMP BULB.....................8L-10
FOG LAMP RELAY....................8L-11
FOG LAMP SWITCH...................8L-12
FRAME..............................13-3
FREEWHEELING CLUTCH.............21-135
FRONT BUMPER - STEPS...............13-2
FRONT DOOR INNER BELT
WEATHERSTRIP.....................23-90
FRONT DOOR OUTER BELT
WEATHERSTRIP.....................23-90
FRONT FASCIA.......................13-2
FRONT LAMP UNIT...................8L-13
FRONT POSITION LAMP BULB..........8L-14
FRONT SEAT BELT & RETRACTOR.......8O-20
FRONT SEAT BELT BUCKLE............8O-23
FRONT TURN / PARK / SIDE MARKER
LAMP BULB.........................8L-15
FRONT WHEEL SPEED SENSOR..........5-31
FRONT...............................2-1
FUEL DELIVERY.......................14-6
FUEL DOSING PUMP.................24-106
FUEL DRAIN TUBES..................14-10
FUEL FILL DOOR.....................23-48
FUEL FILTER CLOGGED INDICATOR......8J-17
FUEL FILTER........................14-10
FUEL GAUGE........................8J-17
FUEL INJECTOR.......................14-35
FUEL LEVEL SENDING UNIT / SENSOR....14-28
FUEL LINE.........................24-107
FUEL LINES.........................14-11
FUEL PRESSURE SENSOR.............14-39
FUEL PRESSURE SOLENOID............14-40
FUEL PUMP MODULE.................14-18
FUEL PUMP.........................14-13
FUEL QUANTITY CONTROL VALVE.......14-21
FUEL RAIL PRESSURE SENSOR.........14-12
FUEL RAIL..........................14-22
FUEL SYSTEM........................14-1
FUEL TANK.........................14-23
FUEL TEMPERATURE SENSOR..........14-42
FUSE BLOCK #1...................8W-97-2
FUSE BLOCK #2...................8W-97-3
GAP AND FLUSH.....................23-91
GEAR SELECTOR INDICATOR...........8J-18
GEAR...............................19-7
GEARSHIFT CABLE..................21-138
GEAR - PINION / RING.................3-41
GENERATOR DECOUPLER PULLEY.......8F-19
GENERATOR........................8F-18
GLOVE BOX.........................23-58
GLOW PLUG RELAY....................8I-1
GLOW PLUG..........................8I-1
GRILLE............................23-48
HCU (HYDRAULIC CONTROL UNIT).......5-36
HEADLAMP LEVELING MOTOR..........8L-16
HEADLAMP LEVELING SWITCH.........8L-17
HEADLINER.........................23-73
HEADREST..........................23-79
HEATED GLASS.......................8G-1
HEATED MIRRORS....................8G-9
HEATED SEAT ELEMENT...............8G-12
HEATED SEAT RELAY.................8G-12
HEATED SEAT SENSOR................8G-13
HEATED SEATS ......................8G-10
HEATER CORE.......................24-76
HEATER UNIT......................24-110
HEATING & AIR CONDITIONING..........24-1
HIGH BEAM HEADLAMP BULB..........8L-18
HIGH BEAM INDICATOR...............8J-19
HINGE..................23-17, 23-32, 23-51
HOISTING............................0-5
HOLDING CLUTCH B1................21-143
HOLDING CLUTCH B2................21-148
HOLDING CLUTCHES.................21-141
HOOD.............................23-51
HORN SWITCH.......................8H-1
HORN..............................8H-1
HOSES.............................19-14
HUB / BEARING........................2-4
HVAC HOUSING......................24-48
HYDRAULIC / MECHANICAL..............5-5
IGNITION CONTROL....................8I-1
INLET HOSE........................24-111
INPUT CLUTCH K1
...................21-92
INPUT CLUTCH K2
...................21-97
INPUT CLUTCH K3
..................21-102
INPUT CLUTCHES
....................21-90
INPUT SPEED SENSORS
..............21-153
VAINDEX 1
Description Group-Page Description Group-Page Description Group-Page

SERVICE MANUAL COMMENTS
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