DaimlerChrysler SPRINTER2006 Service Manual Download Page 115

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ENGINE

TABLE OF CONTENTS

page

ENGINE

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 2

STANDARD PROCEDURE

STANDARD PROCEDURE - COMPRESSION

TESTING ENGINE . . . . . . . . . . . . . . . . . . . . . . 3

STANDARD PROCEDURE - CYLINDER

LEAK DOWN TEST . . . . . . . . . . . . . . . . . . . . . 3

STANDARD PROCEDURE - DETERMINING

CYLINDER PRESSURE LOSS . . . . . . . . . . . . . 4

REMOVAL

REMOVAL - ENGINE COVER

. . . . . . . . . . . . . 4

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION

INSTALLATION - ENGINE COVER

. . . . . . . . . . 9

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS - TORQUE

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . 11

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . 17

AIR CLEANER ELEMENT

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 21

AIR CLEANER HOUSING

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 22

CYLINDER HEAD

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 22

STANDARD PROCEDURE

STANDARD PROCEDURE - CYLINDER

HEAD BOLT INSPECTION . . . . . . . . . . . . . . . 22

STANDARD PROCEDURE - MEASURE

CYLINDER HEAD SURFACE . . . . . . . . . . . . . 22

REMOVAL

REMOVAL - CYLINDER HEAD

. . . . . . . . . . . . 23

REMOVAL - CYLINDER HEAD FRONT

COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REMOVAL - CYLINDER HEAD GUIDE RAIL

. . 26

INSTALLATION

INSTALLATION - CYLINDER HEAD

. . . . . . . . 26

INSTALLATION - CYLINDER HEAD FRONT

COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION - CYLINDER HEAD GUIDE

RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

CAMSHAFT(S)

STANDARD PROCEDURE

STANDARD PROCEDURE - CHECKING

CAMSHAFT POSITION . . . . . . . . . . . . . . . . . 28

STANDARD PROCEDURE - INSPECTING

TAPPET CLEARANCE . . . . . . . . . . . . . . . . . . 30

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 32

CYLINDER HEAD COVER(S)

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 34

VALVE STEM SEALS

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 34

VALVE SPRINGS

REMOVAL

REMOVAL - VALVE SPRINGS

. . . . . . . . . . . . 35

REMOVAL - VALVES

. . . . . . . . . . . . . . . . . . . 36

INSTALLATION

INSTALLATION - VALVE SPRINGS

. . . . . . . . 36

INSTALLATION - VALVES

. . . . . . . . . . . . . . . 37

ENGINE BLOCK

STANDARD PROCEDURE

STANDARD PROCEDURE - REPLACING

ENGINE CORE AND OIL GALLERY PLUGS . . 37

STANDARD PROCEDURE - MEASURING

CYLINDER BORES . . . . . . . . . . . . . . . . . . . . 38

CRANKSHAFT

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 39

STANDARD PROCEDURE - MEASURE

CRANKSHAFT AND BLOCK JOURNALS

. . . . 39

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 40

CRANKSHAFT OIL SEAL - REAR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 42

CRANKSHAFT OIL SEAL - FRONT

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 43

FLYWHEEL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . 44

INSTALLATION - CRANKSHAFT LOCK

. . . . . 44

PISTON & CONNECTING ROD

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 45

STANDARD PROCEDURE

STANDARD PROCEDURE - CHECKING AND

REPAIRING CONNECTING RODS . . . . . . . . . 46

STANDARD PROCEDURE - MEASURING

PISTON PROTRUSION . . . . . . . . . . . . . . . . . 47

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 49

PISTON RINGS

STANDARD PROCEDURE - PISTON RING

FITTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

VIBRATION DAMPER

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 54

ENGINE

9 - 1

Summary of Contents for SPRINTER2006

Page 1: ... FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufac tured Copyright 2004 Daimle...

Page 2: ...ear safety goggles whenever work ing on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to minimize the risk of personal injury or the possibility that improper service methods may damage the vehicle or render it unsafe It is important to note that these Cautions and Warnings cover only the ...

Page 3: ...rren Michigan 48092 U S A MILLER SPECIAL TOOLS SPX Corporation Telephone 1 800 801 5420 FAX 1 800 578 7375 INTERNATIONAL The special service tools referred to herein are required for certain service opera tions These special service tools or their equivalent if not obtainable through a local source are available through the following outlet 28635 Mound Road Warren Michigan 48092 U S A MILLER SPECI...

Page 4: ...tion that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide DaimlerChrysler Corporation with your comments and suggestions Tightening torques are provided as a spec...

Page 5: ...ed Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 14 Fuel System 19 Steering 21 Transmission 22 Tires Wheels 23 Body 24 Heating Air Conditioning 25 Emissions Control Component and System Index Service Manual Comment Forms Rear of Manu...

Page 6: ......

Page 7: ... Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is not released to the general public VIN DECODING INFORMATION POSITION INTERPRETATION CODE DESCRIPTION 1 2 3 World Manufacturer Code WDX Incomplete vehic...

Page 8: ...eels Van 8 001 to 9 000 lbs class G D7 Sprinter 4042 mm 159 in in connection with 16 wheels Van 8 001 to 9 000 lbs class G 7 8 Engine 41 2 7L 5 cyl Diesel 612 ME9 42 2 7L 5 cyl Diesel 612 MF1 43 2 7L 5 cyl Diesel 647 MC0 44 2 7L 5 cyl Diesel 647 MF2 9 Check Digit 10 Model Year 6 2006 11 Assembly Plant 5 Düsseldorf Plant Germany 12 Thru 17 Vehicle Build Sequence INTERNATIONAL SYMBOLS DESCRIPTION Th...

Page 9: ...t strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts Fig 2 and Fig 3 Fig 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp Parking Lamps Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Wa...

Page 10: ...ry SAE Grade Number 5 8 Bolt Head Markings These are all SAE Grade 5 3 line Bolt Torque Grade 5 Bolt Bolt Torque Grade 8 Bolt Body Size Cast Iron Aluminum Cast Iron Aluminum N m ft lb N m ft lb N m ft lb N m ft lb 1 4 20 9 7 8 6 15 11 12 9 28 12 9 9 7 18 13 14 10 5 16 18 20 15 16 12 30 22 24 18 24 23 17 19 14 33 24 25 19 3 8 16 40 30 25 20 55 40 40 30 24 40 30 35 25 60 45 45 35 7 16 14 60 45 45 35...

Page 11: ...or servicing DaimlerChrysler Corporation vehicles AUTOMATIC TRANSMISSION FLUID NAG1 NOTE Refer to Service Procedures in this group for fluid level checking procedures Use ATF approved to MB 236 10 MB 236 12 such as Shell ATF 3403 M 115 MOPARt part number 05127382AA Fuchs Shell ATF 3353 or equivalent Automatic Transmission Fluid ATF is red in color when new The ATF is dyed red so it can be identifi...

Page 12: ...ysantin G05 BASF AG MOPARt part number 05066386AA or an equivalent Extended Life Coolant with the HOAT inhibitor system This cool ant offers the best engine cooling without corrosion when mixed with 50 anti freeze and 50 distilled water to obtain a freeze point of 37 C 34 F If it loses color or becomes contaminated drain flush and replace with fresh properly mixed coolant solu tion CAUTION This co...

Page 13: ...ges The following engine oils have been determined to meet DaimlerChrysler requirements DaimlerChrysler Approved En gine Oil SAE Rating MB Sheet Number 76 Pure Syn thetic Motor Oil 5W 40 229 3 76 Royal Triton QLT 15W 40 228 3 Agip All Guard Motor Oil 15W 40 228 3 DaimlerChrysler Approved En gine Oil SAE Rating MB Sheet Number Agip Eurosport 5W 40 229 3 Agip Synthetic PC 5W 40 229 3 Akron Ultra Cle...

Page 14: ...TDX 10W 30 228 3 Ursa Premium TDX 15W 40 228 3 Valvoline Syn Power MXL 0W 30 229 3 1 Engine oil also meets API classification CI 4 Other oils may meet requirements see oil label to determine Use of the approved fluid is required if the ASSYST Oil Service Reminder is followed Use of a lower quality oil on this service schedule may cause severe engine damage FUEL REQUIREMENTS DIESEL ENGINE WARNING D...

Page 15: ...iate 21 TRANSMISSION AUTO MATIC FLUID STANDARD PROCEDURE REAR AXLE 03L 1 oz 8 1 2 1 8 L 4 0 pts FUEL TANK Primary 100 L 26 4 gal Reserve 10 5 L 2 8 gal Nominal refill capacities are shown A variation may be observed from vehicle to vehicle due to manufac turing tolerance and refill procedure DESCRIPTION SPECIFICATION POWER STEERING SYSTEM Power steering fluid capacities are dependent on engine cha...

Page 16: ...ICE BEING USED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION When using another vehicle as a booster do not allow vehicles to touch Electrical systems can be damaged on either vehicle TO JUMP START A DISABLED VEHICLE 1 Raise hood on disabled vehicle and visually inspect engine compartment for Battery cable clamp condition clean if necessary Frozen battery Yellow or bri...

Page 17: ...L ARM REMOVAL 6 INSTALLATION 7 SPRING REMOVAL 7 INSTALLATION 8 SPRING CLAMP PLATES REMOVAL 8 INSTALLATION 9 SPRING STOP PLATES REMOVAL 9 INSTALLATION 9 STABILIZER BAR DESCRIPTION 9 OPERATION 9 REMOVAL 9 INSTALLATION 9 STABILIZER LINK REMOVAL 10 INSTALLATION 10 STRUT REMOVAL 10 INSTALLATION 10 FRONT SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Lower Ball Joint To ...

Page 18: ...0 44 Outer Tie Rod End Nut 130 96 Outer Tie Rod End Nut Jam Nut 50 37 SPECIAL TOOLS FRONT SUSPENSION SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 9288 LEAF SPRING WEDGE BLOCK N A 9294 LOWER BALL JOINT RE MOVE INSTALLER N A 9302 BUSHING REMOVER IN STALLER N A C 3894 A PULLER TIE ROD 730 589 02 33 00 9282 BALL JOINT SEPARA TOR N A C 4212F BALL JOINT PRESS Puller Tie Rod C 3...

Page 19: ...w bushing into the control arm using special tool C 4212F and 9302 1 Driver with 9302 2 Sizer cup and 9302 4 Receiver Fig 2 3 Press the bushing in all the way until the lip is seated properly into the control arm 4 Install the lower control arm to the vehicle Refer to 2 SUSPENSION FRONT LOWER CON TROL ARM INSTALLATION BALL JOINT SEPARATOR 9282 LEAF SPRING WEDGE BLOCK 9288 BUSHING REMOVER INSTALLER...

Page 20: ...wheels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the wheel flange ring if equipped with dual rear wheels Fig 5 5 Remove the disc brake rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL 6 Remove the grease cap Fig 4 7 Loosen the bolt on the clamping nut and remove the c...

Page 21: ...icle 2 Remove the front wheels Refer to 22 TIRES WHEELS WHEELS REMOVAL 3 Remove the disc brake caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the hub bearing Refer to 2 SUSPEN SION FRONT HUB BEARING REMOVAL 5 Separate the outer tie rod from the steering knuckle Fig 6 using special tool C 3894 A 6 Raise the lower control arm approximately 10 mm us...

Page 22: ...ball joint using special tool 9294 1 Driver with 9294 2 Reciever and C 4212 F Fig 7 INSTALLATION 1 Install the ball joint into the lower control arm using special tool 9294 3 Installer ring inserted in 9294 2 Reciever and C 4212 F Fig 7 2 Install the front strut Refer to 2 SUSPEN SION FRONT STRUT INSTALLATION 3 Install the steering knuckle Refer to 2 SUS PENSION FRONT KNUCKLE INSTALLATION 4 Instal...

Page 23: ...ION 10 PROPELLER SHAFT DIAGNOSIS AND TESTING PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out of round tires or wheels that are out of bal ance will cause a low frequency vibration Driveline vibration can be from loose or damaged engine mounts Propeller shaft vibration increases with vehicle speed A vibration within a specific speed is not usu ally caused by a out of balanced propeller shaft Worn uni...

Page 24: ...ersal Joint Noise 1 Loose U joint clamp screws 1 Install new clamps and screws and tighten to proper torque 2 Lack of lubrication 2 Replace as U joints as neces sary PROPELLER SHAFT BALANCE NOTE Removing and indexing the propeller shaft 180 relative to the yoke may eliminate some vibra tions If propeller shaft is suspected of being out of bal ance verify with the following procedure 1 Place vehicl...

Page 25: ...LLER SHAFT RUNOUT 1 Clean the propeller shaft surface where the dial indicator will contact the shaft 2 The dial indicator must be installed perpendic ular to the shaft surface 3 Measure runout at the center and ends of the shaft away from weld areas to ensure weld process will not effect the measurements 4 Refer to Runout Specifications chart 5 If propeller shaft is out of specification remove pr...

Page 26: ...r bubble in sight glass and record measurement This measurement will give you the transmis sion yoke Output Angle A 6 Rotate propeller shaft 90 degrees and place inclinometer on yoke bearing parallel to the shaft Center bubble in sight glass and record measure ment This measurement can also be taken at the rear end of the shaft This measurement will give you the Propeller Shaft Angle C 7 Rotate pr...

Page 27: ...e propeller shaft angles involved with a two three piece Fig 5 propel ler shaft is the same as those for a one piece propel ler shaft Fig 4 UNIVERSAL JOINT ANGLE EXAMPLE 1 4 9 Angle C 2 3 2 Angle B 3 Input Yoke 4 3 0 Angle A 5 Output Yoke VA PROPELLER SHAFT 3 5 ...

Page 28: ...frame floor bolt 100 74 Center Bearing support to frame floor bolt 95 70 Center Bearing to support nut 105 77 SPECIAL TOOLS SPECIAL TOOL CROSS REFERENCE CHART MB TOOL MILLER TOOL DESCRIPTION N A 938 BRIGE N A 1130 SPLITTER 387 589 05 15 00 9275 INSTALLER N A 7663 INCLINOME TER Fig 5 UNIVERSAL JOINT ANGLE 1 YOKES MUST BE IN SAME PLANE BRIDGE 938 3 6 PROPELLER SHAFT VA ...

Page 29: ...16 WHEELS SRW 11 INSTALLATION REAR 16 WHEELS SRW 11 INSTALLATION REAR DRW 11 DISC BRAKE CALIPERS REMOVAL REMOVAL FRONT SRW 11 REMOVAL FRONT DRW 12 REMOVAL REAR SRW 12 REMOVAL REAR DRW 13 INSTALLATION INSTALLATION FRONT SRW 13 INSTALLATION FRONT DRW 13 INSTALLATION REAR SRW 14 INSTALLATION REAR DRW 14 DISC BRAKE CALIPER ADAPTER REMOVAL REMOVAL FRONT 14 REMOVAL REAR 14 INSTALLATION INSTALLATION FRON...

Page 30: ...noise when braking check suspension components Jounce front and rear of vehicle and listen for noise that might be caused by loose worn or damaged suspension or steering components 3 Inspect brake fluid level and condition Note that the brake reservoir fluid level will decrease in proportion to normal lining wear Also note that brake fluid tends to darken over time This is normal and should not be...

Page 31: ...tant contact with the rotor or drum Drag can occur at one wheel all wheels fronts only or rears only Drag is a product of incomplete brake shoe release Drag can be minor or severe enough to overheat the linings rotors and drums Minor drag will usually cause slight surface char ring of the lining It can also generate hard spots in rotors and drums from the overheat cool down pro cess In most cases ...

Page 32: ...bration BRAKE NOISES Some brake noise is common with rear drum brakes and on some disc brakes during the first few stops after a vehicle has been parked overnight or stored This is primarily due to the formation of trace corrosion light rust on metal surfaces This light corrosion is typically cleared from the metal surfaces after a few brake applications causing the noise to subside BRAKE SQUEAK S...

Page 33: ...g Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding Do not pressure bleed without a proper master cyl inder adapter The wrong adapter can lead to leak age or drawing air back into the system HYDRAULIC MECHANICAL SPECIFICATIONS SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Brake Lines 14 124 Master Cylinder To Brake Boos...

Page 34: ...94 in Rear Disc Brake Rotor Max Axial Runout DRW 02 mm 0 0007 in Front Disc Brake Rotor New DRW 22 mm 0 866 in Front Disc Brake Rotor Wear Limit DRW 19 mm 0 748 in Front Disc Brake Rotor Max Lateral Runout DRW 0 05 mm 0 0019 in DESCRIPTION SPECIFICATION Front Disc Brake Rotor Max Axial Runout DRW 0 02 mm 0 0007 in Front Disc Brake Rotor New SRW 22 mm 0 866 in Front Disc Brake Rotor Wear Limit SRW ...

Page 35: ...E SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more air flow is rec ommended TRAILER TOWING Consult Trailer Towing section of owners manual Do not exceed limits AIR CONDITIONING ADD ON OR AFTER MARKET A maximum cooling package should have been ordered...

Page 36: ...tion ing correctly 2 Check gauge Refer to 8 ELECTRICAL INSTRUMENT CLUS TER DIAGNOSIS AND TESTING 3 Air traped in cooling 3 Drain cooling system Refer to 7 COOLING STANDARD PROCE DURE and refill Refer to 7 COOLING STANDARD PROCE DURE 4 Radiator cap faulty 4 Replace radiator cap 5 Plugged A C or radiator cooling fins 5 Clean all debre away from A C and radiator cooling fins 6 Coolant mixture incorre...

Page 37: ...p 2 Radiator neck surface damaged 2 Replace radiator HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum created in cooling sys tem on engine cool down is not being relieved through coolant re servior overflow system 1 Replace radiator cap check vent hose between radiator and reser voir bottle for blockage also check reservoir bottle vent for blockage NOISY FAN 1 Fan blade s loose damaged 1 Rep...

Page 38: ...ition 2 Obstruction in heater hoses 2 Remove hoses remove obstruc tion 3 Water pump damaged 3 Replace water pump HEAT ODOR 1 Damaged or missing drive line heat shields 1 Repair or replace damaged or missing heat shields 2 Thermal viscous fan drive dam aged 2 Check thermal viscous fan drive Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH DIAGNOSIS AND TESTING 7 4 COOLING VA ...

Page 39: ...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 The wrong belt being installed incorrect length width Worn bearings on an engine accessory A C com pressor power steering pump water pump idler pul ley or generator A pulley on an engine accessory being loose Misalignment of...

Page 40: ... misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace pulley Inspect belt 5 Belt rubber deteriorated 5 Replace belt BELT SLIPS 1 Belt slipping because of insuffi cient tension 1 Inspect Replace tensioner if nec essary 2 Belt or pulley exposed to sub stance that has r...

Page 41: ...ers Refer to 23 BODY INTERI OR HEADLINER REMOVAL 3 Disconnect the antenna and electrical connec tions near the windshield Fig 1 4 Remove the mounting nut 5 Remove the antenna assembly from the roof and pull wire harness and cable through roof open ing INSTALLATION 1 Feed wire harness and cable through roof open ing and position antenna to roof panel 2 Install and tighten antenna mounting nut 3 Con...

Page 42: ...e to instrument panel wire harness 5 Install glove box Refer to 23 BODY INSTRU MENT PANEL GLOVE BOX INSTALLATION 6 Install the headliner Refer to 23 BODY IN TERIOR HEADLINER INSTALLATION 7 Install the A pillar trim Refer to 23 BODY INTERIOR A PILLAR TRIM INSTALLATION 8 Install the radio Refer to 8 ELECTRICAL AUDIO RADIO INSTALLATION 9 Connect the battery negative cable RADIO REMOVAL 1 Disconnect a...

Page 43: ...ector and remove speaker INSTALLATION 1 Install wire harness connector 2 Place speaker into instrument panel 3 Install speaker grille 4 Install the A pillar trim Refer to 23 BODY INTERIOR A PILLAR TRIM INSTALLATION 5 Connect the battery negative cable Fig 4 INSTRUMENT PANEL SPEAKER VA AUDIO VIDEO 8A 3 ...

Page 44: ......

Page 45: ...cal sys tem and to the EMIC through the use of a combina tion of soldered splices splice block connectors and many different types of wire harness terminal con nectors and insulators Refer to the appropriate wir ing information The wiring information includes wiring diagrams proper wire and connector repair procedures further details on wire harness routing and retention as well as pin out and loc...

Page 46: ... internal programming and hard wired inputs from the front door ajar switches the key in ignition switch the ignition switch the seat belt switch and the turn signal hazard warning multi function switches The EMIC relies upon electronic message inputs received from other electronic modules over the CAN data bus network to provide chime service for the low engine oil level warning Upon receiving th...

Page 47: ...vides the optional Remote Keyless Entry RKE system fea tures including support for the RKE Lock with optional horn and park lamps flash Unlock with park lamps flash driver door only unlock and unlock all doors Panic and illuminated entry modes as well as the ability to be programmed to recognize up to four RKE transmitters The RKE horn driver door only unlock and unlock all doors features are prog...

Page 48: ...ment panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before perform ing further diagnosis or service This is the only sure way to disable the supplemental restraint sys tem Failure to take the proper precautions could result in accidental airbag deployment The hard wired inputs to and outputs...

Page 49: ...ower dash panel and consists of an electronic printed circuit board which is designed as a milliliter board assembly fitted on both sides The routing of the wiring harness connector at the ECM connector are split into interfering cables and sensitive cables in order to achieve improved electromagnetic compat ibility The smaller wiring harness connector is used for the vehicle wiring harness and th...

Page 50: ...h electrical appliances Starter control immobilizer cruise control kick down air conditioner Maintenance computer ASSYST optional Glow plug for pre heating post heating and intermittent heating Error code memory diagnostics communication interface for diagnosis and handling the fault codes The maximum vehicle speed is programmable from 19 82 m p h The standard is 82 m p h Fig 2 ECM 1 MASS AIR FLOW...

Page 51: ...accelerator pedal module which is equipped with dual hall sensors Measurement of the intake air mass using new mass air flow MAF sensor with increase precision and extended measuring range O2 sensor for measuring the amount of oxygen in the exhaust in order to calculate the air to fuel ratio With the intake air mass being known the injected fuel quantity can be calculated from the air to fuel rati...

Page 52: ... the function mentioned above The high precision of the MAF measurement enables the calculation of the actual injection quantity from the measured air mass and from the oxygen sensor signal in order to correct injection quantity The MAF signal can also be used as a input parameter for the smoke limiter REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the ECM harness connectors Fig 4 3 ...

Page 53: ...6 INSTALLATION 16 BATTERY TRAY DESCRIPTION 16 OPERATION 16 REMOVAL 16 INSTALLATION 16 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on this model Some vehicles are equipped with a second auxiliary battery for running additional electrical equipment The standard battery is located in the engine compartment while the aux iliary battery if equipped is lo...

Page 54: ...e system In order for the engine to start and the battery to maintain its charge properly all of the components that are used in these systems must perform within specifications It is important that the battery starting and charging systems be thor oughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal bat tery discharge overcharging or early battery f...

Page 55: ...inal con nections are loose or cor roded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The battery has an incor rect size or rating for this vehicle 5 Refer to Battery System Specifications for the proper size and rating Replace an incorrect bat tery as required 6 The battery is faulty 6 Dete...

Page 56: ...agnosis and testing procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electri cal loads 8 Slow driving or prolonged idling with high amperage draw systems in use 8 Advise the vehicle operator as required THE BATTERY WILL NOT ACCEPT A CHARGE 1 The...

Page 57: ...r with a sodium bicarbonate baking soda and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film Fig 2 Rinse the battery with clean water Ensure that the cleaning solution does not enter the battery cells through the vent holes If the battery is being replaced refer to Battery System Specifications for the factory installed battery specifications Confirm ...

Page 58: ... capacity low maintenance storage batteries are standard factory installed equipment on this model The primary battery is located in the engine compartment on all models A second auxiliary bat tery may be installed under the passengers front seat for running additional electrical equipment Male post type terminals made of a soft lead mate rial protrude from the top of the molded plastic bat tery c...

Page 59: ...ended The rear window defogger system also known as the electric backlight EBL consists of a backglass with two vertical bus bars linked by a series of grid lines fired onto the inside surface of the rear window The EBL system is turned On or Off by a control switch Fig 1 located in the instrument panel near the right side of the steering wheel which sends a request signal to the rear window defog...

Page 60: ...uld be detected within three to four minutes of operation 2 If a temperature difference is not detected use a 12 volt DC voltmeter and contact the rear glass heating grid terminal B with the negative lead and terminal A with the positive lead Fig 2 The volt meter should read battery voltage If the voltmeter does not read battery voltage check the following Confirm that the ignition switch is in th...

Page 61: ... are electromechanical switches that uses a low current input from the rear window defogger module to control the high current output to the rear window defogger grids The movable common feed contact point is held against the fixed normally closed con tact point by spring pressure When the relay coil is energized an electromagnetic field is produced by the coil windings This electromagnetic field ...

Page 62: ...lay block as required INSTALLATION NOTE Refer to the fuse and relay map located on the inner surface of the fuse relay block cover for the left and right rear window defogger EBL relay locations 1 Position the rear window defogger EBL relays as required into their proper receptacles in the fuse relay block 2 Align the EBL relay terminals with the termi nal cavities in the fuse relay block receptac...

Page 63: ... rear window defogger system refer to 8W WIRING DIAGRAM INFORMATION 1 Remove the rear window defogger switch from the instrument panel but leave the switch connected Refer to 8 ELECTRICAL HEATED GLASS REAR WINDOW DEFOGGER SWITCH REMOVAL 2 Turn the ignition switch ON 3 Using a voltmeter check for battery voltage at Pin 3 of the rear window defogger switch Fig 6 a If OK go to Step 4 b If NOT OK chec...

Page 64: ... could result in accidental airbag deployment 1 Disconnect and isolate the negative battery cable 2 Remove the cluster bezel from the instrument panel Fig 7 Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL REMOVAL 3 From the back of the cluster bezel squeeze the two latches on the rear window defogger switch body and push the switch out through the face of the bezel Fig 8 4 Remove the rear window d...

Page 65: ...r 3 Connect battery negative cable HORN SWITCH REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the drivers side airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 3 Remove the electrical harness connector 4 Remove the mounting fasteners and horn switch INSTALLATION 1 Connect the wire harness connector 2 Position the horn switch and install the mount ing fasteners 3 ...

Page 66: ......

Page 67: ...f If a failure in the glow plug system occurs the glow plug indicator lamp will be illuminated only as long as the fault is current If the failure is no longer present the glow plug indicator lamp will be switched off but a code will be stored in the ECM After Glow Once the engine has started the ECM determines the after glow time depending on cooling tempera ture During this time the glow plugs c...

Page 68: ...e exhaust smoke after cold start Stabilizing of the cold starting speed The glow plug output stage constantly signals the current operating state and faults The following are faults detected and transmitted to the ECM Open circuit at one or several glow plugs Short circuit in the glow plug circuit Relay fault If the Glow plug relay detects an open circuit at a glow plug it is stored and indicated ...

Page 69: ...FUEL GAUGE DESCRIPTION 17 OPERATION 18 GEAR SELECTOR INDICATOR DESCRIPTION 18 OPERATION 18 HIGH BEAM INDICATOR DESCRIPTION 19 OPERATION 19 LOW FUEL INDICATOR DESCRIPTION 19 OPERATION 19 LOW OIL LEVEL INDICATOR DESCRIPTION 20 OPERATION 20 MAINTENANCE INDICATOR DESCRIPTION 20 OPERATION 21 MALFUNCTION INDICATOR LAMP MIL DESCRIPTION 21 OPERATION 21 MULTI FUNCTION INDICATOR DESCRIPTION 22 OPERATION 22 ...

Page 70: ...ck plastic switch bezel that is integral to the cluster lens and located near the lower edge of the cluster directly below the multi function indicator LCD unit The cluster hood serves as a visor and shields the face of the cluster from ambient light and reflections to reduce glare The cluster hood has eight integral latches that engage eight integral latch tabs on the cluster rear cover sandwichi...

Page 71: ... 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 Active 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 microp...

Page 72: ... and insulators Refer to the appropriate wir ing information The wiring information includes wiring diagrams proper wire and connector repair Fig 3 Gauges Indicators 1 AIRBAG INDICATOR 16 SEATBELT INDICATOR 2 TACHOMETER 17 ABS INDICATOR 3 LEFT TURN INDICATOR 18 MULTI FUNCTION INDICATOR PLUS MINUS SWITCH PUSH BUTTONS 4 SPEEDOMETER 19 MULTI FUNCTION INDICATOR INCLUDES CLOCK GEAR SELECTOR INDICATOR O...

Page 73: ...ndication The EMIC circuitry operates on battery current received through a non switched fused B circuit and on a fused ignition switch output circuit The EMIC circuitry is grounded through a ground circuit and take out of the frame wire harness with an eye let terminal connector that is secured to a stud by a nut at a ground location on the dash panel just for ward of the instrument cluster Separ...

Page 74: ...re 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 plus and minus switch push but tons that extend through the lower edge of the clus t...

Page 75: ...REMOVAL 10 INSTALLATION 10 FOG LAMP BULB REMOVAL 10 INSTALLATION 11 FOG LAMP RELAY REMOVAL 11 INSTALLATION 12 FOG LAMP SWITCH REMOVAL 12 INSTALLATION 13 FRONT LAMP UNIT REMOVAL 13 INSTALLATION 13 ADJUSTMENTS ADJUSTMENT FRONT LAMP UNIT 14 FRONT POSITION LAMP BULB REMOVAL 14 INSTALLATION 15 FRONT TURN PARK SIDE MARKER LAMP BULB REMOVAL 15 INSTALLATION 16 HEADLAMP LEVELING MOTOR REMOVAL 16 INSTALLATI...

Page 76: ...egral to the front lamp units the rear turn lamps that are inte gral to the tail lamp units and a repeater lamp mounted to each front fender just above the front wheel opening Other components of the exterior lighting system for this model include Brake Lamp Switch A plunger type brake lamp switch is located on the steering column sup port bracket under the instrument panel and actu ated by the br...

Page 77: ...ers turn signals and engine start control module located within the fuse block underneath the steering column the ElectroMechanical Instrument Cluster EMIC the Engine Control Module ECM or the Controller Area Network CAN data bus network The most reliable efficient and accurate means to diagnose the electronic module within the fuse block the EMIC the ECM and the CAN data bus network inputs and ou...

Page 78: ...oviding battery current to the selected low or high beam bulbs Each front lamp unit includes two integral adjustment screws to be used for static horizontal and vertical aiming of the headlamp beam reflectors HEADLAMP LEVELING The headlamp leveling system includes a leveling actuator motor integral to each front lamp unit and a rotary thumbwheel actuated headlamp leveling switch in the cluster bez...

Page 79: ...cal turn signal flasher at one of two rates to coincide with the flashing of the turn signals The slow rate emulates normal turn signal operation while the fast rate emulates bulb out turn signal operation SPECIFICATIONS LAMPS LIGHTING EXTE RIOR BULB SPECIFICATIONS LAMP BULB Backup P21W 12V 21W Brake Rear Park P21 5W 12V 21 5W Center High Mounted Stop P21W 12V 21W Clearance W3W 12V 3W Front Fog H1...

Page 80: ...ing further diagnosis or service This is the only sure way to disable the supplemental restraint sys tem Failure to take the proper precautions could result in accidental airbag deployment 1 Disconnect and isolate the battery negative cable 2 Locate the brake lamp switch on the pedal bracket underneath the instrument panel Fig 4 3 Depress the locking tab on the brake lamp switch body behind the pe...

Page 81: ...r will unlock the drivers door pressing it a second time within 2 5 seconds will unlock all other doors The transmitter has a range of 10 meters A key is inte gral to the transmitter When a transmitter is lost it is necessary to dis able the affected transmitter so that it can no longer be used to operate the vehicle It will then be neces sary to program a new transmitter to the vehicle MASTER LOC...

Page 82: ...panel center bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL CENTER BEZEL REMOVAL 3 Remove the central locking switch from the bezel Fig 2 INSTALLATION 1 Install switch to bezel 2 Install instrument panel center bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL INSTALLATION 3 Connect battery negative cable Fig 1 POWER LOCK SWITCH Fig 2 POWER LOCK SWITCH 1 CENTRAL LOCK...

Page 83: ... MIRROR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove power mirror switch Refer to 8 ELECTRICAL POWER MIRRORS POWER MIRROR SWITCH REMOVAL 3 Using an ohmmeter test for continuity between the terminals of the switch Fig 1 MIRROR SWITCH TEST MIRROR SELECT SWITCH IN LEFT POSITION BUTTON POSI TION CONTINUITY BETWEEN UP PIN 6 AND 9 PIN 6 AND 8 DOWN PIN 2 AND 4 PIN 6 AND 10 LEFT PIN...

Page 84: ...d remove switch INSTALLATION 1 Connect electrical harness connector to switch 2 install the mirror switch power window switch trim 3 Install the door handle trim 4 Connect the battery negative cable Fig 2 POWER MIRROR SWITCH 8N 4 POWER MIRRORS VA ...

Page 85: ...motor terminal pins will cause the motor to rotate in one direction Reversing current through the motor terminals will cause the motor to rotate in the opposite direction Refer to the appropriate wiring information The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire harness routing and retention connector pin out information and location view...

Page 86: ...connectors from switches 5 Remove power window switch from trim INSTALLATION 1 Install switch to trim 2 Connect wire harness connectors to switches 3 Install power window switch trim to door trim panel 4 Install door handle cover 5 Connect battery negative cable 8N 6 POWER WINDOWS VA ...

Page 87: ... OPERATION 17 REMOVAL 18 INSTALLATION 19 FRONT SEAT BELT RETRACTOR REMOVAL 20 INSTALLATION 22 FRONT SEAT BELT BUCKLE REMOVAL 23 INSTALLATION 23 PASSENGER AIRBAG DESCRIPTION 24 OPERATION 24 REMOVAL 25 INSTALLATION 27 PASSENGER AIRBAG BRACKET REMOVAL 27 INSTALLATION 28 REAR SEAT BELT RETRACTOR REMOVAL 28 INSTALLATION 30 REAR SEAT BELT BUCKLE REMOVAL REMOVAL INBOARD 30 REMOVAL OUTBOARD 31 INSTALLATIO...

Page 88: ...traints for this model include Front Seat Belts Both outboard front seating positions are equipped with three point seat belt sys tems employing a lower B pillar mounted inertia latch type retractors height adjustable upper B pil lar mounted turning loops travelling lower seat belt anchors secured to the outboard seat tracks and Fig 1 Supplemental Restraint System 1 PASSENGER AIRBAG OPTIONAL 2 SID...

Page 89: ...nt panel in front of the driver Clockspring The clockspring is located near the top of the steering column directly beneath the steering wheel Driver Airbag The driver airbag is located in the center of the steering wheel beneath the driver airbag trim cover Driver Knee Blocker The structure of the lower instrument panel serves as a knee blocker for the driver Passenger Airbag The optional passeng...

Page 90: ...ds upon the angle and severity of an impact Deployment is not based upon vehicle speed rather deployment is based upon the rate of deceleration as measured by the forces of gravity G force upon the impact sensor s When an impact is severe enough the microprocessor in the ACM signals the inflator of the appropriate airbag units to deploy their airbag cushions The front seat belt tensioners are prov...

Page 91: ...als may produce harmful and irritating gases sodium hydroxide is formed in the presence of moisture or combustible compounds An airbag inflator unit may also contain a gas canister pres surized to over 2500 psi WARNING To avoid personal injury or death when handling a seat belt tensioner retractor proper care should be exercised to keep fingers out from under the retractor cover and away from the ...

Page 92: ... deployment must have the deployed restraints replaced In addition if the driver airbag has been deployed the clockspring and the steering wheel must be replaced If the passenger airbag has been deployed the instrument panel must be replaced The seat belt tensioners are deployed by the same signal that deploys the driver and passen ger airbags and must also be replaced if either front airbag has b...

Page 93: ... the system is accomplished by a 4 position instrument panel mounted switch Fig 1 Switch settings Fig 2 are 1 Set Accelerate 2 Resume Set Speed 3 Set Decelerate 4 Off The system is designed to operate at speeds above 25 mph 40 km h WARNING THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMIT MAINTAINING A CONSTANT SPEED SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT ARE WIN...

Page 94: ...n extremely high rate Once the speed control has been disengaged depressing the RES ACCEL switch when speed is greater than 30 mph restores the vehicle to the tar get speed that was stored in the ECM While the speed control is engaged the driver can increase the vehicle speed by depressing the RES AC CEL switch The new target speed is stored in the ECM when the RES ACCEL is released The PCM also h...

Page 95: ...LLATION The speed control switch is mounted to the back of the multi function switch Fig 3 1 Position speed control switch to back of multi function switch 2 Install switch mounting screw Fig 4 Refer to Torque Specifications Install multi function switch Refer to Multi Func tion Switch Removal Installation 3 Plug pigtail electrical connector Fig 3 into instrument panel wiring harness Be sure wires...

Page 96: ......

Page 97: ... door The key must be held in the locking position for more than two seconds Activation is indicated by the turn sig nal lights flashing once Unlocking the vehicle at one of the other doors will trigger an alarm The interior monitoring system included in the anti theft alarm is based on ultrasonics and triggers an alarm if an object intrudes the interior of the vehicle or if any movement is detect...

Page 98: ...ness connector 2 Position module Install and tighten mounting fasteners 3 Install driver seat cushion 4 Connect battery negative cable SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION The Sentry Key Remote Entry Module SKREEM Fig 2 performs the functions of the Sentry Key Immobilizer Module SKIM and the Remote Keyless Entry RKE module SENTRY KEY IMMOBILIZER The Sentry Key Immobilizer System SKIS authent...

Page 99: ...ronically coded in the SKREEM and in all programmed transponder keys It is used for immobilization and RKE functions for data security In addition each transponder key will have a unique identification REMOTE KEYLESS ENTRY After pressing the lock button on the RKE trans mitter all of the door locks will lock the illuminated entry will turn off providing all doors are closed and the VTSS if equippe...

Page 100: ...VER CLUS TER INSTALLATION 4 Connect the battery negative cable 5 Verify vehicle and system operation 6 Close hood SENTRY KEY REMOTE ENTRY MODULE TRAN SPONDER RING 1 Maneuver wiring through instrument panel Fig 5 2 Connect the transponder electrical connect or to the SKREEM Fig 4 3 Install the top cover cluster Refer to 23 BODY INSTRUMENT PANEL TOP COVER CLUS TER INSTALLATION 4 Snap the SKREEM tran...

Page 101: ...within the range of the SKREEM s transponder ring when it is inserted into the ignition lock cylinder When the ignition switch is turned to the ON position the SKREEM communicates with the Sentry Key via a radio frequency RF signal The SKREEM deter mines if a valid key is present based on the informa tion it receives from the Sentry Key If a valid key is detected that fact is communicated to the E...

Page 102: ......

Page 103: ...ER FLUID LEVEL SWITCH DESCRIPTION 16 OPERATION 16 WASHER HOSES TUBES DESCRIPTION 18 OPERATION 18 WASHER NOZZLE DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATION 19 WASHER PUMP MOTOR DESCRIPTION 19 OPERATION 20 REMOVAL 20 INSTALLATION 20 WASHER RESERVOIR DESCRIPTION 21 OPERATION 21 REMOVAL 21 INSTALLATION 22 WIPER ARM DESCRIPTION 23 OPERATION 24 REMOVAL 24 INSTALLATION 24 WIPER BLADE DESCRIPTION ...

Page 104: ... of the wind shield in the engine compartment Multi Function Switch The multi function switch is secured to the top of the steering column just below the steering wheel Only the left lighting control stalk right wiper control stalk and the haz ard warning switch button for the multi function switch are visible the remainder of the switch is con cealed beneath the steering column shrouds The multi ...

Page 105: ...g The wiper linkage module includes the two wiper drive links the wiper motor crank arm the two wiper piv ots and the linkage and motor mounting bracket Wiper Motor The wiper motor is secured to the wiper linkage module bracket on the underside of the cowl panel within the engine compartment The wiper motor output shaft and crank arm extend through a clearance hole in the mounting bracket where th...

Page 106: ... within the fuse block monitors inputs from the intermittent wipe and washer switch cir cuitry of the multi function switch and the park switch in the wiper motor When the intermittent wipe position is selected with the multi function switch control stalk the intermittent wipe logic cir cuitry responds by energizing the wiper relay and calculating the correct delay interval The energized wiper rel...

Page 107: ...the down position at the moment the Off position is selected the park switch is an open cir cuit The control module logic circuit directs battery current to the low speed brush of the wiper motor which causes the wiper motor to continue running until the wiper blades are in the down position on the windshield and the park switch is again closed to ground When the Wash position of the control knob ...

Page 108: ...teering wheel steering column airbag seat belt tensioner or instrument panel component diagno sis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before perform ing further diagnosis or service This is the only sure way to disable the supplemental restraint sys tem Failure to take the proper precautions could result in...

Page 109: ...TEM 8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 CENTRAL TIMER MODULE 8W 45 1 AUDIO SYSTEM 8W 47 1 REAR WINDOW DEFOGGER 8W 48 1 FRONT LIGHTING 8W 50 1 REAR LIGHTING 8W 51 1 TURN SIGNALS 8W 52 1 WIPERS 8W 53 1 TRAILER TOW 8W 54 1 NAVIGATION TELECOMMUNICATIONS 8W 55 1 POWER WINDOWS 8W 60 1 POWER DOOR LOC...

Page 110: ......

Page 111: ...es it is important to understand all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page Fig 1 All switches components and modules are shown in the at rest position with the doors closed and the key removed from the ignition Fig 2 Componen...

Page 112: ... 6l RELAY r 1 MESSAGE 6GA tKC4 T I h 10 h I I Y r t ING Y g OL Y 1 I V V LAMP V LAMP I F JUNCTION L W W W _j 8W 12 24 1BLocK 8 2 3 I 8W 12 3 _ I si o 11 C2 BR WT G19 G83 G84 INDICATES WIRES ARE PART OF 1 20 22 22 THE SAME CONNECTOR G 9 rn cfDELGl OR GlY BK LB BK G oBK C110 5108 2 5 9 371 361 I8W 40 6l LG OR LG OR INDICATES CIRCUIT NUMBER I I SIZE AND WIRE COLOR e e5112 I 9 m m GY BK LG OR 1s _26A ...

Page 113: ... GY 22 NUMBER IS OMITTED GY BK 7 C110 I 5202 6 C4 9 I 1 IJUNCTION I IGNITION _j 4 3 I 1 i 4TC10 11YC2 11 2 3 4 INDICATES G9 SPECIFIC 22 I 0 I 3LOCK OPERATING G9 GY BK 4 ACC CONDITIONS 20 OTHERS I ABS DRL 2 BW 10 4 1 OFTHE lj I LJ COMPONENT GY 1 iafftH j t G1t GY BK l J G 1 A 3 A I 1 BRAKE I IDAYTIME e 5236 ON WHICH OPTIONS THE FLUID RED RUNNING I BW 15 5 VEHICLE IS EQUIPPED LEVEL 1w G 1LAMP WITH 4...

Page 114: ...P _ G101 M RESISTIVE NPN PNP TONE MULTIPLEX TRANSISTOR TRANSISTOR GENERATOR SWITCH y y ZJ OPEN rnCLOSED LED HOTODIODE DIODE SWITCH SWITCH tZENER DIODE II i I t GANGED ill SLIDING UGE _l_ SWITCH DOOR OXYGEN PIEZOELECTRIC CONTACT SENSOR CELL m T T WIRE WIRE ORIGIN t DESTINATION RESIST t VARIABLE HEATER DESTINATION SHOWN IN RESISTOR ELEMENT SHOWN ANOTHER CELL OR WITHIN THERMISTOR CELL POTENTIOMETER E...

Page 115: ...STANDARD PROCEDURE CHECKING CAMSHAFT POSITION 28 STANDARD PROCEDURE INSPECTING TAPPET CLEARANCE 30 REMOVAL 30 INSTALLATION 32 CYLINDER HEAD COVER S REMOVAL 33 INSTALLATION 34 VALVE STEM SEALS DESCRIPTION 34 VALVE SPRINGS REMOVAL REMOVAL VALVE SPRINGS 35 REMOVAL VALVES 36 INSTALLATION INSTALLATION VALVE SPRINGS 36 INSTALLATION VALVES 37 ENGINE BLOCK STANDARD PROCEDURE STANDARD PROCEDURE REPLACING E...

Page 116: ...8 INSTALLATION 69 TIMING CHAIN COVER REMOVAL 70 INSTALLATION 71 TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL TENSIONING AND SLIDE RAILS 72 REMOVAL INTERMEDIATE GEAR 73 REMOVAL TIMING CHAIN TENSIONING RAIL 74 REMOVAL TIMING CHAIN 74 INSTALLATION INSTALLATION TENSIONING AND SLIDE RAIL 76 INSTALLATION INTERMEDIATE GEAR 77 INSTALLATION TIMING CHAIN TENSIONING RAIL 77 ADJUSTMENTS INSTALLATION TIMING CHAI...

Page 117: ...ester and adapter from cylinder head 11 Install glow plugs Refer to 8 ELECTRICAL IGNITION CONTROL GLOW PLUG INSTALLA TION 12 Install engine cover Refer to 9 ENGINE INSTALLATION COMPRESSION SPECIFICATIONS Maximum Compression 29 35 bar 420 507 psi Minimum Compression 18bar 261 psi Permissible Difference Between Cylinders 3bar 44 psi STANDARD PROCEDURE CYLINDER LEAK DOWN TEST 1 Warm engine to operati...

Page 118: ...nder Head Gasket AIR LOSS THROUGH AIR INTAKE AREA 1 Sealing Sur faces 1 Remove Cyl inder Head for Further Inspec tion CONDITION POSSIBLE CAUSES CORRECTION 2 Intake Valves and Seats 2 Replace Valves Guides or Seats AIR LOSS THROUGH EX HAUST Sealing Surfac es Remove Cylin der Head for Further Inspec tion 2 Exhaust Valves and Seats 2 Replace Valves Guides or Seats AIR LOSS THROUGH OIL FILL OPENING 1 ...

Page 119: ...ELEASE PRESSURE STORE COOL ANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER WEAR PROTECTIVE GLOVES CLOTHES AND EYE WEAR 1 Disconnect the negative battery cable NOTE REPLACE THE AIR CONDITIONING DRIER WHEN EVER THE AIR CONDITIONING SYSTEM IS OPENED 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Evacuate and recover air conditioning system Refer to 24 HEATING AIR CON...

Page 120: ...ber 17 Remove the change air cooler A C conderser and fan as an assembly 18 Disconnect the charge air hose at the intake manifold Fig 3 19 Remove the radiator assembly 20 Disconnect the high pressure and return hoses at the power steering pump 21 Disconnect the fuel lines at the fuel filter 22 Disconnect the refrigerant line at the A C compressor 23 Disconnect the vacuum line for the brake booster...

Page 121: ... EXHAUST SYSTEM DESCRIPTION 2 7L DIESEL CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edges is permitted Application of coating will result in excessive floor pan temperatures and objectionable fumes The diesel engine exhaust system consists of an engine exhaust manifold turbocharger exha...

Page 122: ... Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten replace exhaust manifold to cylinder head bolts 7 Turbocharger mounting flange cracked 7 Remove turbocharger and in spect 8 Restriction in exhaust system 8 Remove restriction if possible Replace restricted part if neces sary Fig 1 ...

Page 123: ...tab is inserted into the alignment slot 2 Install mounting bracket and nuts Fig 1 3 Install clamp 4 Lower the vehicle 5 Start the vehicle and inspect for exhaust leaks Repair exhaust leaks as necessary 6 Check the exhaust system for contact with the body panels Make necessary adjustments if neces sary TAILPIPE REMOVAL 1 Raise and support the vehicle 2 Saturate the clamp nuts with heat valve lubri ...

Page 124: ...t low speeds the flow cross section is reduced by closing the guide vanes Fig 2 Consequently the speed at which the exhaust gas impacts on the tur bine wheel is increased as a result of which the speed of the turbocharger and thus the charge pres sure rises At high engine speeds the guide vanes are increas ingly opened and the flow cross section is thus enlarged as a result of which the speed of t...

Page 125: ...apy water check the air inlet ducts rubber sleeves charge air cooler and intake manifold for leaks REMOVAL 1 Remove front bumper 2 Remove headlamp assemblies 3 Remove front cross member together with front grille 4 Remove left and right radiator trim Fig 3 5 Disconnect charge air hoses at charge air cooler Fig 3 6 Disconnect power steering cooler loop from charge air cooler Fig 3 7 Remove charge a...

Page 126: ... for turbo charger boost pressure It generates a control vacuum in response to a PWM signal from the ECM Vacuum is achieved by mixing the system vacuum from the vacuum pump with atmospheric pressure to a certain degree The resulting vacuum is sent to the vacuum unit at the turbocharger Fig 4 OPERATION The vacuum solenoid receives 12V from the ECM The ECM controls the solenoid through a PWM sig nal...

Page 127: ...ICATIONS FRAME DIMENSIONS 3 SPECIFICATIONS TORQUE 8 ENGINE CRADLE CROSSMEMBER REMOVAL 8 INSTALLATION 10 REAR CROSSMEMBER TRANSMISSION REMOVAL 11 INSTALLATION 11 TRAILER HITCH REMOVAL 11 INSTALLATION 12 BUMPERS SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs FRONT BUMPER STEPS BOLTS 20 15 FRONT FASCIA SCREWS 23 17 REAR BUMPER STEP FRAME BOLTS NUTS 38 17 REAR BUMPER STEP SU...

Page 128: ...kets 5 Disconnect electrical connector INSTALLATION 1 Connect outside temperature sensor electrical connector 2 Slide fascia onto the support brackets 3 Install fascia screws and tighten to 23 N m 17 ft lbs 4 Install push pin fasteners 5 Install cover and screws REAR BUMPER STEP REMOVAL 1 Remove rear fascia Refer to 13 FRAME BUMPERS BUMPERS REAR FASCIA REMOVAL 2 Remove frame bolts nuts Fig 3 3 Rem...

Page 129: ...e fascia INSTALLATION 1 Install fascia and seat the corners over the sup port brackets 2 Seat bumper support brackets clips below end panel firmly 3 Install the four plastic rivets to the bumper step if equipped 4 Install fascia bolts and tighten to 23 N m 17 ft lbs 5 Install reflectors and reflector screws FRAME SPECIFICATIONS SPECIFICATIONS FRAME DIMENSIONS NOTE Frame dimensions are listed in me...

Page 130: ...INDEX DESCRIPTION FIGURE 05 FRAME DIMEN SIONS 1 5 05 FRAME DIMEN SIONS 2 6 FRAME DIMENSIONS 7 13 4 FRAME BUMPERS VA ...

Page 131: ...Fig 5 05 FRAME DIMENSIONS 1 VA FRAME BUMPERS 13 5 Ill 1316 92 II I 2991 92 4925 92 DATUM 81590161 ...

Page 132: ...E BUMPERS VA rk if n i w m nn n b ll A l F 1 540 00 389 92 I 495 1 I Ill 1316 92 1 2991 92 3983 92 t 5883 42 I CJ a JlQl1w ri Q 449 00 463 00 449 00 449 00 447 00 823 11 394 45 t t t t t t t ALL DIMENSIONS ARE IN MILLIMETERS DATUM 81590165 ...

Page 133: ...OULD GASOLINE BE MIXED WITH DIESEL FUEL NOT EVEN DURING WINTER THE HIGH PRESSURE PUMP IS LUBRICATED BY DIESEL FUEL IMMEDI ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS ING REPLACEMENT AND FLUSHING OF THE COMPLETE DIESEL FUEL SYSTEM HIGH PRES SURE PUMP SEIZURE WILL CAUSE METAL PARTI CLES TO SPREAD THROUGH OUT THE FUEL CIRCUIT ALL CDI FUEL SYSTEM COMPONENTS CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO BE EXCH...

Page 134: ...tual Fuel Pres sure Start the engine and observe the Fuel Pressure Set Point and the Actual Fuel Pressure If the Actual Fuel Pressure Oscillates above and below the Fuel Pressure Set Point in a regular cycle inspect the fuel system for air intrusion If the Actual Fuel Pressure gradually drops below the Fuel Pressure Set Point then spikes well above the Fuel Pressure Set Point replace the fuel pres...

Page 135: ...conds a maximum of five gradua tion lines 40 ml of the large test vial may be reached If the level has exceeded the five graduation line replace that affected cylinder s injector clear the memory using the scan tool empty the test vials and retest STANDARD PROCEDURE STANDARD PROCEDURES CLEANING FUEL SYSTEM COMPONENTS CAUTION Cleanliness cannot be overemphasized when handling or replacing diesel fu...

Page 136: ...ed fuel filter If no problem is found with the fuel sys tem replace the low pressure fuel pump 1 Disconnect the negative battery cable 2 Connect a fuel gauge to the low pressure fuel supply to the high pressure pump Fig 4 3 Connect negative battery cable 4 Turn the ignition to the ON position and observe the fuel gauge reading Fig 5 5 The fuel pressure should be 4 0 to 4 5 bar 58 65 psi If the fue...

Page 137: ...still below specification replace the fuel pump If the fuel pressure is within the specification replace the fuel filter and retest at the high pressure pump to verify system function Fig 6 FUEL PRESSURE TEST AT FILTER 1 FUEL SUPPLY FROM FUEL TANK 2 FUEL FILTER ASSEMBLY VA FUEL SYSTEM 14 5 ...

Page 138: ...17 INSTALLATION HIGH PRESSURE PUMP 17 FUEL PUMP MODULE DESCRIPTION 18 REMOVAL 18 INSTALLATION 20 FUEL QUANTITY CONTROL VALVE DESCRIPTION 21 OPERATION 21 REMOVAL 21 INSTALLATION 21 FUEL RAIL DESCRIPTION 22 OPERATION 22 REMOVAL 22 INSTALLATION 22 FUEL TANK DESCRIPTION 23 REMOVAL 25 INSTALLATION 26 FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION 28 REMOVAL 29 INSTALLATION 29 WATER IN FUEL SENSOR DESCRIPTI...

Page 139: ...e rotation of the pinion moves the gear rack from side to side This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels Fig 1 Power assist is provided by an engine mounted hydraulic pump which supplies hydraulic fluid pres sure to the steering gear DIAGNOSIS AND TESTING POWER STEERING SYSTEM There is some noise in all power steering systems One of t...

Page 140: ...Internal pump noise 3 Replace pump 4 Air in fluid 4 Check for lekas Evacuate air from P S system SUCKING AIR SOUND 1 Loose return line clamp 1 Replace clamp 2 O ring missing or damaged on hose fitting 2 Replace o ring 3 Low fluid level 3 Fill to proper level 4 Air leak between pump and reservoir 4 Repair as necessary 5 Reservoir cap not installed correctly 5 Install reservoir cap correctly SCRUBBI...

Page 141: ...ubricate suspension compnents 4 High friction in steering gear 4 Replace gear LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING WHEEL 1 Worn or loose suspension or steering components 1 Inspect and repair as necessary 2 Worn or loose wheel bearings 2 Inspect and repair or adjust bearings 3 Steering gear mounting 3 Tighten gear mounting bolts to specific...

Page 142: ...ng wheel and lock the steering wheel in the straight ahead position The position of the steering gear must not be altered again for the entire duration of the work procedure 4 Remove the electrical center 5 Remove the steering wheel bolt 6 Remove the steering wheel from the steering column 7 Remove the clockspring Unscrew the retain ing bolts just enough to be able to remove the clockspring Do not...

Page 143: ... spring for the brake pedal to the steering column 6 Reconnect the electrical connector to the igni tion lock 7 Install the combination switch 8 Install the clockspring 9 Install the steering wheel 10 Install the electrical center 11 Reconnect the ground cable to the battery KEY LOCK CYLINDER REMOVAL 1 Remove the securing cover for the central elec tronics 2 Remove the steering column shroud 3 Rem...

Page 144: ...round cable on the battery 2 Remove the air bag module from the steering wheel 3 Turn the steering wheel and lock the steering wheel in the straight ahead position Fig 7 4 Remove the steering wheel bolt Fig 7 5 Remove the steering wheel from the steering column Fig 7 INSTALLATION 1 Install the steering wheel onto the column Fig 7 2 Install the steering wheel bolt Fig 7 Tighten to 80 N m 59 ft lbs ...

Page 145: ...K2 DISASSEMBLY 97 ASSEMBLY 99 INPUT CLUTCH K3 DISASSEMBLY 102 ASSEMBLY 103 ELECTROHYDRAULIC UNIT DESCRIPTION 105 OPERATION 112 REMOVAL 120 DISASSEMBLY 121 ASSEMBLY 125 INSTALLATION 129 FLUID AND FILTER DESCRIPTION 131 OPERATION 131 DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 131 CAUSES OF BURNT FLUID 132 FLUID CONTAMINATION 132 STANDARD PROCEDURE CHECK OIL LEVEL 132 TRANSMISSION FILL 13...

Page 146: ...7 SHIFT MECHANISM DESCRIPTION 168 OPERATION 168 REMOVAL 169 INSTALLATION 170 SOLENOID DESCRIPTION 171 OPERATION 174 TEMPERATURE SENSOR PARK NEUTRAL CONTACT DESCRIPTION PARK NEUTRAL CONTACT 176 TRANSMISSION TEMPERATURE SENSOR 176 OPERATION PARK NEUTRAL CONTACT 177 TRANSMISSION TEMPERATURE SENSOR 177 TORQUE CONVERTER DESCRIPTION 178 OPERATION 182 REMOVAL 183 INSTALLATION 184 TORQUE CONVERTER HUB SEA...

Page 147: ...of three multi disc holding clutches three multi disc driving clutches and two freewheel ing clutches Electronic transmission control enables precise adaptation of pressures to the respective operating conditions and to the engine output during the shift phase which results in a significant improvement in shift quality Furthermore it offers the advantage of a flexible adaptation to various vehicle...

Page 148: ...ulic control unit comprises the shift plate made from light alloy for the hydraulic control and an electrical control unit The electrical control unit comprises of a supporting body made of plastic into which the electrical components are assembled The supporting body is mounted on the shift plate and screwed to it Strip conductors inserted into the supporting body make the connection between the ...

Page 149: ...some extent the hydraulic control can be used to engage 2nd gear or reverse using the following pro cedure Stop the vehicle Move selector lever to P Switch off engine Wait at least 10 seconds Start engine Move selector lever to D 2nd gear Move selector lever to R Reverse gear The limp home function remains active until the DTC is rectified or the stored DTC is erased with the appropriate scan tool...

Page 150: ...REAR PLANETARY PINION GEARS 7 DRIVING CLUTCH K1 20 FREEWHEELING CLUTCH F1 8 FRONT PLANETARY ANNULUS GEAR 21 FRONT PLANETARY SUN GEAR 9 DRIVING CLUTCH K2 22 CENTER PLANETARY SUN GEAR 10 CENTER PLANETARY ANNULUS GEAR 23 REAR PLANETARY SUN GEAR 11 REAR PLANETARY ANNULUS GEAR 24 FREEWHEELING CLUTCH F2 12 DRIVING CLUTCH K3 25 INPUT SHAFT 13 FRONT PLANETARY CARRIER 26 OUTPUT SHAFT A ENGINE SPEED D SECON...

Page 151: ... 9 DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 9 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 9 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 10 STANDARD PROCEDURE REPAIRING LEAKS 12 CLEANING 12 SPECIFICATIONS TIRES 12 SPARE TIRE CARRIER REMOVAL 12 INSTALLATION 12 WHEELS DESCRIPTION 13 OPERATION 13 DIAGNOSIS AND TESTING WHEEL INSPECTION 13 STANDARD PROCEDURE STANDARD PROCEDURE WHEEL REPLACEMENT 13 STANDARD ...

Page 152: ...proceed to Method 2 METHOD 2 RELOCATE TIRE ON WHEEL NOTE Rotating the tire on wheel is particularly effective when there is runout in both tire and wheel 1 Remove tire from wheel and mount wheel on service dynamic balance machine 2 Check wheel radial runout Fig 2 and lateral runout Fig 3 STEEL WHEELS Radial runout 0 031 in Lat eral runout 0 031 in maximum ALUMINUM WHEELS Radial runout 0 020 in Lat...

Page 153: ...the high spot Place a mark on the tire at the valve stem location Fig 4 3 Break down the tire and remount it 180 degrees on the rim Fig 5 4 Measure the total indicator runout again Mark the tire to indicate the high spot 5 If runout is still excessive the following proce dures must be done If the high spot is within 101 6 mm 4 0 in of the first spot and is still excessive replace the tire If the h...

Page 154: ...heel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balancing find the location of the heavy spot causing the imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counter balance the area of imbalance Place half of ...

Page 155: ...Fig 7 Static Unbalance Balance 1 HEAVY SPOT 2 CENTER LINE OF SPINDLE 3 ADD BALANCE WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP VA TIRES WHEELS 22 5 ...

Page 156: ...an be used but may not provide the same tire longevity benefits CAUTION 3500 Dual rear tires have a new tire rota tion pattern This is to accommodate the asymmet rical design of the ON OFF road tires and the use of the outlined white letter OWL tires When replac ing a flat the spare tire may have to be remounted on the rim or installed at a different location to maintain the correct placement of t...

Page 157: ...e when the ignition is OFF Damage to electrical system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior trim Plastic panels can break DIAGNOSIS AND TESTING...

Page 158: ...cted use a suitable mirror to gain visual access A mirror can also be used to deflect light to a limited access area to assist in locating a leak point BRIGHT LIGHT LEAK TEST METHOD Some water leaks in the luggage compartment can be detected without water testing Position the vehi cle in a brightly lit area From inside the darkened luggage compartment inspect around seals and body seams If necessa...

Page 159: ...me The one difference is the material used for the repair The materials must be specific for each substrate rigid repair material for rigid plastic repair semi rigid repair material for semi rigid plastic repair and flexible repair material for flexible plastic repair Adhesion Promoter Surface Modifier Adhesion Promoters Surface Modifiers are required for certain plastics All three categories may ...

Page 160: ...YCARBONATE LEXAN MERLON CALIBRE MAKROLON PC TAIL LIGHT LENSES IP TRIM VALANCE PANELS PC ABS PC ABS ALLOY GERMAX BAY BLENDS PULSE DOORS INSTRUMENT PAN ELS PPO POLYPHENYLENE OXIDE AZDEL HOSTALEN MAR LEX PRFAX NORYL GTX PPO INTERIOR TRIM DOOR PAN ELS SPLASH SHIELDS STEERING COLUMN SHROUD PPO PA POLYPHENYLENE POLYA MID PPO PA GTX 910 FENDERS QUARTER PAN ELS PR FV FIBERGLASS REINFORCED PLASTIC FIBERGLA...

Page 161: ... BODY TRIMS TPE THERMO POLYETHYLENE TPE HYTREL BEXLOY V FASCIAS BUMPERS CLAD DINGS TPO THERMOPOLYOLEFIN POLYTROPE RENFLEX SANTOPRENE VISAFLEX ETA APEX TPO SHIELDS CLADDINGS BUMPERS END CAPS TEL CAR RUBBER STRIPS SIGHT INTERIOR B POST TPP THERMO POLYPROPYLENE TPP BUMPERS TPU THERMOPOLYURETHANE POLYESTER TPU HYTREL TEXIN ES TANE BUMPERS BODY SIDE MOLDINGS FENDERS FAS CIAS PANEL SECTIONING If it is r...

Page 162: ...etrate through and make a good bond between the panel and the adhesive Structurally the more dry wall tape used the stronger the repair Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of sim ilar plastic and bond with structural adhesive The reinforcement should cover the entire break and should have a generous amount of overlap on either side of th...

Page 163: ...ny obstructions in front of the radiator or A C condenser will reduce the performance of the A C and engine cooling systems The engine cooling system includes the radiator thermostat radiator hoses and the engine coolant pump Refer to 7 Cooling for more information before opening or attempting any service to the engine cooling system All vehicles are equipped with a common ventila tion housing Fig...

Page 164: ... air The automatic temperature control ATC system controls interior temperature by taking actual values from the temperature sensors and the CAN bus and comparing them to the nominal value of the temper ature control switch The electric pulsed heater valve is then energized depending on the requested quan tity of heat and an electrically operated water pump gives a nearly constant water flow for e...

Page 165: ...the amount of moisture in the air is not wasted Wring ing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers Although an owner may expect too much from their A C system on humid days A performance test is the best way to determine whether the system is per forming up to design standards This test also pro vides valuable clues as to the possible cause of ...

Page 166: ...fuse 2 Check the fuses in the Power distribution block and junction block Repair the shorted circuit or component and replace the fuses if required Refer to Group 8 3 Faulty A C compressor clutch coil 3 See A C Compressor Clutch Coil in this group Test the compressor clutch coil and replace if required 4 Improperly installed or faulty evaporator temperature sensor 4 See Evaporator Temperature Sens...

Page 167: ...ant system if required 6 Engine overheating 6 Test the engine cooling system and repair if required Refer to Group 7 Cooling The low side pressure is too high and the high side pres sure is too low 1 Accessory drive belt slip ping 1 Inspect the accessory drive belt condition and tension Repair as required Refer to Group 7 Cooling 2 Faulty A C expansion valve 2 See A C Expansion Valve in this group...

Page 168: ...ooling system connections Inoperative or stuck heater water valve Plugged heater core If proper coolant flow is verified and heater floor outlet air temperature is insufficient a mechanical problem may exist POSSIBLE LOCATIONS OR CAUSE OF INSUFFI CIENT HEAT An obstructed cowl air intake Obstructed heater system outlets Heater water valve not functioning properly TEMPERATURE CONTROL If outlet air t...

Page 169: ...shield 3 Disconnect the CCV heater wiring harness con nector 4 Using a slight twisting motion separate the CCV breather tube from the heater 5 Separate the CCV heater from the turbo charger air inlet duct INSTALLATION 1 Clean all mating surfaces 2 Insert the CCV heater into the turbocharger inlet hose aligning the arrow on the heater with the tab on the hose Fig 1 3 Connect and properly seat the C...

Page 170: ...rn 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 fre...

Page 171: ...rs to 11 N m 97 in lbs Fig 3 4 Connect the CCV breather outlet hose Fig 3 5 Install the engine cover Refer to 9 ENGINE INSTALLATION Fig 3 CCV BREATHER 1 FUEL RAIL 6 CAM POSITION SENSOR 2 FUEL RAIL PRESSURE SENSOR 7 FUEL INJECTOR 3 FUEL INJECTOR RETURN LINE 8 HIGH PRESSURE FUEL INJECTOR SUPPLY LINE 4 CCV BREATHER 9 FUEL PRESSURE SOLENOID 5 CYLINDER HEAD COVER 10 FUEL RAIL SUPPLY LINE VA EVAPORATIVE...

Page 172: ...ng high engine idle to avoid carbon build up on the valve The EGR also deactivates if the EGR temperature is too high The EGR also has a self cleaning function that opens and closes twice after the engine has been shut off to eliminate soot deposits Apart from the charge air distribution manifold and the mixing chamber the intake manifold also includes a finned EGR cooler Coolant flows through the...

Page 173: ...s reduced because the exhaust gas is low in oxygen The result is that the combustion rate is reduced as is the combustion temperature This reduces the quantity of NOx that are emitted in the exhaust gas Fig 2 The ECM power supply relay has a power off delay feature The relay is powered off approximately 15 seconds after the ignition switch is turned off This allows for the self cleaning function o...

Page 174: ...isconnect 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 th...

Page 175: ...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...

Page 176: ...ATION DOOR ACTUATOR 24 22 REFRIGERANT LINE COUPLER 24 98 REFRIGERANT OIL 24 81 REFRIGERANT 24 80 RELAY 8W 97 4 REMOTE KEYLESS ENTRY TRANSMITTER 8N 1 REPEATER LAMP BULB 8L 23 REPEATER LAMP UNIT 8L 24 RESTRAINTS 8O 2 RIGHT MOUNT 9 56 ROTORS 5 20 SAFETY LATCH 23 53 SEAL PINION 3 39 SEAT ADJUSTERS FRONT 23 81 SEAT BACK CUSHION COVER REAR 23 82 SEAT BACK FRONT 23 80 SEAT BELT SWITCH 8O 31 SEAT BELT TEN...

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DaimlerChrysler SPRINTER2006, Service Manual

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