width MERCEDES-BENZ SPRINTER 2006 Service Manual

3.2.2 CAN BUS
The CAN bus (controller area network) is a data
bus system specifically design for inter module
communication on this vehicle. The CAN bus con-
sists of a special twisted two-core cable. Control
modules are connected to this9twisted pair9. The
CAN bus incorporates two terminating resistors.
One terminator is built into the Engine Control
Module (ECM) and the other is built into the Sentry
Key Remote Entry Module (SKREEM). Each resis-
tor has a value of 120 ohms. The resistor condition
can be confirmed by disconnecting the control mod-
ule and measuring the resistance value at the
appropriate control module pins. This measure-
ment should read 120 ohms. The two CAN circuits,
CAN C Bus (+) and CAN C Bus (-), are bridged by
these two terminating resistors when all control
modules are connected to the bus. These two resis-
tors are connected to the CAN bus network in
parallel. The measurement between the two
twisted CAN circuits, with both the ECM and
SKREEM connected, should measure a value of 60
ohms.
The CAN bus is bi-directional. This means that
each connected control module can send and receive
information. Transmission of data takes place re-
dundantly via both circuits. The data bus levels are
mirrored, meaning that if the binary level on one
circuit is 0, the other circuit transmits binary level
1 and vice versa. The two line concept is used for
two reasons: for fault identification and as a safety
concept.
If a voltage peak occurs on just one circuit, the
receivers can identify this as a fault and ignore the
voltage peak. If a short circuit or interruption
occurs on one of the two CAN circuits, a software-
hardware linked safety concept allows switching to
a single-line operation. The defective CAN circuit is
shut down. A specific data protocol controls how and
when the participants can send and receive.
NOTE: It is important to note the CAN Bus
circuits are used for inter-module
communication only, and is no way
connected to the K-Lines.
The following modules that use the CAN Bus on
this vehicle are:
²Automatic Temperature Control (ATC)
²Controller Antilock Brake (CAB)
²Engine Control Module (ECM)
²Instrument Cluster (IC)
²Sentry Key Remote Entry Module (SKREEM)
²Shifter Assembly (SA)
²Transmission Control Module (TCM)
3.3 HEATING & A/C SYSTEM
3.3.1 AUTOMATIC TEMPERATURE
CONTROL (ATC)
3.3.1.1 SYSTEM CONTROLS
The ATC Module:
²is fully addressable with the DRBIIIt.
IThe DRBIIItcommunicates with the ATC
Module through the Diagnostic Link Connector
(DLC) via a K-Line.
²communicates with other modules over the Con-
troller Area Network (CAN) C Bus.
²controls A/C clutch operation.
²controls EBL operation.
²controls water cycle valve operation.
IThe water cycle valve is a normally open valve,
meaning that it allows full engine coolant flow
through the heater core when no power is
delivered to the valve. The ATC controls the
valve with a pulse width signal. The lower the
percentage of the pulse width signal the more
the valve is open.
²controls Residual Heat Utilization (REST) func-
tion.
²controls blower motor operation, providing four
blower speeds (Low, M1, M2, & High).
²controls recirculation air solenoid valve.
²controls the mode door via cables.
²controls the main power supply to the Heater
Booster (if equipped).
²uses air inlet temperature sensor, air outlet tem-
perature sensor, and evaporator temperature
sensor input, as well as data from other modules
to maintain occupant comfort levels.
3.3.1.2 SYSTEM DIAGNOSTICS
Fault detection is through active and stored Diag-
nostic Trouble Codes (DTCs)
²DTCs are displayed by the DRBIIIt.
²Active DTCs are those which currently exist in
the system. The condition causing the fault must
be repaired in order to clear this type of DTC.
²Stored DTCs are those which occurred in the
system since the ATC Module received the last
9clear diagnostic info9message.
Testing Preparation & Diagnostics
Set the necessary system functions accordingly so
that all of the following prerequisites are met prior
to performing diagnostic tests on the ATC system:
5
GENERAL INFORMATION

1. Connect the DRBIIItto the DLC.
2. Place the shift lever in park.
3. Start the engine.
4. Set the blower to high speed.
5. Set the temperature selector to full cold.
6. Press air conditioning switch on.
7. With the DRBIIItin Sensors, verify that the:
A. ambient temperature is above 59F (15C).
B. refrigerant pressure is between 29 and 348
PSI (2 and 24 bar).
C. evaporator temperature is above 36.5F
(2.5C).
D. coolant temperature is above 158F (70C).
When all of the prerequisites have been met, use
the DRBIIItto record and erase all stored ATC
DTCs, and then select System Tests, and run the
ATC Function Test. When complete, check to see if
any active DTCs are present. If so, refer to the
symptom list in the Heating & A/C category for the
diagnostic procedure(s). If there are no DTCs
present, yet the performance seems less than ideal,
use the DRBIIItto look at all sensor values and the
status of the various inputs and outputs to see if
there is a deficiency detected that has not fully shut
down the system. For additional information, refer
to Sensor Values and Input/Output Status under
Diagnostic Tips in this section and to Section 11.0
for evaporator temperature sensor and air outlet
temperature sensor resistance to temperature spec-
ifications charts. Also, confirm that the water cycle
valve is functioning. Remember that the valve is
normally open. The pulse width signal will offer
insight into the valve's operation. The lower the
percentage number, the more open the valve be-
comes. Confirm that the valve is responding to the
signal from the ATC. If functioning correctly, verify
mode and blend door operation. If okay, the diagno-
sis then becomes purely refrigerant system related.
Attach the appropriate gauges and diagnose the
refrigeration system. Refer to the Service Informa-
tion for refrigerant system diagnostic procedures.
DIAGNOSTIC TIPS
SENSOR VALUES
Ambient Air Temperature
The Instrument Cluster transmits Ambient Air
Temperature Sensor data. In the event of a CAN
Bus communication failure, the last stored value is
displayed as a substitute value.
Interior Temperature
The normal range for the Interior Temperature
Sensor is from 32ÉF to 104ÉF. An implausible tem-
perature value indicates that the Interior Temper-
ature Sensor is bad. The repair in this case would be
to replace the ATC Module since the sensor is
integral to the module.Evaporator Temperature
The normal range for the Evaporator Temperature
Sensor is from 14ÉF to 104ÉF. A substitute value of
14ÉF with no updates indicates an Evaporator Tem-
perature Sensor circuit failure.
Air Outlet Temperature
The normal range for the Air Outlet Temperature
Sensor is from 32ÉF to 203ÉF. A substitute value of
111.1ÉF indicates an Air Outlet Temperature Sensor
circuit failure.
Coolant Temperature
The Engine Control Module transmits Coolant
Temperature Sensor date. In the event of a CAN
Bus communication failure, 257ÉF is displayed as a
substitute value.
Interior Temperature Controller
The normal range for the Blend control is from 62ÉF
to 144ÉF. This value represents the temperature set
by the operator. An implausible temperature value
or a temperature value that fails to change when
rotating the Blend control indicates that the Blend
control is bad. The repair in this case would be to
replace the ATC Module since the Blend control
integral to the module.
Refrigerant Pressure
The normal range for the Refrigerant Pressure
Sensor is from 29 PSI to 406 PSI. A substitute value
of 413 PSI indicates a Refrigerant Pressure Sensor
circuit failure. In addition, the normal range for
Pressure Sensor voltage is 0 volts to 5 volts. A value
of 0.9 volts indicates an open voltage supply circuit,
while a value of -999 indicates an open in all three
sensor circuits.
Water Cycle Valve
The normal range of the Water Cycle Valve is from
0% to 100%. The value indicates the extent to which
the valve is closed. A value of 100% indicates that
the valve is fully closed.
Intense Inst Light
The Instrument Cluster transmits this data. The
normal range for lighting intensity is from 0% to
100%. The value indicates the extent to which the
illumination has dimmed. A value of 0% indicates
bright while a value >0% indicates dimming. In the
event of a CAN Bus communication failure, 0% is
displayed as a substitute value.
INPUT/OUTPUT STATUS
Compressor Clutch
The ATC Module transmits this data. A status of
9ON9indicates that the compressor is operational. A
status of9OFF9indicates the compressor is not
operational.
6
GENERAL INFORMATION

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS
DESCRIPTION..........................5
OPERATION............................5
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT..........................5REMOVAL
REMOVAL............................8
REMOVAL............................8
INSTALLATION
INSTALLATION........................8
INSTALLATION........................8
BELT TENSIONERS
DESCRIPTION
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner. This ten-
sioner maintains constant belt tension at all times
and requires no maintenance or adjustment. (Fig. 1)
OPERATION
WARNING: The automatic belt tensioner assembly
is spring loaded. do not attempt to disassemble the
tensioner assembly.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensionerarm pressing the arm into the belt, tensioning the
belt.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing
mark. Belt is considered new if it has been used 15
minutes or less. If this specification cannot be met,
check for:
²The wrong belt being installed (incorrect length/
width)
²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory
²Belt incorrectly routed.
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 2), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 2). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
Fig. 1 Accessory Drive Belt
1 - WATER PUMP
2 - ACCESSORY DRIVE BELT
3 - AUTOMATIC BELT TENSIONER
4 - 3/89SQUARE BOLT
5 - MOUNT. BOLT
VAACCESSORY DRIVE 7 - 5

Located between the rear cover and the cluster
hood is the cluster housing. The molded plastic clus-
ter housing serves as the carrier for the cluster elec-
tronic circuit board and circuitry, the cluster
connector receptacles, the gauges, a Light Emitting
Diode (LED) for each cluster indicator and general
illumination lamp, the multi-function indicator LCD
unit, electronic tone generators, the cluster overlay,
the gauge pointers, the multi-function indicator
switches and the four switch push buttons.
The cluster overlay is a laminated plastic unit. The
dark, visible, outer surface of the overlay is marked
with all of the gauge dial faces and graduations, but
this layer is also translucent. The darkness of this
outer layer prevents the cluster from appearing clut-
tered or busy by concealing the cluster indicators
that are not illuminated, while the translucence of
this layer allows those indicators and icons that are
illuminated to be readily visible. The underlying
layer of the overlay is opaque and allows light from
the LED for each of the various indicators and illu-
mination lamps behind it to be visible through the
outer layer of the overlay only through predeter-
mined cutouts. A rectangular opening in the overlay
at the base of the speedometer provides a window
through which the illuminated multi-function indica-
tor LCD unit can be viewed.
Several versions of the EMIC module are offered
on this model. These versions accommodate all of the
variations of optional equipment and regulatory
requirements for the various markets in which the
vehicle will be offered. The microprocessor-based
EMIC utilizes integrated circuitry, Electrically Eras-
able Programmable Read Only Memory (EEPROM)
type memory storage, information carried on the
Controller Area Network (CAN) data bus, along with
several hard wired analog and multiplexed inputs to
monitor systems, sensors and switches throughout
the vehicle.
In response to those inputs, the hardware and soft-
ware of the EMIC allow it to control and integrate
many electronic functions and features of the vehicle
through both hard wired outputs and the transmis-
sion of electronic message outputs to other electronic
modules in the vehicle over the CAN data bus. (Refer
to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/COMMUNICATION - DESCRIPTION -
CAN BUS).
Besides typical instrument cluster gauge and indi-
cator support, the electronic functions and features
that the EMIC supports or controls include the fol-
lowing:
²Active Service System- In vehicles equipped
with the Active Service SYSTem (ASSYST) engine oil
maintenance indicator option, the EMIC electronic
circuit board includes a second dedicated micropro-
cessor. This second microprocessor evaluates various
data including time, mileage, and driving conditionsto calculate the required engine oil service intervals,
and provides both visual and audible alerts to the
vehicle operator when certain engine oil maintenance
services are required.
²Audible Warnings- The EMIC electronic cir-
cuit board is equipped with an audible tone generator
and programming that allows it to provide various
audible alerts to the vehicle operator, including buzz-
ing and chime tones. An audible contactless elec-
tronic relay is also soldered onto the circuit board to
produce audible clicks that is synchronized with turn
signal indicator flashing to emulate the sounds of a
conventional turn signal or hazard warning flasher.
These audible clicks can occur at one of two rates to
emulate both normal and bulb-out turn or hazard
flasher operation. (Refer to 8 - ELECTRICAL/
CHIME/BUZZER - DESCRIPTION).
²Panel Lamps Dimming Control- The EMIC
provides a hard wired 12-volt Pulse-Width Modulated
(PWM) output that synchronizes the dimming level
of all panel lamps dimmer controlled lamps with that
of the cluster general illumination lamps and multi-
function indicator.
The EMIC houses four analog gauges and has pro-
visions for up to nineteen indicators (Fig. 3). The
EMIC includes the following analog gauges:
²Coolant Temperature Gauge
²Fuel Gauge
²Speedometer
²Tachometer
The EMIC includes provisions for the following
indicators (Fig. 3):
²Airbag (SRS) Indicator
²Antilock Brake System (ABS) Indicator
²Brake Indicator
²Brake Wear Indicator
²Charging Indicator
²Clogged Fuel Filter Indicator
²Constant Engine Speed (ADR) Indicator
²Coolant Low Indicator
²Electronic Stability Program (ESP) Indica-
tor
²High Beam Indicator
²Low Fuel Indicator
²Malfunction Indicator Lamp (MIL)
²Multi-Function Indicator (LCD)
²Park Brake Indicator
²Seatbelt Indicator
²Traction Control (ASR) Indicator
²Traction Control (ASR) Malfunction Indica-
tor
²Turn Signal (Right and Left) Indicators
²Washer Fluid Indicator
²Wait-To-Start Indicator
²Water-In-Fuel Indicator
VAINSTRUMENT CLUSTER 8J - 3

INDICATORS
Indicators are located in various positions within
the EMIC and are all connected to the EMIC elec-
tronic circuit board. The ambient temperature indica-
tor (optional), brake indicator, brake wear indicator,
charging indicator, coolant low indicator, high beam
indicator, low fuel indicator, park brake indicator,
seatbelt indicator, turn signal indicators, and washer
fluid indicator operate based upon hard wired inputs
to the EMIC. The airbag (SRS) indicator is normally
controlled by a hard wired input from the Airbag
Control Module (ACM); however, if the EMIC sees an
abnormal or no input from the ACM, it will automat-
ically turn the airbag indicator On until the hard
wired input from the ACM has been restored. The
Malfunction Indicator Lamp (MIL) is normally con-
trolled by CAN data bus messages from the Engine
Control Module (ECM); however, if the EMIC loses
CAN data bus communication, the EMIC circuitry
will automatically turn the MIL on until CAN data
bus communication is restored. The EMIC uses CAN
data bus messages from the ECM, the ACM, and the
Controller Antilock Brake to control all of the
remaining indicators.
The various EMIC indicators are controlled by dif-
ferent strategies; some receive battery feed from the
EMIC circuitry and have a switched ground, while
others are grounded through the EMIC circuitry and
have a switched battery feed. However, all indicators
are completely controlled by the EMIC microproces-
sor based upon various hard wired and electronic
message inputs. Except for the indications provided
by the multi-function indicator Liquid Crystal Dis-
play (LCD) unit, all indicators are illuminated at a
fixed intensity, which is not affected by the selected
illumination intensity of the EMIC general illumina-
tion lamps.
The hard wired indicator inputs may be diagnosed
using conventional diagnostic methods. However,
proper testing of the EMIC circuitry and the CAN
bus message controlled indicators requires the use of
a diagnostic scan tool. Refer to the appropriate diag-
nostic information. Specific details of the operation
for each indicator may be found elsewhere in this
service information.
CLUSTER ILLUMINATION
The EMIC has several general illumination lamps
that are illuminated when the exterior lighting is
turned on with the multi-function switch. The illumi-
nation intensity of these lamps is adjusted by a dim-
ming level input received from the multi-function
indicator ª+º (plus) and ª±º (minus) switch push but-
tons that extend through the lower edge of the clus-
ter lens below the right end of the multi-function
indicator. When the exterior lighting is turned Off,
the display is illuminated at maximum brightness.
When the exterior lighting is turned On and thetransmission gear selector is in the Park position,
depressing the plus switch push button brightens the
display lighting, and depressing the minus switch
push button dims the display lighting. The EMIC
also provides a Pulse-Width Modulated (PWM) panel
lamps dimmer output that can be used to synchro-
nize the illumination lighting levels of external illu-
mination lamps (up to about 23 to 30 watts) with
that of the EMIC.
The hard wired multi-function switch input and
the EMIC panel lamps dimmer output may be diag-
nosed using conventional diagnostic methods. How-
ever, proper testing of the PWM control of the EMIC
and the electronic dimming level inputs from the
multi-function indicator push buttons requires the
use of a diagnostic scan tool. Refer to the appropriate
diagnostic information.
INPUT AND OUTPUT CIRCUITS
HARD WIRED INPUTS
The hard wired inputs to the EMIC include the fol-
lowing:
NOTE: Final approved circuit names were not yet
available at the time this information was compiled.
²Airbag Indicator Driver
²Ambient Temperature Sensor Signal
(Optional)
²Brake Wear Indicator Sense
²Charging Indicator Driver
²Coolant Level Switch Sense
²Front Door Jamb Switch Sense
²Fuel Level Sensor Signal
²Fused B(+)
²Fused Ignition Switch Output
²High Beam Indicator Driver
²Key-In Ignition Switch Sense
²Left Turn Signal
²Park Brake Switch Sense
²Right Turn Signal
²Seat Belt Switch Sense
²Washer Fluid Switch Sense (Optional)
Refer to the appropriate wiring information for
additional details.
HARD WIRED OUTPUTS
The hard wired outputs of the EMIC include the
following:
²Engine Running Relay Control
²Panel Lamps Driver
Refer to the appropriate wiring information for
additional details.
8J - 6 INSTRUMENT CLUSTERVA

STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS
NOTE: Connecting rods with blue discoloration,
cross scores or notches must be replaced. Com-
pensate for different weights by milling off the bal-
ancing weight.
(1) Inspect connecting rod for discoloring, cross
scores and notches.
NOTE: Connecting rod and bearing cap are marked
in sets and attached with two sleeves.
(2) Bolt connecting rod bearing cap to connecting
rod. Tighten connecting rod bearing caps to initialspecification (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON & CONNECTING ROD - INSTALLATION).
(3) Using a dial indicator, measure connecting rod
bearing basic bore, repair as necessary (Fig. 38).
NOTE: If excessive wear is present, press in new
connecting rod bushings.
(4) Measure connecting rod bushing inner diame-
ter (Fig. 38).
(5) Inspect wristpin bushing.
(6) Measure piston pin end play in connecting rod
bushing.
(7) Measure peak to valley height of connecting
rod bushing on inside.CONNECTING ROD SPECIFICATIONS
Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Width of connecting rod
bearing bore at connect-
ing rod bushing bore21.940 mm to 22 mm
Connecting rod bearing
shell basic bore51.600 mm to 51.614
mm
Fig. 37 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 38 MEASURING CONNECTING RODS
9 - 46 ENGINEVA

FUEL QUANTITY CONTROL
VA LV E
DESCRIPTION
The fuel quantity control valve mounts to front of
the high pressure pump and is controlled by the
ECM. The quantity control valve assists in maintain-
ing proper fuel quantity injected under all operating
conditions. Fuel tank heat protection is also provided
by the quantity control valve. The valve meters the
exact amount of fuel to prevent excess heated fuel
from returning to the tank.
OPERATION
The ECM monitors the fuel system and measures
for pressure vibrations. The ECM will then send a
pulse width signal to the quantity control valve to
regulate the amount of fuel to the high pressure
pump plunger and barrel assemblies. The valve then
adjusts the injection correction quantity for each
individual cylinder in line with the firing order, there
by eliminating the pressure resonance in the fuel rail
and improving each independent injectors operation.
The fuel quantity valve also interrupts the fuel sup-
ply to the high pressure pump plunger and barrel
assemblies when the engine is switched off.
The ECM detects the operating state which exists
at the engine by means of the sensors. In order to
adapt the quantity injected, either the rail pressure
can be adjusted by way of the pressure regulator
valve and the quantity control valve, or the actuationtime of the solenoid valves in the fuel injectors can
be extended or shortened.
Fuel quantity control is performed under the fol-
lowing operating conditions:
²Approximately 30 seconds after the engine has
started
²Fuel temperature > 20ÉC (68ÉF)
²Engine not in deceleration mode
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the control valve wiring harness
connector (Fig. 18).
(3) Remove the valve fasteners and remove the
control valve (Fig. 18).
INSTALLATION
(1) Clean sealing surfaces.
(2) Install new seal on sensor.
(3) Position the control valve on to the high pres-
sure pump and install fasteners (Fig. 19).
(4) Connect wiring harness connector to control
valve (Fig. 19).
(5) Connect negative battery cable.
(6) Start the engine, allow to run, turn engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION - WARNING).
Fig. 17 ALIGN PUMP MODULE
1 - LOCKNUT
2 - ALIGNMENT ARROW (POSITION TOWARDS RIGHT SIDE OF
VEHICLE)
Fig. 18 HIGH PRESSURE FUEL PUMP
1 - HIGH PRESSURE PUMP
2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
8 - VACUUM PUMP
VAFUEL DELIVERY 14 - 21

directly, which means that the solenoids must have
very high outputs to close the valves against the siz-
able flow areas and line pressures found in current
transmissions. Fast response time is also necessary
to ensure accurate control of the transmission.
The strength of the magnetic field is the primary
force that determines the speed of operation in a par-
ticular solenoid design. A stronger magnetic field will
cause the plunger to move at a greater speed than a
weaker one. There are basically two ways to increase
the force of the magnetic field:
1. Increase the amount of current applied to the
coil or
2. Increase the number of turns of wire in the coil.
The most common practice is to increase the num-
ber of turns by using thin wire that can completely
fill the available space within the solenoid housing.
The strength of the spring and the length of the
plunger also contribute to the response speed possi-
ble by a particular solenoid design.
A solenoid can also be described by the method by
which it is controlled. Some of the possibilities
include variable force, pulse-width modulated, con-
stant ON, or duty cycle. The variable force and pulse-
width modulated versions utilize similar methods to
control the current flow through the solenoid to posi-
tion the solenoid plunger at a desired position some-
where between full ON and full OFF. The constant
ON and duty cycled versions control the voltage
across the solenoid to allow either full flow or no flow
through the solenoid's valve.UPSHIFT / DOWNSHIFT SOLENOID VALVES
The solenoid valves (1) for upshifts and downshifts
(Fig. 229) are located in the shell of the electric con-
trol unit and pressed against the shift plate with a
spring.
The solenoid valves (1) initiate the upshift and
downshift procedures in the shift plate.
The solenoid valves (1) are sealed off from the
valve housing of the shift plate (5) by two O-rings (4,
6). The contact springs (8) at the solenoid valve
engage in a slot in the conductor tracks (7). The force
of the contact spring (8) ensures safe contacts.
Fig. 229 Upshift/Downshift Solenoid Valves
1 - UPSHIFT/DOWNSHIFT SOLENOID VALVE
2 - CONTACT SPRING
3 - CONDUCTOR TRACK
4 - O-RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - O-RING
7 - CONDUCTOR TRACK
8 - CONTACT SPRING
21 - 172 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

WHEELS
DESCRIPTION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or aluminum wheels.
Aluminum wheels require special balance weights
and alignment equipment.
(1) On vehicles equipped with dual rear wheels,
The slots in the wheel must be aligned to provide
access to the valve stem.
OPERATION
The wheel (Fig. 19) has raised sections between
the rim flanges and the rim well. Initial inflation of
the tire forces the bead over these raised sections. In
case of tire failure, the raised sections hold the tire
in position on the wheel until the vehicle can be
brought to a safe stop.
DIAGNOSIS AND TESTING
WHEEL INSPECTION
Inspect wheels for:
²Excessive run out
²Dents or cracks
²Damaged wheel lug nut holes
²Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL REPLACE-
MENT
The wheel stud/lugs are designed for specific appli-
cations. They must be replaced with equivalent parts.
Do not use replacement parts of lesser quality or a
substitute design.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in
sequence to the proper torque specification.Never
use oil or grease on studs.
Wheels must be replaced if they have:
²Excessive runout
²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width
²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle.
Replacement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
STANDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
Fig. 19 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
VATIRES/WHEELS 22 - 13

(5) If desired, a thin film coat of adhesive can be
applied to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)
away from edge of patch across from holes drilled
around cutout.
(7) Drill 3 mm (0.125 in.) holes in the support
squares 13 mm (0.5 in.) from the edge in the center
of one side.
(8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(9) Mix enough adhesive to cover one side of all
support squares.
(10) Apply adhesive to cover one side of all support
squares.
(11) Using number 8 sheet metal screws, secure
support squares to back side of body panel with
adhesive sandwiched between the panel and squares
(Fig. 9).(12) Position patch in cutout against support
squares and adjust patch until the gap is equal along
all sides (Fig. 10).
(13) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
(14) Apply a coat of adhesive to the exposed ends
of the support squares (Fig. 11).
(15) Install screws to hold the patch to support
squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.
(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.
(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 14).
(19) Mix enough adhesive to cover the entire patch
area.
(20) Apply adhesive over the mesh around patch,
and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 9 SECURE SUPPORT SQUARES TO BODY
PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
23 - 8 BODYVA