Table Of Contents - Dodge 2001 Ram 1500 Owner's Manual

Table of Contents

Table Of Contents2
Body Code Plate2
Fastener Identification4
Bolt Markins And Torque - Metric5
Bolt Marking And Torque Values - Us Customary5
How To Determine Bolt Strength6
Fastener Usage7
International Vehicle Control & Display Symbols7
Metric System7
Conversion Formulas And Equivalent Values8
Common Metric Equivalents8
Torque References10
Specified Torque For Standard Bolts10
Veci Label Description11
Veci Label Operation11
Vehicle Identification Number11
Vin Coding/Locations11
Vehicle Safety Certification Label13
Equipment Identification Plate13
Lubrication & Maintenance14
Description - Fuel Requirements - Gas Engines14
Reformulated Gasoline14
Gasoline/Oxygenate Blends14
Sulfur In Gasoline15
Materials Added To Fuel15
Fuel System Cautions15
Description - Fuel Requirements - Diesel Engine15
Parts & Lubricant Recommendation16
Fluid Types16
Standard Procedure - Classification Of Lubricants16
Description - Engine Oil16
Energy Conserving Oil17
Container Identification17
Api Service Grade Certified17
Sae Viscosity17
Description - Transfer Case Fluid18
Description - Automatic Transmission Fluid18
Fluid Additives18
Operation - Automatic Transmission Fluid18
Fluid Capacities19
Maintenance Schedules20
Light Duty Engine20
Emission Control System Maintenance20
Fluid Fill Locations And Lubrication Points20
Description - Medium Duty Truck Maintenance Schedule26
Jump Starting40
To Jump Start A Disabled Vehicle40
Jumper Cable Clamp Connections40
Hoisting41
Floor Jack41
Safety Stands41
Towing42
Vehicle Lifting Locations42
Front Lift Pad Location42
Tow Vehicles With Approved Equipment42
Ground Clearance43
Ramp Angle43
Towing When Keys Are Not Available43
Four-Wheel-Drive Vehicle Towing43
Suspension44
Wheel Alignment44
Diagnosis And Testing - Pre-Alignment45
Standard Procedures - Alignment I.f.s.45
Alignment Angles - Link/Coil45
Standard Procedures - Caster Correction Measurement46
Caster Camber Adjustment Location46
Corrected Caster Chart-Cab Chassis48
Standard Procedures - Alignment Link/Coil Suspension48
Toe Position48
Adjustment Cam48
Front - 2Wd50
Torque Chart51
Torque Specifications51
Independent Front Suspension51
Description51
Hub / Bearing52
Special Tools52
Removal52
Installation52
Jounce Bumper Description52
Operation52
Knuckle Description52
Lower Ball Joint Diagnosis And Testing53
Lower Control Arm Removal53
Shock Description54
Diagnosis And Testing54
Spring Description54
Stabilizer Bar Operation55
Stabilizer Bar Removal55
Diagnosis And Testing - Upper Ball Joint55
Coil Spring55
Upper Control Arm Removal56
Upper Control Arm Installation56
Front - 4Wd57
Link/Coil Suspension58
Rotor, Hub/Bearing And Stud61
Hub Spacer61
Brake Shield61
Brake Shield With Wheel Speed Sensor62
Hub Bearing Mounting Bolts62
Lower Control Arm63
Cam Adjuster64
Shock Absorber And Bracket64
Stabilizer Bar65
Shock Absorber Axle Mount65
Track Bar Operation66
Track Bar Removal66
Dial Indicator Location66
Stabilizer Link66
Lower Ball Joint Removal67
Track Bar Puller67
Upper And Lower Suspension Arm67
Lower Snap Ring67
Upper Ball Joint Removal68
Upper Ball Joint Installation68
Rear Description69
Diagnosis And Testing - Spring And Shock69
Spring And Shock Absorber70
Specifications70
Suspension-Rear71
Shock71
Bushings Removal71
Jounce Bumper71
Rear Spring - 4X272
Rear Spring - 4X472
Rear Spring - Cab-Chassis 11000 Gvw72
Stabilizer Bar Description73
Differential & Driveline74
Propeller Shaft Description74
Propeller Shaft Operation74
Front Propeller Shaft75
Rear Propeller Shaft With Center Bearing75
Diagnosis And Testing - Propeller Shaft Vibration76
Rear Propeller Shaft - Dana Axles76
Rear Propeller Shaft - Corporate Axles76
Propeller Shaft And Yoke76
Driveline Vibration77
Balance77
Runout78
Runout Specifications78
Clamp Screw At Position 178
Two Clamp Screws At The Same Position78
Two-Piece Propeller Shaft79
Front (Output) Angle Measurement79
Propeller Shaft Angle Measurement79
Rear (Input) Angle Measurement79
Universal Joint Angle Example80
Universal Joint Angle Two-Piece Shaft80
Propeller Shaft - Front Removal81
Propeller Shaft - Front Installation81
Rear Axle81
Propeller Shaft - Rear Removal82
Propeller Shaft - Rear Installation82
Center Bearing82
Rear Propeller Shaft—Dana Axles82
Center Bearing Operation83
Center Bearing Removal83
Center Bearing Installation83
Center Bearing Adjustment83
Single Cardan Universal Joints84
Remove Snap Ring84
Press Out Bearing84
Press Out Remaining Bearing84
Disassembly84
Front Axle - 216Fbi Description85
Front Axle - 216Fbi Operation85
Diagnosis And Testing - Axle86
Gear Noise86
Fbi Differential Cover86
Differential Operation-Straight Ahead Driving86
Bearing Noise87
Low Speed Knock87
Driveline Snap87
Pinion Gear Id Numbers90
Pinion Gear Depth Variance91
Pinion Depth Measurement And Adjustment91
Adjustment Shim Loactions91
Pinion Gear Depth Gauge Tools92
Pinion Height Block92
Gauge Tools In Housing92
Differential Side Bearing Preload And Gear Backlash93
Shim Selection93
Pinion Gear Depth Measurement93
Bearing Cap Bolts93
Seat Pinion Gear Side Dummy Bearing94
Seat Ring Gear Side Differential Dummy Bearing94
Differential Side Play Measurement94
Differential Case To Ring Gear Side95
Differential Case To Pinion Gear Side95
Gear Contact Pattern96
Ring Gear Backlash Measurement96
Backlash Shim96
Axle Shafts Removal101
Axle Shafts Installation101
Axle Shafts - Intermediate Removal101
Axle Shafts - Intermediate Installation101
Axle Shaft Seals102
Axle Vacuum Motor102
Vacuum Control System103
Diagnosis And Testing - Vacuum Motor104
Axle Vacuum Shift Motor104
Shift Motor Housing106
Shift Motor Components106
Pinion Seal107
Axle Shaft U-Joint107
Yoke Bearing Cap107
Pinion Yoke108
Pinion Seal Installer108
Pinion Yoke Installer108
Pinion Rotation Torque108
Differential109
Pinion Shaft Nut109
Bearing Cap Reference109
Spread Differential Housing109
Differential Removal110
Pinion Mate Shaft110
Pinion Mate/Side Gear110
Pinion Mate Shaft Roll-Pin111
Differential Case111
Differential Case Bearings112
Differential Cover112
Differential Bearing Puller112
Pinion Gear/Ring Gear113
Differential Bearing Installer113
Ring Gear113
Pinion Gear114
Front Pinion Bearing Cup114
Rear Pinion Bearing Cup114
Collapsible Spacer114
Rear Pinion Bearing115
Collapsible Preload Spacer116
Tightening Pinion Nut117
Pinion Rotating Torque117
Ring Gear Bolt117
Front Axle - 248Fbi118
Front Axle - 248Fbi Description119
Adjustments123
Axle Shafts133
Axle Shafts - Intermediate133
Vacuum Motor138
Assembly138
Rear Axle - 9 1/4150
Differential Cover 9 1/4 Inch Axle152
Differential Operation - Straight Ahead Driving152
Trac-Lok Differential153
Differential Operation - On Turns153
Trac-Lok Limited Slip Differential153
Rear Axle - 248Rbi182
Rear Axle - 267Rbi213
Differential Case Bearings Removal237
Rear Axle - 286Rbi242
Axle246
Axle Bearings Removal258
Differential - Trac-Lok263
Pinion Gear/Ring Gear/Tone Ring Removal266
Brakes272
Brakes - Base Specifications273
Brakes - Base Torque Chart274
Base Brakes Special Tools275
Hydraulic/Mechanical Description275
Diagnosis And Testing - Base Brake System276
Preliminary Brake Check276
Road Testing276
Warning276
Pedal Falls Away277
Low Pedal277
Spongy Pedal277
Hard Pedal Or High Pedal Effort277
Rear Brake Grab Or Pull278
Brake Lining Contamination278
Wheel And Tire Problems278
Brake Noises278
Brake Lines279
Standard Procedure - Pressure Bleeding279
Standard Procedure - Double Inverted Flaring279
Standard Procedure - Iso Flaring279
Combination Valve Description280
Combination Valve Operation280
Pressure Differential Switch280
Metering Valve280
Disc Brake Calipers281
Pressure281
Rear Caliper281
Caliper282
C-Clamp One Piston282
Protect Caliper Piston282
Piston Dust Boot Removal283
Piston Seal283
Bushings And Boot Seals283
Cleaning283
Inspection283
Polishing Piston Bore284
Caliper Piston Installation284
Seating Dust Boot284
Fluid285
Diagnosis And Testing - Brake Fluid Contamination285
Standard Procedure - Brake Fluid Level285
Rear Caliper Install285
Fluid Reservoir Removal286
Fluid Reservoir Installation286
Loosening Reservoir286
Brake Fluid Contamination286
Pedal Description287
Pedal Operation287
Pedal Removal287
Grommet Removal287
Power Brake Booster288
Diagnosis And Testing - Hydraulic Booster288
Noises288
Clunk-Chatter-Clicking288
Seal Leakage289
Hydraulic Booster Diagnosis Chart289
Hydraulic Booster Seals289
Standard Procedure - Bleeding290
Master Cylinder And Booster290
Booster Push Rod290
Hydraulic Booster290
Diagnosis And Testing—Disc Brake Rotor291
Rotor Minimum Thickness291
Rotor Runout291
Rotor Thickness Variation291
Checking Rotor Runout And Thickness Variation292
Measuring Rotor Thickness292
Rotor / Hub Removal292
Caliper Adapter Assembly292
Rotor To Hub293
Brake Pads/Shoes294
Rotor / Pads/ Caliper294
Inboard Brake Shoe294
Outboard Brake Shoe294
Top Anti-Rattle Spring295
Bottom Anti-Rattle Spring295
Removal - Rear Brake Shoes-11 Inch296
Master Cylinder Description300
Master Cylinder/Power Booster300
Master Cylinder Bleeding301
Wheel Cylinders302
Support Plate303
Drum303
Wheel Cylinder Mounting Surface303
Diagnosis And Testing - Brake Drum304
Brake Drum Runout304
Standard Procedure - Brake Drum Machining304
Adjustment - Rear Brake Drum305
Adjustment With Brake Gauge305
Shoe Contact Surfaces305
Adjusting Gauge On Drum305
Parking Brake306
Adjustment With Adjusting Tool306
Parking Brake Pedal Assembly307
Cables308
Removal - Front Parking Brake Cable308
Lock Out Parking Cable308
Disengagement Of Cable308
Removal - Rear Park Brake Cables309
Installation - Rear Park Brake Cable309
Cables And Tensioner309
Installation - Front Parking Brake Cable310
Cable Tensioner311
Release311
Adjustment Mark311
Shoes312
Park Brake Release Handle Remove/Install312
Installation - Rear Drum In Hat Park Brake Shoes - 2500/3500313
Shoes Removal313
Shoe Assembly313
Clutch314
Diagnostic And Testing - Clutch315
Clutch Contamination315
Engine Powerflow315
Clutch Operation315
Clutch Components And Inspection316
Improper Release Or Clutch Engagement317
Clutch Misalignment317
Clutch Flywheel Runout317
Clutch Cover And Disc Runout317
Clutch Diagnosis Chart318
Specifications - Clutch320
Clutch Disc320
Clutch Disc-V6 Engine321
Clutch Disc-V8 Engine321
Clutch Disc-V10/Diesel Engines321
Supporting Engine With Jack Stand And Wood Block—Diesel Model Shown322
Marking Clutch Cover Position322
Clutch Cover Bolt Loosening/Tightening Pattern322
Clutch Disc And Cover Alignment/Installation322
Clutch Release Component Lubrication Points323
Input Shaft Lubrication Points323
Release Fork And Bearing Spring Clip Position323
Clutch Housing323
Diagnosis And Testing - Clutch Housing324
Measuring Clutch Housing Bore Runout324
Dial Indicator Mounting Stud Or Rod324
Housing Bore Measurement Points And Sample Readings325
Housing Bore Alignment Dowel Selection325
Measuring Clutch Housing Face Runout325
Housing Face Measurement Points And Sample Readings326
Housing Face Alignment Shims326
Clutch Release Bearing327
Transmission/Clutch Housing - Nv4500327
Clutch Housing Installation - Nv4500327
Clutch Release Components328
Pressure Plate Description328
Flywheel329
Pressure Plate - V6/V8 Gas Engine329
Pressure Plate - V10/Diesel Engine329
Diagnosis And Testing - Flywheel330
Pilot Bearing330
Clutch Pedal331
Typical Method Of Installing Pilot Bearing331
Clutch Cylinder Push Rod Attachment331
Linkage332
Knee Bolster Removal—Typical332
Clutch/Brake Pedal Mounting332
Clutch Hydraulic Linkage333
Clutch Slave Cylinder334
Clutch Pedal Position (Interlock) Switch335
Cooling336
Description—Cooling System Flow - 3.9L/5.2L/5.9L Engine336
Description—Cooling System Flow - 5.9L Diesel336
Description—Hose Clamps337
Operation—Hose Clamps337
Engine Cooling System Flow337
Cooling System Components 5.9L Diesel Engine337
Cooling System Circulation—Diesel Engine338
Operation—Cooling System339
Diagnosis And Testing - Preliminary Checks339
Engine Cooling System Overheating339
Diagnosis And Testing—On-Board Diagnostics (Obd)339
Diagnosis And Testing—Cooling System Leaks340
Erasing Trouble Codes340
Ultraviolet Light Method340
Pressure Tester Method340
Internal Leakage Inspection341
Combustion Leakage Test—Without Pressure Tester341
Diagnosis And Testing - Cooling System Gas Engine342
Standard Procedure—Draining Cooling System 5.9L Diesel Engine350
Standard Procedure—Refilling Cooling System 5.9L Diesel Engine350
Standard Procedure—Adding Additional Coolant351
Standard Procedure—Coolant Level Check351
Standard Procedure—Cooling System Cleaning/Reverse Flushing351
Reverse Flushing351
Reverse Flushing Engine352
Chemical Cleaning352
Standard Procedure—Coolant Selection-Additives352
Accessory Drive354
Belt Tensioners - 3.9L/5.2L/ 5.9L354
Belt Tensioners - 8.0L355
Tensioner Indexing Marks And Mounting Nut355
Belt Tensioner—8.0L V-10 Engines356
Indexing Marks—8.0L Engines Typical356
Belt Tensioner357
Tensioner Dowel Pin357
Belt Tensioners - 5.9L Diesel358
Tensioner Dowel Hole358
Belt358
Diagnosis And Testing—Accessory Drive Belt359
Visual Diagnosis359
Noise Diagnosis359
Automatic Belt Tensioner Diesel Engine—Typical359
Accessory Drive Belt Diagnosis Chart360
Belt Tensioner—5.2L/5.9L Gas Engines361
Belt Routing—5.2L/5.9L Engines With A/C362
Belt Routing—5.2L/5.9L Engines Without A/C362
Belt Wear Patterns363
Belt Routing—With A/C365
Diagnosis And Testing—Vacuum Pump Output370
Diagnosing Low Vacuum Output Condition370
Diesel Vacuum & Power Steering Pump Assembly370
Vacuum Pump Oil Feed Line371
Vacuum Pump Mounting371
Pump Assembly Upper Mounting Bolt371
Adapter To Power Steering Pump Nuts372
Steering Pump, Vacuum Pump And Adapter372
Pump Mounting Flange Gasket372
Engine374
Coolant375
Ethylene-Glycol Mixtures375
Propylene-Glycol Mixtures375
Coolant Reserve/Overflow Tank376
Coolant Recovery Container - 3.9L/5.2L/ 5.9L/5.9L Diesel Description376
Coolant Recovery Container - 8.0L377
Radiator Fan - 3.9L/5.2L/5.9L/8.0L377
Using Special Tool 6958 Spanner Wrench378
Fan Blade/Viscous Fan Drive—Gas Engines378
Radiator Fan - 5.9L Diesel379
Fan Blade/Viscous Fan Drive379
Engine Block Heater - 3.9L/5.2L/5.9L Description380
Engine Block Heater - 8.0L381
Engine Block Heater - 5.9L Diesel382
Engine Coolant Temp Sensor - 3.9L/5.2L/ 5.9L Description383
Block Heater—Diesel Engine383
Engine Coolant Temperature383
Engine Coolant Thermostat - 3.9L/5.2L/5.9L384
Diagnosis And Testing—Thermostat384
Thermostat—5.2L And 5.9L Gas Powered Engines384
Generator Support Bracket385
Automatic Belt Tensioner385
Spring Clamp Size Location385
Thermostat—3.9L And 5.9L Engines386
Thermostat Position—5.2L And 5.9L Engines386
Belt Routing—5.2L And 5.9L Engines386
Engine Coolant Thermostat - 8.0L387
Thermostat Seal—8.0L V-10 Engine388
Support Rod—8.0L V-10 Engine388
Thermostat—8.0L V-10 Engine388
Engine Coolant Thermostat - 5.9L Diesel389
Engine Coolant Thermostat - 5.9L390
Fan Drive Viscous Clutch391
Diagnosis And Testing—Viscous Fan Drive391
Fan Drive Viscous Clutch - 5.9L Diesel392
Radiator - 3.9L/5.2L/5.9L394
Diagnosis And Testing—Radiator394
Coolant Flow394
Coolant Recovery Bottle395
Fan Shroud Mounting—3.9L/5.2L/5.9L395
Typical Radiator Mounting395
Radiator - 8.0L396
Cross Flow Radiator—Typical396
Fan Shroud Mounting—8.0L Engine397
Radiator - 5.9L Diesel398
Coolant Recovery Bottle—Typical399
Fan Shroud Mounting—5.9L Diesel Engine399
Radiator Pressure Cap400
Radiator Pressure Cap And Filler Neck400
Diagnosis And Testing—Radiator Cap-To-Filler Neck Seal401
Diagnosis And Testing—Radiator Cap401
Pressure Testing Radiator Cap401
Water Pump - 3.9L/5.2L/5.9L402
Water Pump Location402
Typical Fan Shroud Mounting403
Using Special Tool 6958 Spanner Wrench And Adapter Pins 8346403
Fan Blade And Viscous Fan Drive404
Belt Tensioner—3.9L V-6 Or 5.2/5.9L V-8404
Coolant Return Tube—3.9L V-6 Or 5.2/5.9L V-8 Engines404
Water Pump Bolts—3.9L V-6 Or 5.2/5.9L V-8 Gas Engines—Typical404
Water Pump - 8.0L405
Belt Tensioner—8.0L V-10 Engine406
Water Pump Bolts—8.0L V-10407
Water Pump O-Ring Seal—8.0L V-10407
Heater Hose Fitting Position408
Water Pump - 5.9L Diesel408
Water Pump Inlet Tube - 3.9L/5.2L/5.9L409
Water Pump Removal/Installation409
Pump O-Ring Seal409
Generator—A/C Compressor Mounting Bracket—Typical409
Idler Pulley—3.9L V-6 Or 5.2/5.9L V-8 Ldc-Gas Engines410
Belt Tensioner—5.9L Hdc-Gas Engine410
Coolant Return411
Coolant Return Tube—5.9L Hdc-Gas Engine411
Bracket Bolts—3.9L V-6 Or 5.2/5.9L V-8 Ldc-Gas411
Bracket Bolts—5.9L Hdc-Gas Engine411
Removal—Water Pump Bypass Hose Without Air Conditioning412
Installation—Water Pump Bypass Hose With Air Conditioning412
Water Pump Bypass Hose—Typical412
Tensioner Dowel Pin—5.9L Hdc-Gas Engine412
Installation—Water Pump Bypass Hose Without Air Conditioning413
Tensioner Mounting413
Transmission414
Trans Cooler - 3.9L/5.2L/5.9L414
Automatic Transmission Oil415
Trans Cooler - 8.0L417
Transmission Oil Cooler—3.9/5.2/5.9L Engines417
Transmission Oil Cooler Thermostat Removal/Installation417
Automatic Transmission Oil Cooler418
Transmission Oil Cooler—8.0L Engine419
Trans Cooler - 5.9L Diesel420
Transmission Water-To-Oil Cooler420
Auxiliary Transmission Oil Cooler420
Removal—Air To Oil Cooler422
Removal—Water To Oil Cooler422
Installation—Air To Oil Cooler423
Transmission Water-To- Oil Cooler—Diesel423
Audio424
Central Timer Module425
Diagnosis And Testing - Audio425
Antenna Body & Cable427
Antenna Nut Wrench C-4816427
Diagnosis And Testing - Antenna428
Antenna Tests429
Antenna Coaxial Cable Connector429
Antenna Mounting430
Antenna Mast Remove/Install - Typical430
Antenna Cap Nut Remove/Install - Typical430
Radio Choke Relay431
Diagnosis And Testing - Radio Choke Relay431
Instrument Panel Antenna Cable432
Filter, Choke, And Speaker Relay Remove/Install432
Antenna Cable Routing432
Radio433
Diagnosis And Testing - Radio433
Radio Receiver Remove/Install434
Radio Noise Suppression Components435
Diagnosis And Testing - Radio Noise Suppression Components435
Radio Receiver Connections435
Engine-To-Body Ground Strap436
Engine-To-Body Ground Strap Remove/Install - V6 & V8 Engine436
Cab-To- Bed Ground Strap437
Heater Core Ground Strap Removal437
Engine-To-Body Ground Strap Remove/Install - V10 Engine437
Cab-To-Bed Ground Strap Remove/Install437
Remote Switches438
Heater Core Ground Strap Remove/Install438
Remote Radio Switches438
Diagnosis And Testing - Remote Switches439
Remote Radio Switch Test439
Speaker440
Remote Radio Switches Remove/Install440
Diagnosis And Testing - Speaker441
A-Pillar Tweeter Speaker442
A-Pillar Tweeter Remove/Install442
Front Door Speaker443
Front Door Speaker Remove/Install443
Rear Speaker Remove/Install - Standard Cab443
Rear Cab Side Panel Speaker Removal443
Rear Door Speaker444
Rear Speaker Remove/Install - Club Cab444
Rear Door Speaker Remove/Install - Quad Cab444
Chime/Buzzer446
Chime Warning System446
Fasten Seat Belt Warning446
Diagnosis And Testing - Chime Warning System447
Head/Park Lights-On Warning447
Key-In-Ignition Warning447
Warning Chime Support447
Chime Warning System Diagnosis448
Electronic Control Modules452
Body Control/Central Timer Module452
Central Timer Module (Base)452
Central Timer Module (High-Line/Premium)452
Hard Wired Inputs454
Hard Wired Outputs454
Diagnosis And Testing - Central Timer Module455
Messaging455
Central Timer Module (Base) Remove/Install456
Communication457
Description - Ccd Data Bus457
Operation - Ccd Data Bus458
Bus (+) And Bus (–) Circuits458
Ccd Chips458
Bus Bias And Termination459
Bus Messaging459
Bus Biasing459
Bus Message Coding460
Priority460
Bus Termination460
Message Identification461
Transmission Verification461
Message Arbitration461
Voltage Cycling To Correspond To Message461
Controller Antilock Brake462
Diagnosis And Testing - Ccd Data Bus462
Ccd Bus Failure462
Bus Failure Visual Symptom Diagnosis462
Data Link Connector463
Description - Data Link Connector463
Operation - Data Link Connector463
Harness Connector Locks463
Engine Control Module464
Engine Control Module (Ecm) Location464
Fuel Injection Pump Control Module (Fpcm) Location464
Powertrain Control Module465
Engine Control Module (Ecm) Location And Mounting465
Description - Modes Of Operation465
Ignition Switch (Key-On) Mode466
Engine Start-Up Mode466
Engine Warm-Up Mode466
Pcm Location466
Cruise Mode467
Idle Mode467
Acceleration Mode467
Deceleration Mode467
Description - 5 Volt Supplies468
Description - Ignition Circuit Sense468
Description - Power Grounds468
Description - Sensor Return468
Operation - Diesel469
Operation - 5 Volt Supplies470
Operation - Ignition Circuit Sense470
Pcm Location And Mounting470
Engine Systems472
Battery System472
Diagnosis And Testing - Battery System473
Battery System Description473
Battery System Diagnosis474
Abnormal Battery Discharging475
Clean Battery Cable Terminal Clamp - Typical476
Clean Battery - Typical476
Clean Battery Terminal Post - Typical477
Battery Description477
Diagnosis And Testing - Battery478
Low-Maintenance Battery - Typical478
Standard Procedure - Checking Battery Electrolyte Level479
Battery Caps - Export Battery479
Standard Procedure - Battery Charging480
Hook Inside Battery Cap Holes - Export Battery480
Charging A Completely Discharged Battery481
Charging Time Required481
Charge Rate Table481
Voltmeter481
Standard Procedure - Built-In Indicator Test482
Built-In Indicator482
Standard Procedure - Hydrometer Test483
Built-In Indicator Sight Glass Chart483
Standard Procedure - Open-Circuit Voltage Test484
Hydrometer484
Standard Procedure - Load Test485
Testing Open-Circuit Voltage - Typical485
Volt-Ammeter-Load Tester - Typical485
Open Circuit Voltage Table485
Standard Procedure - Ignition-Off Draw Test486
Volt-Ammeter-Load486
Remove Surface Charge From Battery486
Load Test Temperature Table486
Electronic Module Ignition-Off Draw (Iod) Table487
Remove Battery Cable Terminal Clamp - Typical488
Battery Cables - Typical488
Battery Holddown489
Battery Cable490
Left Battery Hold Downs Remove/Install490
Diagnosis & Testing - Battery Cables491
Voltage Drop Test492
Fuel Shutdown Solenoid Connector493
Test Battery Negative Connection Resistance - Typical493
Test Battery Positive Connection Resistance493
Test Battery Positive Cable Resistance493
Negative Cable Removal - Gasoline494
Positive Cable Removal - Gasoline494
Positive Cable Installation - Gasoline494
Test Ground Circuit494
Negative Cable Installation - Gasoline495
Battery Tray495
Battery Tray - Typical495
Left Battery Tray Remove/Install - Typical For Right Battery Tray496
Diagnosis And Testing - Charging498
Charging Description498
Generator Ratings499
Specifications - Torque - Generator/Charging System499
Battery Temperature Sensor500
Battery Temperature Sensor Location500
Generator Description500
Remove/Install Generator—3.9L/5.2L/5.9L501
Remove/Install Generator—8.0L Engine501
Remove/Install Generator—Diesel Engine502
Generator Connectors—Typical Bosch502
Generator Connectors—Typical Denso502
Voltage Regulator Description502
Starting503
Diagnosis And Testing - Starting System504
Testing505
Cold Cranking Test505
Starting System Diagnosis505
Feed Circuit Test506
Volts-Amps Tester Connections - Typical506
Test Battery Positive Cable507
Test Starter Ground - Typical508
Control Circuit Testing508
Specifications Starting System509
Specifications - Torque - Starting System509
Engine Starter Motor Description510
Diagnosis And Testing - Starter Motor510
Starter Motor Solenoid510
Continuity Test Between Solenoid Terminaland Solenoid Case - Typical511
Starter Motor Remove/Install - 3.9L/5.2L/5.9L Gasoline Engine511
Starter Motor Wire Harness Remove/Install512
Engine Starter Motor Relay513
Diagnosis And Testing - Starter Relay513
Relay Circuit Test514
Starter Relay514
Power Distribution Center514
Heated Systems516
Heated Mirrors516
Description - Heated Mirror System516
Operation - Heated Mirror System517
Diagnosis And Testing - Heated Mirror System517
Mirror Switch518
Diagnosis And Testing - Heated Mirror Switch518
Heated Mirror Switch518
Heated Mirror Grid519
Diagnosis And Testing - Heated Mirror Grid519
Heated Seat System520
Heated Seat System Switches520
Diagnosis & Testing - Heated Seat System521
Heated Seat System Self-Diagnosis521
Driver Seat Heater Switch522
Heated Seat Switches522
Diagnosis & Testing - Heated Seat Switch523
Heated Seat Switch And Bezel Remove/Install524
Heated Seat Switch Continuity524
Heated Seat Cushion Trim Cover525
Heated Seat Element Description525
Diagnosis & Testing - Heated Seat Element And Sensor526
Heated Seat Relay526
Heated Seat Sensor526
Diagnosis & Testing - Heated Seat Relay527
Relay Test527
Passenger Seat Heater Switch528
Heated Seat528
Horn532
Diagnosis And Testing - Horn533
Horns Remove/Install533
Horn Description533
Horn Relay534
Diagnosis And Testing - Horn Relay534
Horn Switch535
Driver Side Airbag Module Trim Cover And Horn Switch536
Ignition Control538
Specifications - Torque - Ignition539
Spark Plug Cable Order539
Engine Firing Order539
Automatic Shut Down Relay540
Spark Plug Cable Resistance540
Ignition Coil Resistance—3.9L/5.2L/5.9L Engines540
Operation - Asd Sense - Pcm Input540
Asd And Fuel Pump Relay Terminals541
Camshaft Position Sensor542
Power Distribution Center (Pdc)542
Camshaft Position Sensor (Cmp) Location542
Cmp Sensor Location—8.0L V-10 Engine542
Camshaft Position Sensor (Cmp)543
Notches At Rear Of Camshaft Drive Gear543
Cmp Sensor Operation—8.0L V-10 Engine544
Cmp Location - Diesel544
Cmp R/I - Diesel544
Replacing Old Sensor With Original545
Replacing With New Sensor545
Camshaft Position Sensor—Typical545
Cmp Location - 8.0L545
Camshaft Sensor O-Ring—8.0L546
Sensor Operation—8.0L V-10 Engine546
Distributor547
Replacing With A New Sensor547
Sensor Depth Dimensions547
Distributor And Camshaft Position Sensor548
Damper-To-Cover Alignment Marks—Typical548
Distributor Cap549
Diagnosis And Testing - Distributor Cap549
Checking Distributor Position549
Rotor Alignment Mark549
Distributor Rotor550
Ignition Coil550
Diagnosis And Testing - Distributor Rotor550
Cap Inspection—External—Typical550
Ignition Coil Packs—8.0L V-10 Engine551
Ignition Coil—3.9L V-6 Or 5.2/5.9L V-8 Ldc-Gas Engines551
Ignition Coil—5.9L V-8 Hdc-Gas Engine552
Spark Plug553
Diagnosis And Testing - Spark Plug Conditions553
Spark Plug Cable Order—8.0L V-10 Engine553
Normal Operation And Cold (Carbon) Fouling553
Cold Fouling/Carbon Fouling554
Wet Fouling Or Gas Fouling554
Oil Or Ash Encrusted554
Scavenger Deposits554
Chipped Electrode Insulator555
Preignition Damage555
Spark Plug Overheating555
Heat Shields—3.9L/5.2L/5.9L Engines556
Spark Plug Cable Description556
Spark Plug Cables556
Engine Firing Order—5.2L/5.9L V-8 Engines558
Engine Firing Order—3.9L V-6 Engine558
Instrument Cluster560
Instrument Cluster Components561
Instrument Cluster Description561
Instrument Cluster Operation562
Gauges563
Vacuum-Fluorescent Display563
Indicators564
Cluster Illumination564
Diagnosis And Testing - Instrument Cluster565
Chime Warning Requests565
Actuator Test566
Instrument Cluster Failure Message567
Chime Warning Request Diagnosis568
Cluster Illumination Diagnosis568
Instrument Cluster Remove/Install569
Gear Selector Indicator570
Cluster Bulb570
Gear Selector Indicator Remove/Install570
Gear Selector Indicator Cable Remove/Install570
Cluster Lens And Hood571
Cluster Housing Rear Cover571
Cluster Housing571
Cluster Bulb Remove/Install571
Abs Indicator573
Airbag Indicator574
Brake/Park Brake Indicator575
Diagnosis And Testing - Brake Indicator575
Check Gauges Indicator576
Cruise Indicator577
Engine Oil Pressure Low Message577
Cruise Lamp-On Message577
Engine Temperature Gauge Description578
Engine Temperature Message578
Engine Temperature Low Message578
Engine Temperature High Message578
Fuel Gauge579
High Beam Indicator Description580
Diagnosis And Testing - High Beam Indicator581
Indicator Does Not Illuminate With High Beams Selected581
Indicator Stays Illuminated With High Beams Not Selected581
Low Fuel Indicator582
Bulb Test582
Malfunction Indicator Lamp (Mil)583
Odometer583
Oil Pressure Gauge584
Odometer/Trip Odometer Display Toggling584
Trip Odometer Reset584
Engine Oil Pressure Message585
Engine Oil Pressure High Message585
Overdrive Off Indicator Description586
Seatbelt Indicator586
Service Reminder Indicator587
Seatbelt Reminder Function587
Driver Side Front Seatbelt Not Buckled587
Shift Indicator (Transfer Case)588
Diagnosis And Testing - Four-Wheel Drive Indicator588
Indicator Does Not Illuminate With Four-Wheel Drive Mode Selected588
Speedometer589
Tachometer589
Indicator Stays Illuminated With Four-Wheel Drive Mode Not Selected589
Transmission Overtemp Indicator590
Diagnosis And Testing - Turn Signal Indicators591
Turn Signal Indicators Description591
Upshift Indicator592
Voltage Gauge592
Wait-To-Start Indicator593
Washer Fluid Indicator Description594
Diagnosis And Testing - Washer Fluid Indicator595
Water-In-Fuel Indicator595
Indicator Does Not Illuminate With Washer Reservoir Empty595
Indicator Stays Illuminated With Washer Reservoir Full595
Lamps598
Lamps/Lighting - Exterior598
Description - Turn Signal & Hazard Warning System599
Operation - Turn Signal & Hazard Warning System599
Diagnosis And Testing - Turn Signal & Hazard Warning System600
Headlamp Alignment601
Brake Lamp Switch601
Diagnosis And Testing - Brake Lamp Switch602
Switch Circuit Identification602
Switch Continuity Test602
Brake Lamp Switch Terminal Identification602
Clearance Lamp603
Center High Mounted Stop Lamp Unit Removal603
Combination Flasher604
Roof Clearance Lamps604
Combination Flasher - Typical604
Junction Block605
Daytime Running Lamp Module606
Fog Lamp606
Diagnosis And Testing - Fog Lamp606
Daytime Running Lamp Module (Drlm)606
Fog Lamp Unit608
Diagnosis And Testing - Headlamp610
Fog Lamp Alignment610
Headlamp Description610
Headlamp Relay613
Headlamp Bulb613
Headlamp Switch613
Diagnosis And Testing - Headlamp Relay614
Diagnosis And Testing - Headlamp Switch615
Headlamp Switch Removal616
Headlamp Unit617
Headlamp-Sport617
Lamp Alignment Screen Preparation618
Vehicle Preparation For Headlamp Alignment618
License Plate Lamp Unit619
Marker Lamp619
Headlamp Adjustment619
Multi-Function Switch620
Rear Identification Lamps620
Continuous Wipe Modes621
Hazard Warning Control621
Headlamp Beam Selection621
Headlamp Optical Horn621
Diagnosis And Testing - Multi-Function Switch622
Multi-Function Switch Tests623
Steering Column Shrouds Remove/Install624
Outboard Identification Lamp625
Multi-Function Switch Connector625
Park/Turn Signal Lamp Unit626
Tail Lamp626
Chassis Cab626
Tail Lamp Unit627
Turn Signal Cancel Cam627
Pickup627
Underhood Lamp628
Underhood Lamp Lens628
Underhood Lamp Unit629
Underhood Lamp Bulb629
Lamps/Lighting - Interior630
Dome Lamp630
Door Ajar Switch631
Diagnosis And Testing - Door Ajar Switch631
Dome Lamp Lens631
Glove Box Lamp And Switch632
Door Ajar Switch Remove/Install632
Glove Box Lamp And Switch Remove/Install632
Reading Lamp633
Overhead Console Reading Lamp Bulb Removal633
Vanity Lamp634
Message Systems636
Overhead Console636
Garage Door Opener Storage Bin636
Sunglass Storage Bin638
Compass638
Thermometer638
Standard Procedure - Compass Calibration639
Standard Procedure - Compass Variation Adjustment639
Zone Method639
Direct Method639
Standard Procedure - Compass Demagnetizing640
Variance Settings640
Roof Demagnetizing Pattern641
Overhead Console Latch Tabs641
Overhead Console Remove/Install641
Garage Door Opener Storage Bin Removal642
Sunglass Storage Bin Removal642
Compass Mini-Trip Lens Removal642
Compass/Mini-Trip Computer643
Mini-Trip Computer Lens643
Diagnosis & Testing - Compass Mini-Trip Computer645
Self-Diagnostic Test645
Ambient Temp Sensor646
Compass Mini-Trip Computer646
Diagnosis & Testing - Ambient Temperature Sensor647
Sensor Test647
Sensor Circuit Test647
Ambient Temperature Sensor Remove/Install647
Power Systems650
Power Locks650
Description - Power Lock System650
Description - Remote Keyless Entry System651
Operation - Power Lock System652
Operation - Remote Keyless Entry System652
Door Lock Inhibit652
Enhanced Accident Response652
Diagnosis And Testing - Power Lock System653
Diagnosis And Testing - Power Lock & Remote Keyless Entry System653
Preliminary Tests653
Door Cylinder Lock Switch654
Diagnosis & Testing - Door Cylinder Lock Switch654
Power Lock Motor655
Remote Keyless Entry Transmitter656
Diagnosis And Testing - Power Lock Motor656
Diagnosis And Testing - Remote Keyless Entry Transmitter656
Power Lock Switch657
Standard Procedure - Rke Transmitter Programming657
Diagnosis And Testing - Power Lock Switch657
Power Lock Switch Continuity - Driver Side658
Power Lock Switch Continuity - Passenger Side658
Driver Side Lock Switch658
Passenger Side Lock Switch658
Power Mirrors659
Automatic Day / Night Mirror659
Outside Rear View Mirror659
Diagnosis And Testing - Automatic Day/Night Mirror660
Power Mirror Switch661
Automatic Day/Night Mirror Remove661
Power Mirror Switch Remove/Install661
Sideview Mirror662
Diagnosis And Testing - Sideview Mirror662
Power Mirror Switch Continuity663
Power Mirror Test663
Power Seat System664
Diagnosis & Testing - Power Seat System664
Driver Power Seat Switch665
Diagnosis & Testing - Driver Power Seat Switch665
Seat Switches And Bezel - Standard Cab665
Testing Driver Power Seat Switch665
Lumbar Control Switch666
Power Seat Switch Connector Remove666
Lumbar Motor667
Diagnosis & Testing - Power Lumbar Adjuster667
Passenger Power Seat Switch668
Diagnosis & Testing - Passenger Power Seat Switch668
Testing Passenger Power Seat Switch668
Recliner Motor669
Power Seat Switch Remove/Install669
Power Seat Track670
Diagnosis & Testing - Power Seat Recliner670
Diagnosis & Testing - Power Seat Track670
Power Windows672
Diagnosis And Testing - Power Windows672
One Window Inoperative672
Power Window Switch673
Power Window Switch Continuity - Driver Side674
Power Window Switch Continuity - Passenger Side674
Power Window And Lock Switch And Bezel Unit Remove/Install674
Window Motor675
Diagnosis And Testing - Window Motor675
And Location Views For The Various Wire Harness Con675
Restraints676
Srs Logo677
Diagnosis And Testing - Airbag System679
Standard Procedure - Handling Non-Deployed Airbags679
Standard Procedure - Service After An Airbag Deployment679
Airbag Storage679
Standard Procedure - Verification Test680
Vacuum Heater And A/C Outlets - Typical680
16-Way Data Link Connector - Typical680
Special Tools - Airbag System681
Airbag Control Module681
Airbag Control Module Trim Cover Remove/Install682
Airbag Control Module Remove/Install682
Child Tether684
Child Tether Anchor684
Clockspring685
Standard Procedure - Clockspring Centering686
Clockspring Auto-Locking Tabs686
Driver Airbag689
Driver Airbag Remove/Install690
Driver Airbag Trim Cover Retainer Nuts Remove/Install691
Driver Airbag Trim Cover Retainers691
Driver Airbag Trim Cover Remove/Install691
Driver Airbag Trim Cover Locking Blocks Engaged692
Front Seat Belt & Retractor693
Removal - Club/Quad Cab694
Installation - Standard Cab694
Seat Belt Retractor694
Installation - Club/Quad Cab695
Front Seat Belt Buckle Removal695
Passenger Airbag696
Passenger Airbag Connector697
Passenger Airbag Remove/Install697
Passenger Airbag Door Disengage697
Passenger Airbag On/Off Switch Description698
Passenger Airbag On/Off Switch Connectors700
Passenger Airbag On/Off Switch Remove/Install700
Passenger Airbag On/Off Switch Face Plate Remove/Install700
Rear Seat Belt & Retractor701
Rear Seat Belt & Retractor - Typical701
Rear Seat Belt Buckle Remove/Install702
Seat Belt Switch703
Diagnosis And Testing - Seat Belt Switch703
Seat Belt Turning Loop Adjuster704
Turning Loop Height Adjuster Knob705
Speed Control706
Description - Speed Control System706
Description - Vehicle Speed Input706
Gas Engines And/Or Diesel With Automatic Trans706
Operation - Speed Control System707
Diagnosis And Testing - Vacuum Supply707
Diagnosis And Testing - Road Test708
Torque - Speed Control System709
Removal - Gas Engines709
Removal - Diesel With Auto. Trans709
Installation - Gas Engines709
Speed Control Servo710
Servo Mounting At Battery Tray712
Servo Cable Clip Remove/Install—Typical712
Battery Heat Shield712
Removal - Diesel With Auto. Trans.713
Forward Battery Tray Nuts713
Battery Tray Mounting713
Battery Holddown Bolts713
Battery Tray Lower Mounting Nuts714
Battery Tray Upper Mounting Bolts/Nuts714
Cable/Lever/Throttle Linkage Cover714
Servo Cable At Throttle Lever715
Servo Location—Removal/Installation715
Installation - Diesel With Auto. Trans.716
Switch Description717
Vacuum Reservoir718
Speed Control Switches718
Cowel Grille Panel Weather-Strip719
Plastic Anchor Screws Remove/Install719
Vacuum Reservoir Remove/Install719
Vehicle Theft Security720
Diagnosis And Testing - Vehicle Theft Security System722
Vtss Indicator722
Diagnosis And Testing - Vtss Indicator722
Wipers/Washers724
Washer Fluid Level Switch725
Washer Nozzles725
Washer Pump/Motor725
Washer Reservoir725
Diagnosis And Testing - Wiper & Washer System726
Washer System728
Cleaning - Wiper & Washer System729
Inspection - Wiper & Washer System729
Wiper Blade Inspection730
Washer Hoses/Tubes731
Washer Nozzle732
Wiper Arm734
Wiper Arm Remove/Install735
Wiper Arm Installation735
Wiper Blade Description735
Wiper Blade Remove/Install - Typical736
Wiper Module Remove/Install737
Wiper Module Description737
Wiper Module Electrical Connections738
Wiper Relay Description738
Diagnosis And Testing - Wiper Relay739
Wiring742
8W-01 Wiring Diagram Information744
Description - How To Use Wiring Diagrams744
Symbols744
Diagnosis And Testing - Wiring Harness748
Troubleshooting Tools748
Intermittent And Poor Connections749
Troubleshooting Wiring Problems749
Standard Procedure - Testing For Voltage Potential749
Standard Procedure - Testing For Continuity749
Standard Procedure - Testing For A Voltage Drop750
Special Tools - Wiring/Terminal751
Connector - Augat751
Connector - Molex752
Connector - Thomas And Betts752
Removing Wire Terminal753
Single Lock Tab753
Diode Identification753
Diode Removal753
Terminal754
Connector Locking Wedge Tab754
Terminal Removal754
Terminal Removal Using Special Tool754
Standard Procedure - Wire Splicing755
Splice Clip755
Heat Shrink Tubing755
8W-02 Component Index756
8W-10 Power Distribution758
8W-12 Junction Block786
8W-15 Ground Distribution808
8W-18 Bus Communications826
8W-20 Charging System830
8W-21 Starting System834
8W-30 Fuel/Ignition System838
8W-31 Transmission Control System880
8W-33 Vehicle Speed Control886
8W-34 Rear Wheel Antilock Brakes890
8W-35 All Wheel Antilock Brakes894
8W-39 Vehicle Theft Security System898
8W-40 Instrument Cluster902
8W-41 Horn/Cigar Lighter/Power Outlet910
8W-42 Air Conditioning-Heater914
8W-43 Airbag System920
8W-44 Interior Lighting924
8W-45 Central Timer Module930
8W-47 Audio System940
8W-49 Overhead Console950
8W-50 Front Lighting956
8W-51 Rear Lighting970
8W-52 Turn Signals976
8W-53 Wipers980
8W-54 Trailer Tow984
8W-60 Power Windows988
8W-61 Power Door Locks990
8W-62 Power Mirrors994
8W-63 Power Seats998
8W-70 Splice Information1006
8W-80 Connector Pin-Outs1014
8W-90 Connector/Ground Locations1092
Engine Compartment (Gas )1099
Engine Compartment (Diesel Engine)1099
3.9-5.2-5.9 Liter Engine1100
8W-95 Splice Locations1124
Dash Panel (Gas Engines)1127
Dash Panel (Diesel Engine)1127
8W-97 Power Distribution1136
Cigar Lighter Outlet1137
Power Distribution Systems1137
Diagnosis & Testing - Cigar Lighter1137
Cigar Lighter And Power Outlet1138
Cigar Lighter And Power Outlet Remove/Install1138
Circuit Breaker1139
Generator Cartridge Fuse1139
Iod Fuse1139
Diagnosis & Testing - Circuit Breaker1139
Ignition-Off Draw Fuse1140
Junction Block Location1141
Junction Block Remove/Install1142
Power Distribution Center Location1142
Engine Wire Harness In-Line Connector1143
Power Outlet1144
Battery And Generator Connections To Pdc1144
Diagnosis & Testing - Power Outlet1145
Engine 3.9L1148
Diagnosis And Testing—Cylinder Compression Pressure1156
Diagnosis And Testing—Cylinder1156
Combustion Pressure Leakage1156
Cylinder Combustion Pressure Leakage Diagnosis Chart1156
Diagnosis And Testing—Rear Seal Area Leaks1157
Standard Procedure—Cylinder Bore Honing1157
Standard Procedure—Hydrostatic Lock1158
Standard Procedure—Repair Damaged Or Worn Threads1158
Standard Procedure—Form-In-Place Gaskets & Sealers1158
Form-In-Place Gasket And Sealer Application1159
Air Cleaner Element1168
Description—Cylinder Head1169
Description—Cylinder Head Cover1169
Operation—Cylinder Head1169
Operation—Cylinder Head Cover1169
Cylinder Head Bolt -Tightening Sequence1171
Cylinder Head Cover Gasket1171
Intake/Exhaust Valves & Seats1172
Standard Procedure—Valves, Guides And Springs1172
Reamer Sizes Chart1172
Measuring Valve Guide Wear1172
Refacing Valves And Valve Seats1173
Valve Face And Valve Seat Angle Chart1173
Valve Springs1174
Testing Valve Spring For Compressed Length1174
Positioning Valve With Tool C-39731174
Engine Block1175
Oil Line Plug1175
Camshaft & Bearings1176
Removal—Camshaft Bearings1176
(1) Disconnect Battery Negative Cable.1176
Installation—Camshaft Bearings1176
Camshaft Holding Tool C-35091177
Compressing Tensioner Shoe For Timing Chain Installation1177
Alignment Of Timing Marks1177
Checking Camshaft End Play1177
Connecting Rod Bearings1178
Crankshaft1178
Standard Procedure-Connecting Rod1178
Crankshaft Main Bearings1179
Sealant Application To Bearing Cap1179
Apply Sealant To Bearing Cap-To-Block Joint1179
Standard Procedure—Main Bearing Fitting1180
Crankshaft Identification Location Chart1180
Upper Main Bearing Removal And Installation With Tool C-30591180
Crankshaft Oil Seal - Front1181
Crankshaft Oil Seal - Rear1181
Placing Oil Seal On Installation Tool 66351181
Upper Seal — Crankshaft Removed1182
Upper Seal — Crankshaft Installed1182
Lower Seal1182
Distributor Bushing1184
Distributor Driveshaft Bushing Installation1184
Burnishing Distributor Bushing1184
Distributor Driveshaft Bushing Removal1184
Hydraulic Lifters (Cam In Block)1185
Diagnosis And Testing—Hydraulic Tappets1185
Oil Level1185
Tappet Noise Diagnosis1185
Piston & Connecting Rod1187
Standard Procedure—Piston Fitting1187
Piston Measurements Chart1187
Piston Rings1188
Standard Procedure—Piston Ring Fitting1188
Vibration Damper1189
Second Compression Ring Identification1189
Compression Ring Chamfer Location1189
Top Compression Ring Identification1189
Front Mount1190
Proper Ring Installation1190
Vibration Damper Assembly1190
Installing Vibration Damper1190
Rear Mount1191
Positioning Engine Front Mounts1191
Engine Rear Support Cushion Assemblies1191
Lubrication1192
Positive Displacement Oil Pump—Typical1192
Oil Lubrication System1193
Diagnosis And Testing—Engine Oil Pressure1194
Diagnosis And Testing—Engine Oil Leaks1194
Standard Procedure—Engine Oil1194
Crankcase Oil Level Inspection1194
Oil Filter1195
Oil Pan1195
Engine Oil Change1195
Oil Filter Removal—Typical1195
Oil Pressure Sensor/Switch1196
Fabrication Of Alignment Dowels1196
Position Of Dowels In Cylinder Block1196
Oil Pump1197
Oil Pressure Relief Valve1197
Checking Oil Pump Cover Flatness1197
Measuring Outer Rotor Thickness1198
Measuring Inner Rotor Thickness1198
Measuring Outer Rotor Clearance In Housing1198
Measuring Clearance Between Rotors1198
Intake Manifold1199
Measuring Clearance Over Rotors1199
Proper Installation Of Retainer Cap1199
Intake Manifold With Tightening Sequence1199
Diagnosis And Testing—Intake Manifold Leakage1200
Plenum Pan Bolt Tightening Sequence1200
Cross-Over Gaskets1201
Intake Manifold Flange Gasket Alignment1201
Intake Manifold Bolt Tightening Sequence1201
Exhaust Manifold1202
Timing Belt / Chain Cover(S)1203
Timing Belt/Chain Tensioner1204
Timing Belt/Chain And Sprockets1204
Compressing Tensioner For Chain Installation1204
Inspection—Measuring Timing Chain Stretch1205
Measuring Timing Chain Wear And Stretch1205
Engine 5.2L1206
Diagnosis And Testing-Engine Diagnosis - Introduction1208
Diagnosis And Testing—Performance1208
Diagnosis And Testing— Mechanical1210
Engine Mechanical Diagnosis Chart1210
Diagnosis And Testing—Lubrication1213
Diagnosis And Testing—Cylinder Combustion Pressure Leakage1214
Description—Cylinder Cover Gasket1226
Diagnosis And Testing—Cylinder Head Gasket Failure1226
Cylinder-To-Cylinder Leakage Test1226
Cylinder-To-Water Jacket Leakage Test1226
Cylinder Head Bolt Tightening Sequence1227
Cylinder Head Cover(S)1228
Engine 5.9L Diesel1376
Exhaust System1456
Exhaust System Gasoline Engines—Federal Emissions (Typical1457
Description—5.9L Diesel1458
Catalytic Converter With Pipes And Mini Catalytic Converters1458
Diagnosis And Testing - Gas Engine1459
Exhaust System Diagnosis Chart1459
Catalytic Converter - 3.9L/5.2L/5.9L1460
Catalytic Converter - 5.9L Heavy Duty/8.0L1461
Exhaust Pipe - 3.9L/5.2L/5.9L1462
Exhaust Pipe - 5.9L Heavyduty/8.0L1463
Exhaust Pipe - 5.9L Diesel1464
Catalytic Converter And Clamp Location 5.9L Heavy Duty1464
Catalytic Converter And Clamp Location 8.0L1464
Exhaust Pipe Removal/Installation1464
Heat Shields1465
Muffler - 3.9L/5.2L/5.9L/8.0L1465
Muffler - 5.9L Diesel1466
Tailpipe - 3.9L/5.2L/5.9L1466
Tailpipe - 5.9L Heavy Duty/8.0L1467
Tailpipe - 5.9L Diesel1467
Resonator1468
Turbocharger1468
Turbocharger Operation1469
Turbocharger Wastegate Actuator1469
Wastegate Operation1469
Turbocharger Oil Supply And Drain1470
Turbocharger Air Inlet Hose1470
Oil Supply Line And Charge Air Cooler Inlet Duct1471
Inspect Compressor Housing For Impeller Rubbing Condition1471
Charge Air Cooler And Plumbing1472
Measure Turbocharger Axial End Play1472
Measure Turbocharger Bearing Radial Clearance1472
Intake Air Circulation1472
Condenser And Transmission Auxiliary Cooler1473
Air Intake System Tubes1473
Frame & Bumpers1476
Front Fascia1477
Front Bumper Air Dam1477
Fascia Rivet1477
Fascia Gap1477
Front Lower Fascia1478
Front Fascia—Sport1478
Front Bumper1478
Fascia Adjustment Ribs1478
Front Bumper—Sport1479
Rear Bumper1480
Front Bumper & Fascia — Sport1480
Frame1481
Frame Service1481
Frame Straightening1482
Frame Repairs1482
Frame Fasteners1482
Frame Dimension1482
Cab Chassis Adapter Bracket1484
Front Tow Hook1484
Dimensions For Differing Wheelbases1484
Cab Chassis Adapter Brackets1484
Spare Tire Winch1485
Trailer Hitch1485
Transfer Case Skid Plate1486
Fuel System1488
Fuel Delivery - Gasoline1488
Description - Fuel Delivery System1489
Operation - Fuel Delivery System1489
Diagnosis And Testing - Fuel Pressure Leak Down Test1489
Standard Procedure - Fuel System Pressure Release1490
Specifications - Fuel System Pressure - Gas Engines1491
Specifications - Torque - Fuel Delivery1491
Fuel Filter/Pressure Regulator1492
Fuel Filter/Fuel Pressure Regulator1493
Filter/Regulator Location1493
Fuel Level Sending Unit / Sensor1494
Filter/Regulator Removal And Installation1494
Fuel Tube And Clamp1494
Tightening Fuel Tube Clamp1494
Diagnosis And Testing - Fuel Gauge Sending Unit1495
Fuel Gauge Sending Unit Location1495
Fuel Gauge Sending Unit Lock Tab/Tracks1495
Fuel Lines1496
Fuel Pump1496
Diagnosis And Testing - Fuel Pump Capacity Test1496
Diagnosis And Testing - Fuel Pump Pressure Test1497
Diagnosis And Testing - Fuel Pump Amperage Test1497
Fuel Pump Module1499
Fuel Tank1506
Fuel Tank Mounting1507
Inlet Filter1509
Quick Connect Fitting1509
Standard Procedures - Quick-Connect Fittings1509
Fuel Pump Inlet Filter1509
Single-Tab Type Fitting1510
Removing Pull Tab1510
Disconnecting Single-Tab Type Fitting1510
Typical Two-Tab Type Quick-Connect Fitting1511
Plastic Retainer Ring Type Fitting1511
Latch Clip1511
Rollover Valve1512
Fuel Line Disconnection Using Special Tool1512
Rollover Valve Location—Diesel Powered1512
Rollover Valve Locations1513
Fuel Injection - Gasoline1515
Specifications - Torque - Gas Fuel Injection1522
Accelerator Pedal1524
Cable Removal/Installation At Pedal1524
Crankshaft Position Sensor1525
Ckp Sensor Location1525
Fuel Pump Relay1528
Idle Air Control Motor1528
Mounting Bolts (Screws)—Iac Motor1529
Iac Motor—8.0L Engine1529
Intake Air Temperature Sensor1530
Manifold Absolute Pressure Sensor1531
Map Sensor Location1532
Map Sensor L-Shaped Rubber Fitting1532
O2 Sensor1533
Pre-Catalyst/Post Catalyst Oxygen Sensors1534
Oxygen Sensors1534
Pto Switch1535
Throttle Body1535
Sensor Electrical Connectors1535
Fuel Delivery - Diesel1541
Description - Diesel Fuel Delivery System1541
Fuel System Components1542
Diagnosis And Testing - Air In Fuel System1543
Diagnosis And Testing - Fuel Supply Restrictions1543
Low-Pressure Lines1543
Standard Procedures - Water Draining At Fuel Filter1543
Standard Procedures - Cleaning Fuel System Parts1544
Standard Procedure - Air Bleed1544
Fuel Supply Line Banjo Bolt1544
Fuel System Pressures—Diesel Engines1545
Bleeding High-Pressure Fuel Lines At Injectors1545
Fuel Filter / Water Separator1546
Water Drain Valve And Drain Hose1547
Fuel Filter/Water Separator Components1547
Water-In-Fuel Sensor1548
Fuel Filter/Water Separator Location1548
Fuel Heater1549
Diagnosis And Testing - Fuel Heater1549
Fuel Heater Location1549
Fuel Heater Relay1550
Diagnosis And Testing - Fuel Heater Relay1551
Fuel Injection Pump1552
Diagnosis And Testing—Fuel Injection Pump Timing1553
Fuel Injection Pump Location1553
Bosch Vp44 Fuel Injection Pump1553
Crankcase Vent Hose1554
Injection Pump Gear Nut/Washer1554
Pump Keyway, Keyway Arrow And Keyway Number1554
Pump Data Plate Location1554
Checking Fuel Injection Pump Gear Timing1555
Fpcm 9–Way Connector1555
Fuel Supply And Return Lines At Pump1556
Pump Shaft Nut/Washer1556
Rotating Engine With Barring Tool1556
Placing Keyway at 12 O'clock Position1557
Separating Injection Pump Gear From Pump Shaft1557
Rear/Lower Pump Bracket And Mounting Bolts1557
Injection Pump Mounting Nuts1557
Cleaning Pump Mounting Flange1558
Keyway, Keyway Arrow And Keyway Number1558
Injection Pump Installation1559
Injection Pump Data Plate Location1559
Fuel Injection Pump Data Plate1560
Fuel Injection Pump Data Plate Location1560
Description—High Pressure Fuel Lines1561
Operation—High Pressure Fuel Lines1561
Diagnosis And Testing - High-Pressure Fuel Line Leaks1561
Fuel Tank Module1565
Description - Diesel Fuel Tank1565
Fuel Transfer Pump1566
Diagnosis And Testing - Fuel Transfer Pump Pressure1567
Fuel Transfer Pump Location1567
Injection Pump Overflow Valve Location1567
Fuel Pressure Test Port Fitting (Inlet)1568
Fuel Pressure Test Port Fitting (Outlet)1568
Fuel Return And Supply Line Quick-Connect Locations1569
Overflow Valve1570
Diagnosis And Testing - Overflow Valve1571
Water In Fuel Sensor1572
Overflow Valve Location1572
Water-In-Fuel Sensor Location1572
Fuel Drain Manifold1573
Fuel Drain Manifold Passage1573
Fuel Return Line At Rear Of Cylinder Head1573
Fuel Injection - Diesel1574
Fuel System Components - Diesel1575
Diagnosis And Testing - Boost Pressure1576
Boost Pressure Test At Intake Manifold1576
Boost Pressure Test At Turbocharger1576
Accelerator Pedal Position Sensor1578
Apps Assembly Location1578
Apps Sensor Location (Rear View)1578
Fuel Injector1580
Fuel Injector Connections1581
Fuel Injector Spray Pattern1581
Fuel Injector Edge Filter1581
Diagnosis And Testing—Fuel Injector Test1582
Inspecting Injector Operation1582
Intake Air Heater1587
Air Heater Elements Location1587
Intake Manifold Air Heater Element Location1587
Intake Air Heater Relay1588
Air Intake Housing (Front View)1588
Air Intake Housing (Rear View)1588
Intake Manifold Air Heater Relays Location1588
Intake Manifold Air Heater Relays1589
Intake Manifold Air Temperature (Iat) Sensor Location1589
Map Sensor1590
Iat Sensor1590
Throttle Control Cable1591
Steering1594
Power Steering Gear & Pump1594
Diagnosis And Testing - Power Steering System1595
Steering Noise1595
Binding And Sticking1596
Insufficient Asst. Or Poor Return To Center1596
Loose Steering And Vehicle Lead1596
Diagnosis And Testing - Power Steering Flow And Pressure1597
Power Steering Analyzer Installation1597
Flow And Pressure Test1597
Pressure Test Gauge1597
Pump Specification1598
Column1599
Steering Column1599
Observe Cautions1600
Steering Coupler-Typical1601
Prndl Drive1601
Steering Column Wiring1601
Key-In Ignition Switch1602
Lock Cylinder Housing1603
Diagnosis And Testing - Ignition Switch And Key Lock Cylinder1603
Mechanical Diagnosis (Key Difficult To Rotate)1603
Ignition Switch1604
Diagnosis And Testing - Ignition Switch1604
Retaining Pin1604
Gear Shift Lever1606
Steering Wheel1606
Gear1607
Transmission And Transfer Case1636
Manual - Nv35001636
Nv3500 Manual Transmission1637
Diagnosis And Testing - Manual Transmission1638
Low Lubricant Level1638
Hard Shifting1638
Transmission Noise1638
Two Wheel Drive1639
Four Wheel Drive1639
Transmission Rear Support Brackets1639
Backup Light Switch1640
Shift Tower1640
Shift Shaft Lock Bolt1640
Loosening Bearing1640
Input Shaft Bearing Retainer1641
Input Shaft1641
Housing And Bearing Retainer Bolt1641
Front Housing1641
Shift/Fork Shafts And Reverse Idler Segment1642
Shift Shaft Lever And Bushing Roll Pin1643
Shift Socket And Roll1643
Shift Shaft Lever And Bushing1643
Shift Fork1643
Rear Housing - 2Wd1644
Reverse Idler1650
Shift Lever Assembly1650
Shift Shaft And Forks1650
Front/Rear Housings And Bearing Retainers1650
Reverse Idler Components1651
Shift Forks And Shaft1651
Countershaft Bearings And Races1652
Shift Socket1652
Output Shaft And Geartrain1652
Synchronizer1653
Output Shaft1653
Reverse Gear Synchro1654
Fifth-Reverse Synchro Assembly1654
Fifth-Reverse Synchro Hub Snap Ring1654
Fifth Gear Synchro Ring1654
Fifth Gear Bearing1655
Fifth Gear1655
First Gear1655
First Gear Synchro Ring1656
Starting 1-2 Synchro1656
Synchro Hub Snap Ring1657
Second Gear Synchro Ring1657
Two-Piece Thrust1658
Retaining Ring1658
Thrust Retainer1658
Manual - Nv45001679
Manual - Nv56001726
Automatic Transmission - 42Re1769
Overrunning Clutch Cam/Overdrive Piston Retainer1870
Torque Converter Drainback Valve1897
Transmission Temperature Sensor1897
Standard Procedure - Torque Converter Drainback Valve1897
Valve Body1898
Upper Housing Control Valve Locations1898
Shuttle And Boost Valve Locations1899
Automatic Transmission - 44Re1940
Overdrive Clutch2020
Overdrive Switch2020
Diagnosis And Testing - Overdrive Electrical Controls2021
Overdrive Off Switch2021
Overdrive Off Switch Retainer2021
Remove The Overdrive Off Switch2021
Overdrive Unit2022
Overdrive Unit Bolts2022
Transmission Speed Sensor Removal2022
Overdrive Piston2023
Overdrive Piston Thrust Bearing Removal2023
Overdrive Piston Thrust Plate Removal2023
Intermediate Shaft Spacer Location2023
Overdrive Clutch Pack2024
Overdrive Geartrain2024
Removing Overdrive Clutch Pack Retaining Ring2024
Overdrive Clutch Pack Removal2024
Access Cover And Gasket Removal2025
Releasing Bearing From Locating Ring2025
Removing Gear Case From Geartrain Assembly2025
Rear Bearing Removal2025
Direct Clutch, Hub And Spring2026
Geartrain Mounted In Shop Press2026
Direct Clutch Pack Snap-Ring Removal2026
Geartrain2027
Direct Clutch Hub Retaining Ring Removal2027
Direct Clutch Pack Removal2027
Overrunning Clutch2028
Clutch Drum Inner Retaining Ring Removal2028
Clutch Drum Outer Retaining Ring Removal2028
Gear Case And Park Lock2029
Annulus Gear Snap-Ring Removal2029
Annulus Gear Removal2029
Geartrain And Direct Clutch2030
Output Shaft Pilot Bushing2030
Annulus Gear Installation2030
Torque Converter Clutch (Tcc)2067
Torque Converter2067
Drainback Valve2067
Automatic Transmission - 46Re2112
Clutch And Band Application Chart2122
Diagnosis And Testing - Hydraulic Pressure Test2122
Pressure Test Port Locations2122
Standard Procedure - Aluminum Thread Repair2137
Automatic Transmission - 47Re2283
Accumulator2342
Transfer Case - Nv231Hd2455
Transfer Case - Nv241Ld2490
Transfer Case - Nv241Hd2525
Extension Housing Bushing And Seal2556
Front Output Shaft Seal2557
Front Output Seal Installation2558
Checking Front Output Seal Installation Depth2558
Installing Companion Flange On Front Shaft2558
Shift Lever2559
Adjustment - Shift Lever2560
Shift Rod Lock Bolt Location2560
Shifter Adjustment Location2560
Tires/Wheels2562
Diagnosis And Testing - Tire And Wheel Runout2562
Standard Procedures - Tire Rotation2563
Standard Procedures - Match Mounting2563
Dual Wheel Tire Rotation Pattern2564
First Measurement On Tire2564
Remount Tire 180 Degrees2564
Standard Procedures - Tire And Wheel Balance2565
Remount Tire 90 Degrees In Direction Of Arrow2565
Static Unbalance & Balance2565
Tires2566
Dynamic Unbalance & Balance2566
Tire Identification2567
Diagnosis And Testing - Pressure Gauges2568
Diagnosis And Testing - Tread Wear Indicators2568
Diagnosis And Testing - Tire Wear Patterns2568
Diagnosis And Testing - Tire Noise Or Vibration2569
Standard Procedures - Repairing Leaks2569
Spare Tire2570
Wheels2570
Tire Revolutions Per Mile2570
Diagnosis And Testing - Wheel Inspection2571
Standard Procedure - Dual Rear Wheel Installation2571
Body2574
Description – Push-In Fasteners2574
Description – Lock Cylinders2574
Diagnosis And Testing – Water Leaks2575
Visual Inspection Before Water Leak Tests2575
Water Leak Detection2575
Mirror Inspection Method2575
Diagnosis And Testing – Wind Noise2576
Visual Inspection Before Tests2576
Road Testing Wind Noise2576
Possible Cause Of Wind Noise2576
Weld Locations2577
Body Side Aperture — Quad Cab2578
Decklid/Hatch/Liftgate/Tailgate2635
Applique2635
Check Cable2635
Decals2636
Handle Escutcheon2636
Latch2637
Tailgate Latch And Linkage Rod2637
Latch Handle2638
Latch Striker2638
Slam Bumper2639
Tailgate2639
Door - Front2640
Door2641
Pillar Applique2641
Door Hinge Hidden Bolt2641
Door Glass2642
Adjustment – Front Door Up/Down2642
Adjustment – Front Door In/Out2642
Exterior Handle2643
Glass Run Channel2643
Hinge2643
Inside Handle Actuator2644
Adjustment – Front Door Latch2645
Lock Cylinder2646
Side View Mirror Flag2647
Trim Panel2647
Waterdam2648
Window Regulator2648
Door Trim Panel2648
Power Window/Lock Switch Panel2648
Door - Cargo2650
Adjustment – Cargo Door2651
Cargo Door Fore/Aft And Up/Down2651
Exhaust Vent2652
Cargo Door In/Out2652
Latch - Lower2653
Heat Staked Locations2653
Cargo Door Lower Latch2653
Latch - Upper2654
Cargo Door Lower Latch Installation Pin2654
Cargo Door Upper Latch2654
Latch Striker - Lower2655
Latch Striker - Upper2655
Release Cable2655
Shutface Handle2656
Cargo Door Trim Panel2657
Cargo Door Trim Panel Fastener2657
Cargo Door Release Cable2657
Vent Window2658
Exterior2659
Body Side Moldings2660
Body Stripes And Decals2660
Tape Stripe2661
Tape Stripe Overlay2661
Exterior Name Plates2662
Tape Stripe Application2662
Cowl Grille2663
Exterior Nameplates2663
Roof Joint Molding2664
Grille — Sport2664
Grille — Slt2664
Front End Splash Shields2665
Left Front Fender2665
Left Front Fender Access Components2666
Fender To Cowl Reinforcement—Typical2666
Right Front Fender2667
Fuel Fill Door2668
Rear Fender2668
Rear Splash Shield2669
Rear Wheelhouse Liner2669
Cargo Box2669
Side View Mirror2670
Sideview Mirror—Power2670
Side View Mirror - Low Mounted2671
Side View Mirror Glass2671
Hood2672
Latch Release Cable2674
Hood Release Handle2674
Instrument Panel System2677
Instrument Panel Assembly Remove/Install2680
Ash Receiver2681
Cluster Bezel2682
Instrument Panel Ash Receiver Remove/Install2682
Cluster Bezel Remove/Install2682
Cubby Bin2683
Cup Holder2683
Instrument Panel Cup Holder2684
Glove Box2685
Disassembly - Glove Box2685
Assembly - Glove Box2685
Glove Box Latch Striker2686
Glove Box Latch Striker Remove/Install2686
Glove Box Opening Upper Trim2687
Instrument Panel Top Cover2687
Steering Column Opening Cover2688
Storage Bin2689
Instrument Panel Storage Bin Remove/Instal2689
Interior2691
A-Pillar Grab Handle2692
A-Pillar Trim2692
Cowl Trim Cover2692
B-Pillar Trim2693
Rear Closure Panel Trim2693
Lower Cowl Trim Cover Retaining Tab2693
Rear Floor Stowage Tray2694
Door Sill Trim2694
Shift Boot - Manual Transmission2695
4Wd Floor Shift Boot2695
Center Console2695
Carpets And Floor Mats2696
Floor Carpet Or Mat2696
Assist Handle2697
Coat Hook2697
Quad/Club Cabs2697
Overhead Assist Handle2697
Headliner2698
Headliner Push-In Fasteners2698
Body Vent2699
Rear View Mirror2699
Installation - Rearview Mirror Support Bracket2699
Sun Visor2700
Quarter Trim Panel2700
C-Pillar Trim2701
Paint2702
Base Coat/Clear Coat Finish2702
Paint Code2702
Paint Touch-Up2702
Wet Sanding/Buffing & Polishing2703
Seats2704
Center Console Lid2704
Center Seat Armrest/ Console2705
Center Seat Armrest/ Latch Cover2705
Lumbar Support2706
Seat - Bench Seat2706
Inertia Latch Cover Upper Strap2706
Seat - Split Bench2707
Seat Back - Bench Seat2708
Seat Back - Split Bench2708
Seat Back Cover2710
Seat Back Cover - Split Bench2710
Recliner2710
Lumbar Handle Removal2710
Seat Back Recliner2711
Seat Cushion2711
Seat Cushion Cover2712
Seat Cushion Cover - Split Bench2712
Seat Riser2714
Seat Track2714
Seat Track - Split Bench2715
Easy Entry Seat Track2715
Seat Track Adjuster2716
Stanchion Cover2716
Rear Seat2717
Stationary Glass2718
Backlite2718
Backlite Latch And Keeper2719
Urethane Adhesive Application2719
Backlite Installation2719
Backlite Vent Glass2720
Lower Run Channel2720
Lower Run Channel Removal2720
Glass Panel Installation2720
Windshield2721
Windshield Moldings2721
Cut Urethane Around Windshield2722
Center Windshield And Mark At Support2722
Work Surface Set Up2722
Position Urethane Compression Spacer2723
Applicator Tip2723
Lower Windshield Into Position2723
Quarter Window2724
Vent Window—Club Cab2724
Weatherstrip/Seals2725
B-Pillar Door Seal2725
Cowl Weatherstrip2726
Door Opening Seal2726
Front Door Glass Run Weatherstrip2726
Front Door Inner Belt Weatherstrip2727
Front Door Outer Belt Weatherstrip2727
Front Door Upper Corner Seal2727
Front Door Second Weatherstrip2727
Heating & Air Conditioning2730
Description - Heater And Air Conditioner2730
Description - Cooling System Requirements2730
Operation - Heater And Air Conditioner2730
Operation - Refrigerant System Service Port2731
Diagnosis And Testing - A/C Performance2731
Performance Temperature And Pressure2732
A/C Diagnosis2732
Diagnosis And Testing - Heater Performance2735
Maximum Heater Output2735
Temperature Control2735
Temperature Reference2735
Standard Procedure - Diode Replacement2736
Heater Diagnosis2736
A/C Application Table2737
Controls2738
Diagnosis And Testing - Vacuum System2739
Vacuum Check Valve2739
A/C Heater Controls2739
Locating Vacuum Leaks2740
Vacuum Circuits2741
A/C Compressor Clutch2742
Diagnosis And Testing - A/C Compressor Clutch Coil2742
Standard Procedure - A/C Compressor Clutch Break-In2742
Clutch Nut Remove2743
Clutch Puller - Diesel Models2743
External Snap Ring Remove2743
Shaft Protector And Puller2744
Install Puller Plate2744
Clutch Coil Lead Wire Harness2744
Clutch Field Coil Snap Ring Remove2744
Rotor Installer Set2745
Rotor Install2745
Diagnosis And Testing - A/C Compressor Clutch Relay2746
Clutch Plate Install2746
Check Clutch Air Gap2746
A/C Heater Control2747
Compressor Clutch Relay2747
Diagnosis And Testing - A/C Heater Control2748
A/C Heater Control Vacuum Harness Routing2748
A/C High Pressure Switch2749
Diagnosis And Testing - A/C High Pressure Switch2749
A/C Low Pressure Switch2750
Diagnosis And Testing - A/C Low Pressure Switch2750
Blower Motor Relay2751
Diagnosis And Testing - Blower Motor Relay2751
Blower Motor Resistor Block2752
Blower Motor Switch2753
Diagnosis And Testing - Blower Motor Resistor Block2753
Blend Door Actuator2754
Diagnosis And Testing - Blower Motor Switch2754
Mode Door Actuator2755
Removal - Heat/Defrost Door Actuator2755
Blend Door Actuator Remove/Install2755
Heat/Defrost Door Actuator2755
Recirculation Door Actuator2756
Removal - Panel/Defrost Door Actuator2756
Installation - Heat/Defrost Door Actuator2756
Installation - Panel/Defrost Door Actuator2756
Distribution2760
Description - Hvac System Airflow2760
Air Outlets2760
Blower Motor2761
Removal - Panel Outlet Barrels2761
Installation - Demister Grilles2761
Installation - Panel Outlet Barrels2761
Diagnosis And Testing - Blower Motor2762
Defroster Ducts2763
Removal - Defroster And Demister Ducts2763
Hvac Housing2764
Removal - Defroster And Demister Duct Adapter2764
Installation - Defroster And Demister Ducts2764
Installation - Defroster And Demister Duct Adapter2764
Removal - Hvac Housing Inlet Baffle2765
Instrument Panel Demister Ducts2766
Instrument Panel Ducts2766
Installation - Hvac Housing Inlet Baffle2766
Blend Door2767
Mode Door2767
Removal - Heat/Defrost Door2767
Removal - Panel/Defrost Door2767
Recirculation Door2768
Installation - Heat/Defrost Door2768
Installation - Panel/Defrost Door2768
Plumbing2769
Operation - A/C Line Couplers2770
Caution - Refrigerant Hoses/Lines/Tubes Precautions2771
Diagnosis And Testing - Refrigerant System Leaks2772
Standard Procedure - A/C Line Couplers2772
Standard Procedure - Refrigerant System Service Equipment2773
Manifold Gauge Set Connections2773
Standard Procedure - Refrigerant Recovery2774
Standard Procedure - Refrigerant System Evacuate2774
Standard Procedure - Refrigerant System Charge2775
Description - A/C Compressor2775
Description - High Pressure Relief Valve2775
Operation - High Pressure Relief Valve2775
A/C Condenser2777
Suction And Discharge Line2779
Suction And Discharge Line Remove/Install - Gasoline Engine2780
Suction And Discharge Line Remove/ Install - Diesel Engine2780
Liquid Line2781
A/C Evaporator2781
Liquid Line Remove/Install2781
A/C Orifice Tube2782
Diagnosis And Testing - Fixed Orifice Tube2783
Fixed Orifice Tube - Typical2783
Heater Core2784
Accumulator - Typical2784
Refrigerant2785
Refrigerant Oil2785
Standard Procedure - Refrigerant Oil Level2786
Refrigerant Oil Capacities2786
Emissions Control2788
Description - State Display Test Mode2788
Description - Circuit Actuation Test Mode2788
Description - Diagnostic Trouble Codes2789
Bulb Check2789
Obtaining Dtc's Using Drb Scan Tool2789
Description - Task Manager2802
Description - Monitored Systems2802
Oxygen Sensor (O2S) Monitor2802
Oxygen Sensor Heater Monitor2803
Leak Detection Pump Monitor2803
Misfire Monitor2804
Fuel System Monitor2804
Catalyst Monitor2804
Description - Trip Definition2805
Description - Component Monitors - Gas Engines2805
Description - Component Monitors - Diesel Engines2805
Operation - Gas Engines2805
Operation - Task Manager2806
16-Way Data Link Connector2806
Test Sequence2807
Mil Illumination2807
Diagnostic Trouble Codes (Dtcs)2807
Dtc Self Erasure2808
Trip Indicator2808
Fuel System Good Trip2808
Warm-Up Cycles2808
Operation - Non-Monitored Circuits - Gas Engines2809
Similar Conditions Window2809
Operation - Non-Monitored Circuits - Diesel2810
Cylinder Compression2810
Fuel Injector Mechanical Malfunctions2810
Excessive Oil Consumption2810
Air Flow2811
Air Pressure Leaks2811
Pcm/Ecm System Grounds2811
Pcm/Ecm Connector Engagement2811
Air Injection2812
Description - Air Injection System2812
Operation - Air Injection System2814
Air Inlet For Air Pump2814
Air Inlet And Air Pump Air2814
Air Injection Pump2815
Diagnosis And Testing - Air Injection Pump2815
Air Pump Filter2816
One Way Check Valve2817
Diagnosis And Testing - One-Way Check Valve2817
Evaporative Emissions2818
Ccv Hose2819
Evap/Purge Solenoid2819
Fuel Filler Cap2820
Leak Detection Pump2820
Evaporative System Monitor Schematic—Typical2821
Pcv Filter2822
Pcv Valve2822
Diagnosis And Testing - Pcv Valve - V–6/V–8 Engines2823
Vacuum Lines2824
Diagnosis And Testing - Vacuum Schematics2824
Vapor Canister2824
New Vehicle Preparation2826
Description - The Importance Of Careful New Vehicle Preparation2826
Receiving2828
Major Inspection Points2828
Under Hood2829
Inspection - Hood Latch/Safety Catch2829
Inspection - Fluid Levels2829
Automatic Transmission2829
Brake Master Cylinder2830
Power Steering Reservoir2830
Windshield Washer Reservoir2830
Cooling System Reservoir2831
Inspection - Lines/Hoses2831
Engine Coolant Reservoir2831
Parking Brake Cable And Brake Line2831
Inspection - Battery2832
Inspection - Wiring2832
Battery Voltage Gauge Diesel Engine2832
Battery Voltage Gauge Gas Engine2832
Under Vehicle2833
Inspection - Tire Pressures2833
Inspection - Visual2833
Exhaust Hangers2834
Tailpipe Hangers2834
Transmission Cooler Lines2834
Transfer Case Inspection2834
Installation - Wheel Covers2835
Inspection—Body Sealing2835
Inspection - Fit And Finish2835
Inspection - Keyless Entry2836
Inspection - Doors And Door Locks2836
Body Interior2837
Inspection - Compass2837
Inspection - Lights And Switches2837
Inspection - Seats2838
Emergency Flasher Switch2838
Seat Belt Labels2838
Inspection - Windows, Doors And Locks2839
Installation - Shipped Loose Items2839
Power Window And Lock Switches2839
Door Operation2839
Description - Road Test Inspection2840
Inspection - Squeaks, Rattles And Wind Noise2840
Inspection - Steering And Handling2840
Inspection - Transmission/Transfer Case2840
4X4 Transfer Case2841
Inspection - Engine Performance2841
Clutch Pedal Operation2841
Transfer Case Selector2841
Inspection - Trip Computer/ Maintenance Reminder2842
Inspection - Parking Brake2842
Inspection - Service Brakes2842
Inspection - Radio2842
Inspection Windshield Wipers/Washers2843
Trip Computer2843
Radio Operation2843
Pre Delivery Storage2844
Inspection - Mirror2844
Inspection - Turn And Emergency Signals2844
Inspection - Gauges/Warning Lights2844
Programmable Electronic Features2845
Standard Procedure - Pre Delivery Storage2845
Rolling Power Door Locks2845
Horn Chirp2845
Appearance Tips2846
Headlamp Flash2846
Headlights On Automatically With Wipers2846
12V Power Outlet2846
Final Steps2847
Standard Procedure - Owner Check Out2847
Standard Procedure - Inspection - Information Labels2847
New Vehicle Preparation Form2847
Index2848