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DaimlerChrysler SPRINTER2006 Service Manual

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SERVICE MANUAL
2006
SPRINTER
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED,
STORED
IN
A
RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY 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 DaimlerChrysler Corporation
81-370-06070CD

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Summary of Contents for DaimlerChrysler SPRINTER2006

  • Page 1 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.
  • Page 2 Consequently, DaimlerChrysler Corporation has not undertaken any such broad service review. Accordingly, anyone who uses...
  • Page 3 UNITED STATES and CANADA 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 SPECIAL TOOLS SPX Corporation Telephone 1-800-801-5420...
  • Page 4 OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

  • Page 5: Table Of Contents

    GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
  • Page 7 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page VEHICLE IDENTIFICATION NUMBER THREADED HOLE REPAIR DESCRIPTION ......1 DESCRIPTION - THREADED HOLE REPAIR .
  • Page 8 INTRODUCTION POSITION INTERPRETATION CODE = DESCRIPTION D1 = Sprinter, 3000 mm (118 in.) wheelbase, 8,001 up to 9,000 lbs. class G D2 = Sprinter, 3550 mm (140 in.) wheelbase, 8,001 up to 9,000 lbs. class G D3 = Sprinter, 4025 mm (158 in.) wheelbase, 8,001 up to 9,000 lbs.

  • Page 9: Number

    INTRODUCTION Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS High Beam Rear Window Washer Fog Lamps Fuel Headlamp, Parking Lamps, Panel Lamps Engine Coolant Temperature Turn Warning Battery Charging Condition Hazard Warning Engine Oil Windshield Washer Seat Belt Windshield Wiper Brake Failure Windshield Wiper and Washer Parking Brake Windscreen Demisting and Defrosting...

  • Page 10: Number

    INTRODUCTION Fig. 2 FASTENER IDENTIFICATION...

  • Page 11: Lubrication & Maintenance

    These claims have not been sup- 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION ported to the satisfaction of DaimlerChrysler and 3 - CHASSIS AND WHEEL BEARINGS these additives must not be used. The use of trans- mission “sealers”...

  • Page 12: Axle Fluid

    0 - 2 LUBRICATION & MAINTENANCE AXLE FLUID Coolant with the HOAT inhibitor system. This cool- ant offers the best engine cooling without corrosion Use oils approved to MB 235.0 or 235.6, such as when mixed with 50% anti-freeze and 50% distilled Shell Spirax MB90, Caltex Hypoid LD, or MOPAR water to obtain a freeze point of -37°C (-34°F).

  • Page 13: Engine Oil - Diesel Engines

    Full Synthetic Motor Oil Long Life EF 15W-40 228.3 OIL VISCOSITY CHART Diesel Engine The following engine oils have been determined to Oil Multigrade meet DaimlerChrysler requirements: Lubral Super 15W-40 228.3 Diesel MB-III DaimlerChrysler SAE Rating MB Sheet Approved En-...

  • Page 14: Fuel Requirements - Diesel Engine

    0 - 4 LUBRICATION & MAINTENANCE DaimlerChrysler SAE Rating MB Sheet DaimlerChrysler SAE Rating MB Sheet Approved En- Number Approved En- Number gine Oil gine Oil Mobil Delvac 1 5W-40 228.5 Shell Rotella T 15W-40 228.3 Multigrade (1) Mobil Delvac 15W-40 228.3...

  • Page 15: Power Steering Fluid

    LUBRICATION & MAINTENANCE 0 - 5 Do not blend other specific fuel additives with die- DESCRIPTION SPECIFICATION sel fuel. They only result in unnecessary cost, and POWER STEERING SYSTEM may be harmful to the engine operation. Power steering fluid capacities are dependent on POWER STEERING FLUID engine/chassis options as well as steering gear/cool- er options.

  • Page 16: Jump Starting

    0 - 6 LUBRICATION & MAINTENANCE • IF EQUIPPED, DO NOT JUMP START WHEN HOIST MAINTENANCE FREE BATTERY INDICATOR DOT IS A vehicle can be lifted with: YELLOW OR BRIGHT COLOR. • A single-post, frame-contact hoist. • DO NOT JUMP START A VEHICLE WHEN THE •...
  • Page 17 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page FRONT ....... . . 1 WHEEL ALIGNMENT .

  • Page 18: Front

    2 - 2 FRONT DESCRIPTION N·m Ft. Lbs. In. Lbs. Bottom Spring Clamp — Plate To Front Axle M10 Bolt Sway Bar Clamp To The — Front Axle Hexagon Socket Bolt For Clamping Nut To Adjust Wheel Bearing Play Lower Control Arm To —...

  • Page 19: Bushings Removal

    FRONT 2 - 3 (3) Install special tool C-4212F (Press) with special tool 9302-1 (Driver) and 9302–3 (Receiver) (Fig. 1). BALL JOINT SEPARATOR - 9282 Fig. 1 LCA BUSHING REMOVAL 1 - SPECIAL TOOL C-4212F (PRESS) 2 - SPECIAL TOOL 9302-1 (DRIVER) 3 - LOWER CONTROL ARM 4 - SPECIAL TOOL 9302-3 (RECEIVER CUP) 5 - BUSHING...

  • Page 20: Hub / Bearing

    2 - 4 FRONT Fig. 2 LCA BUSHING INSTALL Fig. 3 MEASURING & ADJUSTING WHEEL BEARING 1 - SPECIAL TOOL C-4212F (PRESS) 1 - WHEEL HUB 2 - SPECIAL TOOL 9302-1 (DRIVER) 2 - LOCKING SCREW 3 - BUSHING 3 - DIAL INDICATOR 4 - SPECIAL TOOL 9302-2 (SIZER CUP) 5 - LOWER CONTROL ARM REMOVAL...

  • Page 21: Installation

    FRONT 2 - 5 INSTALLATION (1) Install the wheel hub with the tapered roller bearing on the stub axle (Fig. 4). (2) Grease the outer tapered roller bearing thor- oughly and push onto the steering knuckle (Fig. 4). NOTE: The smooth side of the thrust washer must point toward the wheel bearing.

  • Page 22: Installation

    2 - 6 FRONT (4) Remove the steering knuckle (Refer to 2 - SUS- PENSION/FRONT/KNUCKLE - REMOVAL). (5) Remove the lower ball joint using special tool 9294-1 (Driver) with 9294-2 (Reciever) and C-4212–F. (Fig. 7). Fig. 6 STEERING KNUCKLE 1 - STRUT 2 - STRUT BOLT 3 - STEERING KNUCKLE 4 - LOWER BALL JOINT NUT...

  • Page 23: Differential & Driveline

    DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . . 1 REAR AXLE .

  • Page 24: Propeller Shaft

    3 - 2 PROPELLER SHAFT DRIVELINE VIBRATION Drive Condition Possible Cause Correction Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash material on shaft. with solvent. 2) Loose U-joint clamp screws. 2) Install new clamps and screws and tighten to proper torque.
  • Page 25 PROPELLER SHAFT 3 - 3 Fig. 3 Clamp Screws Separated Fig. 1 Clamp Screw At Position 1 ⁄ INCH 1 - CLAMP 2 - SCREWDRIVER (14) Increase distance between clamps and repeat test until vibration is at the lowest level. Bend the (11) Start engine and re-check for vibration.

  • Page 26: Standard Procedure

    3 - 4 PROPELLER SHAFT RUNOUT SPECIFICATIONS RULES • Good cancellation of U-joint operating angles Front of Shaft 0.020 in. (0.50 mm) should be within 1degree. • Operating angles should be less than 3 degrees. Center of Shaft 0.025 in. (0.63 mm) •...
  • Page 27 PROPELLER SHAFT 3 - 5 Fig. 4 UNIVERSAL JOINT ANGLE EXAMPLE 1 - 4.9° Angle (C) 4 - 3.0° Angle (A) 2 - 3.2° Angle (B) 5 - Output Yoke 3 - Input Yoke TWO / THREE - PIECE PROPELLER SHAFT The procedure to measure the propeller shaft angles involved with a two/three-piece (Fig.

  • Page 28: Specifications

    3 - 6 PROPELLER SHAFT Fig. 5 UNIVERSAL JOINT ANGLE 1 - YOKES MUST BE IN SAME PLANE SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Propeller shaft to trans- mission bolt Propeller shaft to axle bolt Retaining bracket to frame floor bolt Center Bearing support to frame floor bolt...
  • Page 29 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
  • Page 30 5 - 2 BRAKES - BASE POWER BRAKE BOOSTER INSTALLATION ......24 DESCRIPTION ......19 CABLES OPERATION .
  • Page 31 BRAKES - BASE 5 - 3 (3) During road test, make normal and firm brake Drag is a product of incomplete brake shoe release. stops in 25-40 mph range. Note faulty brake opera- Drag can be minor or severe enough to overheat the tion such as low pedal, hard pedal, fade, pedal pulsa- linings, rotors and drums.
  • Page 32 5 - 4 BRAKES - BASE As the dragging brake overheats, efficiency is so after a few brake applications causing the noise to reduced that fade occurs. Since the opposite brake subside. unit is still functioning normally, its braking effect is BRAKE SQUEAK / SQUEAL magnified.
  • Page 33 BRAKES - BASE 5 - 5 the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. STANDARD PROCEDURE - PRESSURE BLEED- Use approved brake fluid (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIP- TION).
  • Page 34 5 - 6 BRAKES - BASE DESCRIPTION N·m Ft. Lbs. In. Lbs. Booster To Pedal Bracket — Brake Caliper Guide Pins — M8 Bolt Brake Caliper Guide Pins — M10 Bolt ALB Operating Linkage Lever To The Rear Axle Wheel Flange Ring To —...

  • Page 35: Cooling

    COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING COOLING SYSTEM ..... 2 OPERATION - COOLING SYSTEM ... 1 ACCESSORY DRIVE .

  • Page 36: Engine

    7 - 2 COOLING COOLING SYSTEM COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATUREGAUGE READS 1. Vehicle is equipped with a 1. None. System operating norma- heavy duty cooling system. 2. Temperature gauge not connect- 2. Connect gauge. 3.
  • Page 37 COOLING 7 - 3 CONDITION POSSIBLE CAUSES CORRECTION 13. Brakes dragging. 13. Check brakes. (Refer to 5 - BRAKES/HYDRAULIC/MECHANI- CAL - DIAGNOSIS AND TESTING) TEMPERATURE GAUGE READ- 1. Heavy duty cooling system, ex- 1. None. System operating norma- ING INCONSISTENT ( ERRATIC, tream cold ambient (outside) tem- CYCLES OR FLUCTUATES) perature or heater blower motor in...
  • Page 38 7 - 4 COOLING CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER PERFOR- 1. Heavy duty cooling system, and 1. None. Normal condition. MANCE. GUAGE MAY OR MAY cooler ambient temperatures. NOT READ LOW. 2. Obstruction in heater hoses. 2. Remove hoses, remove obstruc- tion.
  • Page 39 ACCESSORY DRIVE 7 - 5 ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONERS REMOVAL DESCRIPTION ......5 REMOVAL .
  • Page 40 7 - 6 ACCESSORY DRIVE resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment, glazing, or excessive end play. Fig. 2 Belt Wear Patterns 1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle.
  • Page 41 AUDIO/VIDEO 8A - 1 AUDIO / VIDEO TABLE OF CONTENTS page page AUDIO INSTALLATION ......2 SPECIAL TOOLS RADIO AUDIO .
  • Page 42 8A - 2 AUDIO/VIDEO INSTRUMENT PANEL RADIO ANTENNA CABLE REMOVAL (1) Disconnect and isolate the battery negative REMOVAL cable. (1) Disconnect and isolate the battery negative (2) Using special tool 9241 or equivalent, insert cable. one into each slot on the face of the radio (Fig. 3). (2) Remove the A-pillar trim (Refer to 23 - BODY/ INTERIOR/A-PILLAR TRIM - REMOVAL).
  • Page 43 AUDIO/VIDEO 8A - 3 Fig. 4 INSTRUMENT PANEL SPEAKER (4) Using a trim stick (C-4755 or equivalent), pry up on the speaker. (5) Disconnect electrical harness connector and remove speaker. INSTALLATION (1) Install wire harness connector. (2) Place speaker into instrument panel. (3) Install speaker grille.
  • Page 45 CHIME/BUZZER 8B - 1 CHIME / BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME DESCRIPTION ......1 WARNING SYSTEM .
  • Page 46 8B - 2 CHIME/BUZZER the status of the driver side front seat belt. This received from other electronic modules over the CAN audible warning occurs independent of the visual data bus network to provide chime service for the low warning provided by the EMIC “Seatbelt” indicator. engine oil level warning.
  • Page 47 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page CENTRAL TIMER MODULE INSTALLATION ......3 DESCRIPTION .

  • Page 48: Central Timer Module

    8E - 2 ELECTRONIC CONTROL MODULES actuators.These outputs allow the CTM the ability to tem. Failure to take the proper precautions could control numerous accessory systems in the vehicle. result in accidental airbag deployment. The CTM monitors its own internal circuitry as The hard wired inputs to and outputs from the well as many of its input and output circuits, and central timer module (CTM) may be diagnosed and...

  • Page 49: Installation

    ELECTRONIC CONTROL MODULES 8E - 3 REMOVAL (1) Remove the negative battery cable from the battery. (2) Pull up on the CAB harness connector release and remove connector. (3) Remove the CAB mounting bolts. (4) Remove the CAB from the HCU. INSTALLATION (1) Install CAB to the HCU.
  • Page 50 8E - 4 ELECTRONIC CONTROL MODULES Fig. 2 ECM 1 - MASS AIR FLOW SENSOR 8 - CHARGE AIR PRESSURE SENSOR 2 - TURBOCHARGER SERVO MOTOR 9 - CHARGE AIR TEMPERATURE SENSOR 3 - CAMSHAFT POSITION SENSOR 10 - COOLANT TEMPERATURE SENSOR 4 - ENGINE OIL SENSOR 11 - FUEL RAIL PRESSURE SENSOR 5 - CRANKSHAFT POSITION SENSOR...
  • Page 51 ELECTRONIC CONTROL MODULES 8E - 5 Fig. 3 ECM CONTROL • Measurement of the intake air mass using new New software has been loaded to the ECM for EGR control. This is due to the wider operating range and mass air flow (MAF) sensor with increase precision larger volume of recirculated gas.

  • Page 52: Removal

    8E - 6 ELECTRONIC CONTROL MODULES rate and boost pressure are adjusted to the actual injection quantity. • Injection valve quantity drift compensation in full load range: this function is to limit the maximum injection quantity for engine protection. The injection quantity signal is compared to the injection quantity calculated from the oxygen sensor signal and MAF signal.
  • Page 53 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING SYSTEM .

  • Page 54: Operation

    8F - 2 BATTERY SYSTEM For battery system maintenance schedules and the components that are used in these systems must jump starting procedures, see the owner’s manual in perform within specifications. It is important that the vehicle glove box. Optionally, refer to the Lubri- the battery, starting, and charging systems be thor- cation and Maintenance section of this manual for oughly tested and inspected any time a battery needs...
  • Page 55 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system igni- 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN tion-off draw is excessive. Standard Procedure for the proper test proce- ATTEMPTING TO START dures.
  • Page 56 8F - 4 BATTERY SYSTEM BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an incor- 1. Refer to Battery System Specifications for the CHARGE CANNOT BE rect size or rating for this proper specifications. Replace an incorrect bat- MAINTAINED.
  • Page 57 BATTERY SYSTEM 8F - 5 CLEANING The following information details the recommended cleaning procedures for the battery and related com- ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
  • Page 58 8F - 6 BATTERY SYSTEM SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS Fig. 3 Clean Battery Terminal Post - Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE 3 - BATTERY Micro 420 Battery Tester INSPECTION BATTERY The following information details the recommended inspection procedures for the battery and related components.
  • Page 59 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEATS .

  • Page 60: Heated Glass

    8G - 2 HEATED GLASS • Confirm that the ignition switch is in the On relays which allows battery current to flow to the rear window defogger grid lines. The heated grid position. • Make sure that the rear glass heating grid feed lines heat the rear glass to help clear the rear win- dow surfaces of fog or frost.

  • Page 61: Rear Window Defogger Relay

    HEATED GLASS 8G - 3 Fig. 2 Grid Line Test 1 - VOLTMETER 2 - VOLTAGE FEED (A) 3 - FEED WIRE Fig. 3 Rear Window Defogger (EBL) Relays 4 - MID-POINT (C) 5 - HEATED WINDOW GRID 1 - REAR WINDOW DEFOGGER (EBL) RELAY (2) 6 - GROUND WIRE 2 - TERMINAL PATTERN 7 - GROUND (B)

  • Page 62: Removal

    8G - 4 HEATED GLASS • The coil ground terminal (86) is hardwired to INSTALLATION ground point G202. • The coil battery terminal (85) receives a battery NOTE: Refer to the fuse and relay map located on current input from the rear window defogger module the inner surface of the fuse/relay block cover for when the rear window defogger switch is energized.
  • Page 63 HEATED GLASS 8G - 5 energizes the timing circuit of the rear window defog- (b) If NOT OK, no voltage in the On position or ger module which then activates the rear window voltage in the Off position, replace the rear window defogger (EBL) relays.

  • Page 64: Removal

    8G - 6 HEATED GLASS DEFOGGER SWITCH CONNECTOR PIN CALL-OUT FUNCTION FUSED B+ (DRL RELAY) IGNITION SWITCH OUTPUT (START- RUN) PANEL LAMPS DRIVER DEFOGGER SWITCH OUTPUT PANEL LAMPS DRIVER GROUND REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, airbag, seat belt Fig.
  • Page 65 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN HORN SWITCH REMOVAL ......1 REMOVAL .
  • Page 67 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL GLOW PLUG RELAY OPERATION - GLOW PLUG ....1 DESCRIPTION ......1 SPECIAL TOOLS .
  • Page 68 8I - 2 IGNITION CONTROL Fig. 1 GLOW PLUG (S) 1 - GLOW PLUG 3 - INTAKE MANIFOLD 2 - WIRING HARNESS CONNECTOR 4 - ENGINE COVER • Open circuit at one or several glow plugs is to improve combustion for low emissions and to •...
  • Page 69 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER HIGH BEAM INDICATOR DESCRIPTION ......2 DESCRIPTION .

  • Page 70: Instrument Cluster

    8J - 2 INSTRUMENT CLUSTER The EMIC module also incorporates a multi-func- INSTRUMENT CLUSTER tion indicator that consists of a digital Liquid Crystal Display (LCD) unit for displaying odometer/trip DESCRIPTION odometer information, an electronic digital clock, engine oil level information, automatic transmission gear selector position (PRNDL), and certain diagnos- tic information.
  • Page 71 INSTRUMENT CLUSTER 8J - 3 Located between the rear cover and the cluster to calculate the required engine oil service intervals, hood is the cluster housing. The molded plastic clus- and provides both visual and audible alerts to the ter housing serves as the carrier for the cluster elec- vehicle operator when certain engine oil maintenance tronic circuit...
  • Page 72 8J - 4 INSTRUMENT CLUSTER 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, ODOMETER, TRIP ODOMETER, EN- GINE OIL LEVEL DATA, AMBIENT TEMPERATURE INDICATOR...
  • Page 73 INSTRUMENT CLUSTER 8J - 5 procedures, further details on wire harness routing EMIC circuitry is grounded through a ground circuit and retention, as well as pin-out and location views and take out of the frame wire harness with an eye- for the various wire harness connectors, splices and let terminal connector that is secured to a stud by a grounds.
  • Page 74 8J - 6 INSTRUMENT CLUSTER INDICATORS transmission gear selector is in the Park position, depressing the plus switch push button brightens the Indicators are located in various positions within display lighting, and depressing the minus switch the EMIC and are all connected to the EMIC elec- push button dims the display lighting.
  • Page 75 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....28 LAMPS / LIGHTING - EXTERIOR TABLE OF CONTENTS page...
  • Page 76 8L - 2 LAMPS/LIGHTING - EXTERIOR REAR TURN LAMP BULB INSTALLATION ......25 REMOVAL ......23 TAIL LAMP UNIT INSTALLATION .
  • Page 77 LAMPS/LIGHTING - EXTERIOR 8L - 3 electrical package have a heavy duty 7-way trailer Controller Area Network (CAN) data bus network. tow connector installed in a bracket on the trailer The most reliable, efficient, and accurate means to hitch receiver. This package includes a 7-way to diagnose the electronic module within the fuse block, 4-way connector adapter unit.
  • Page 78 8L - 4 LAMPS/LIGHTING - EXTERIOR seat riser, a fog lamp switch installed in the cluster bezel on the instrument panel outboard of the steer- ing column, and a fog lamp bulb installed in each of the two front lamp units. The front fog lamps have a path to ground at all times through their connection to the vehicle wire harness.
  • Page 79 LAMPS/LIGHTING - EXTERIOR 8L - 5 TURN SIGNAL LAMPS BACKUP LAMP BULB When the left (lighting) control stalk of the multi- function switch is activated (Fig. 1), the turn signal REMOVAL system illuminates the selected right or left turn sig- (1) Disconnect and isolate the battery negative nal indicator and the turn signal lamps begin to cable.
  • Page 80 8L - 6 LAMPS/LIGHTING - EXTERIOR Fig. 3 Tail Lamp Bulb Remove/Install 1 - BRAKE/PARK LAMP BULB 2 - BACKUP LAMP BULB 3 - TURN SIGNAL LAMP BULB Fig. 4 Brake Lamp Switch Location 4 - SIDE MARKER LAMP BULB 5 - TAIL LAMP SOCKET PLATE 1 - PEDAL BRACKET 2 - BRAKE LAMP SWITCH...

  • Page 81: Power Locks

    POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER WINDOWS.
  • Page 82 8N - 2 POWER LOCKS Fig. 1 POWER LOCK SWITCH Fig. 2 POWER LOCK SWITCH 1 - CENTRAL LOCKING SWITCH MASTER LOCK SWITCH 2 - INSTRUMENT PANEL SWITCH POSITION CONTINUITY BETWEEN (3) Remove the central locking switch from the OPEN 4 AND 7 bezel (Fig.

  • Page 83: Power Mirrors

    POWER MIRRORS 8N - 3 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......3 DESCRIPTION .

  • Page 84: Installation

    8N - 4 POWER MIRRORS Fig. 2 POWER MIRROR SWITCH (4) Disconnect the electrical wire harness and 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.

  • Page 85: Description

    POWER WINDOWS 8N - 5 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS POWER WINDOW SWITCH DESCRIPTION ......5 DIAGNOSIS AND TESTING - POWER OPERATION .

  • Page 86: Installation

    8N - 6 POWER WINDOWS (3) Remove power window switch trim from door trim panel. (4) disconnect wire harness 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.
  • Page 87 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS PASSENGER AIRBAG DESCRIPTION ......2 DESCRIPTION .
  • Page 88 8O - 2 RESTRAINTS RESTRAINTS DESCRIPTION Fig. 1 Supplemental Restraint System 1 - PASSENGER AIRBAG (OPTIONAL) 2 - SIDE IMPACT SENSOR (2 - WITH OPTIONAL SIDE CURTAIN AIRBAGS ONLY) 3 - DRIVER AIRBAG 4 - AIRBAG CONTROL MODULE 5 - SEAT BELT TENSIONER (DRIVER SIDE - STANDARD, PASSENGER SIDE - OPTIONAL WITH PASSENGER AIRBAG ONLY) 6 - SIDE CURTAIN AIRBAG (2 - OPTIONAL) An occupant restraint system is standard factory- ACTIVE RESTRAINTS...
  • Page 89 RESTRAINTS 8O - 3 • Airbag Control Module - The Airbag Control travelling end-release seat belt buckles secured to the inboard seat track. The driver side front seat belt Module (ACM) is located on a mount on the floor buckle of all models includes an integral seat belt panel within the driver side seat riser, beneath the switch that detects whether its seat belt has been driver seat in the passenger compartment.
  • Page 90 8O - 4 RESTRAINTS and to the supplemental restraint system compo- the microprocessor in the ACM signals the inflator of nents through the use of a combination of soldered the appropriate airbag units to deploy their airbag splices, splice block connectors, and many different cushions.
  • Page 91 Straighten any belt that replace all restraint system components only with is twisted. Tighten any loose fasteners. Replace any parts specified in the DaimlerChrysler Mopar Parts belt that has a damaged or inoperative buckle or Catalog. Substitute parts may appear interchange- retractor.
  • Page 92 8O - 6 RESTRAINTS intended for reuse and will be damaged or weakened STANDARD PROCEDURE as a result of a supplemental restraint deployment, which may or may not be obvious during a visual STANDARD PROCEDURE - HANDLING NON - inspection. DEPLOYED SUPPLEMENTAL RESTRAINTS It is also critical that the mounting surfaces and/or At no time should any source of electricity be per-...
  • Page 93 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL SERVO DESCRIPTION ......1 DESCRIPTION .
  • Page 94 8P - 2 SPEED CONTROL • Pressing the speed control switch to OFF • Depressing the clutch pedal (if equipped). NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored in the ECM. For added safety, the speed control system is pro- grammed to disengage for any of the following condi- tions:...
  • Page 95 SPEED CONTROL 8P - 3 SWITCH REMOVAL The speed control switch is mounted to the back of the multi-function switch (Fig. 3). The multi-function switch must be removed first to gain access to the speed control switch mounting screw. (1) Remove and isolate negative battery cable from battery.
  • Page 97 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION ......1 DESCRIPTION .

  • Page 98: Vehicle Theft Security

    8Q - 2 VEHICLE THEFT SECURITY and pull that edge of the lamp away from its mount- SENTRY KEY REMOTE ENTRY ing location (Fig. 1). 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.

  • Page 99: Sentry Key Remote Entry Module

    VEHICLE THEFT SECURITY 8Q - 3 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 equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver door lock will unlock, the illuminated entry will turn on the courtesy lamps, and the VTSS...

  • Page 100: Installation

    8Q - 4 VEHICLE THEFT SECURITY (5) Remove top cover - cluster (Refer to 23 - BODY/INSTRUMENT PANEL/TOP COVER - CLUS- TER - REMOVAL). (6) Disconnect the transponder electrical connector from the SKREEM (Fig. 4). (7) Maneuver wiring from instrument panel and remove transponder from vehicle.

  • Page 101: Transponder Key

    VEHICLE THEFT SECURITY 8Q - 5 ECM or no status at all is communicated, the vehicle TRANSPONDER KEY will stall after two (2) seconds of running. The indi- cator light will be flashing at this point. The Sentry DESCRIPTION Key’s transponder can not be repaired. If it is faulty The Sentry Key Immobilizer System (SKIS) which or damaged, it must be replaced.
  • Page 103 WIPERS/WASHERS 8R - 1 WIPERS / WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS WASHER PUMP/MOTOR DESCRIPTION ......2 DESCRIPTION .
  • Page 104 8R - 2 WIPERS/WASHERS WIPERS/WASHERS DESCRIPTION Fig. 1 Wiper & Washer System 1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL SWITCH 4 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH 2 - WIPER MOTOR, LINKAGE & PIVOTS MODULE 5 - RAIN SENSOR (W/AUTOMATIC WIPERS ONLY) 3 - WIPER RELAY 6 - RAIN SENSOR CONTROL MODULE (W/AUTOMATIC WIPERS ONLY)
  • Page 105 WIPERS/WASHERS 8R - 3 both the wiper and washer systems. (Refer to 8 - wiper linkage module includes the two wiper drive ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ links, the wiper motor crank arm, the two wiper piv- MULTI-FUNCTION SWITCH - DESCRIPTION) ots, and the linkage and motor mounting bracket. •...
  • Page 106 8R - 4 WIPERS/WASHERS other minor debris from the outside windshield glass tent wipe logic circuitry of the wiper, turn signals surface that might be encountered while driving the and engine start control module within the fuse vehicle under numerous types of inclement operating block, the multi-function switch, the wiper relay and conditions.
  • Page 107 WIPERS/WASHERS 8R - 5 is closed with the wiper system turned Off, the inter- until the wiper blades are in the down position on mittent wipe logic circuitry operates the wiper motor the windshield and the park switch is again closed to in the same manner as it does to provide the inter- ground.
  • Page 108 8R - 6 WIPERS/WASHERS DIAGNOSIS AND TESTING - WIPER & tested using conventional diagnostic tools and proce- dures. However, conventional diagnostic methods WASHER SYSTEM may not prove conclusive in the diagnosis of the If the wiper motor operates, but the wipers do not intermittent wipe logic circuitry contained within the move on the windshield, replace the faulty wiper fuse block underneath the steering column, the rain...
  • Page 109 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 CENTRAL TIMER MODULE... . . 8W-45-1 COMPONENT INDEX ....8W-02-1 AUDIO SYSTEM .
  • Page 111 DaimlerChrysler Corporation vehicles, it is important as simply as possible, with regard to function only. to understand all of their features and characteris- tics. SYMBOLS Diagrams are arranged such that the power (B+)
  • Page 112 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION Fig. 1 WIRING DIAGRAM EXAMPLE 1...
  • Page 113 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 Fig. 2 WIRING DIAGRAM EXAMPLE 2...
  • Page 114 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION Fig. 3 Wiring Diagram Symbols...
  • Page 115 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE CYLINDER HEAD COVER(S) DESCRIPTION ......2 REMOVAL .
  • Page 116 9 - 2 ENGINE VACUUM PUMP INSTALLATION - OIL PUMP CHAIN ..62 DESCRIPTION ......54 OIL SENSOR OPERATION .
  • Page 117 ENGINE 9 - 3 (12) Install engine cover (Refer to 9 - ENGINE - DESCRIPTION SPECIFICATION INSTALLATION). Engine 2.7L CDI COMPRESSION SPECIFICATIONS Engine Description 5 Cylinder In-Line En- gine With 4-Valve Tech- Maximum Compression 29-35 bar (420-507 psi) nology Minimum Compression 18bar (261 psi) Air Intake Turbo-Charged Engine...
  • Page 118 9 - 4 ENGINE NOTE: If the retaining lock is installed, remove it, CONDITION POSSIBLE CORRECTION rotate engine and install lock once again. CAUSES (2) Carry out test of other cylinders in the firing 2. Intake 2. Replace order of engine. Valves and Valves, Guides Seats...
  • Page 119 ENGINE 9 - 5 (5) Disconnect the engine wiring harness at the cabin side and carefully guide though the cowl into the engine area. Fig. 2 ENGINE COVER 1 - ENGINE COVER 2 - FASTENERS REMOVAL WARNING: NO SPARKS, OPEN FLAMES OR SMOK- ING.
  • Page 120 9 - 6 ENGINE Fig. 3 ENGINE COVER 1 - ENGINE COVER 6 - HIGH PRESSURE FUEL PUMP 2 - FUEL RAIL 7 - VACUUM PUMP 3 - INTAKE MANIFOLD 8 - OIL LEVEL INDICATOR 4 - EGR VALVE 9 - HEAT SHIELD 5 - AIR INLET TUBE 10 - TRANSMISSION OIL LEVEL INDICATOR (6) Remove the turbocharger heat shield (Fig.
  • Page 121 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM OPERATION ......5 DESCRIPTION - 2.7L DIESEL .
  • Page 122 11 - 2 EXHAUST SYSTEM Fig. 1 Exhaust System 1 - TURBOCHARGER 7 - WASHER 2 - HEAT SHIELD 8 - INSULATOR 3 - CLAMP 9 - BOLT 4 - EXHAUST PIPE 10 - MUFFLER/CATALYTIC CONVERTER ASSEMBLY 5 - FRONT INSULATOR 11 - TAILPIPE 6 - NUT DIAGNOSIS AND TESTING - DIESEL ENGINE...

  • Page 123: Catalytic Converter

    EXHAUST SYSTEM 11 - 3 (4) Lower the vehicle. CATALYTIC CONVERTER (5) Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary. REMOVAL (6) Check the exhaust system for contact with the (1) Raise and support the vehicle. body panels.
  • Page 124 11 - 4 EXHAUST SYSTEM • Reduction in exhaust emissions as a result of an improvement in the air supply of the engine. • Increased power output as a result of the higher charge pressure combined with a reduced exhaust backpressure and thus improved charge cycle.
  • Page 125 EXHAUST SYSTEM 11 - 5 OPERATION Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressur- ized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold.
  • Page 126 11 - 6 EXHAUST SYSTEM INSPECTION OPERATION Visually inspect the charge air cooler for cracks, The vacuum solenoid receives 12V from the ECM. holes, or damage. Inspect the tubes, fins, and welds The ECM controls the solenoid through a PWM sig- for tears, breaks, or other damage.
  • Page 127 FRAME & BUMPERS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page page BUMPERS FRAME SPECIFICATIONS - TORQUE ....1 SPECIFICATIONS FRONT BUMPER - STEPS SPECIFICATIONS - FRAME DIMENSIONS .

  • Page 128: Front Bumper - Steps

    13 - 2 FRAME & BUMPERS FRONT BUMPER - STEPS REMOVAL (1) Remove fascia. (Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT FASCIA REMOVAL) (2) Remove the bolts and remove the steps. (Fig. Fig. 2 FRONT FASCIA 1 - ELECTRICAL CONNECTOR 2 - OUTSIDE TEMPERATURE SENSOR 3 - FASCIA SUPPORT BRACKET 4 - FASCIA...

  • Page 129: Specifications

    FRAME & BUMPERS 13 - 3 Fig. 4 REAR FASCIA 1 - FASCIA 2 - BOLTS 3 - TAB 4 - REFLECTOR 5 - SUPPORT BRACKET INSTALLATION (1) Install fascia and seat the corners over the sup- port brackets. (2) Seat bumper support brackets clips below end panel firmly.
  • Page 130 13 - 4 FRAME & BUMPERS INDEX DESCRIPTION FIGURE 05 FRAME DIMEN- SIONS 1 05 FRAME DIMEN- SIONS 2 FRAME DIMENSIONS...
  • Page 131 Fig. 5 05 FRAME DIMENSIONS 1...
  • Page 132 Fig. 6 05 FRAME DIMENSIONS 2...

  • Page 133: Fuel System

    FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL SYSTEM STANDARD PROCEDURE WARNING STANDARD PROCEDURES - CLEANING WARNING - HIGH FUEL SYSTEM FUEL SYSTEM COMPONENTS ... . 3 PRESSURE .
  • Page 134 14 - 2 FUEL SYSTEM If a high-pressure line connection is leaking, coun- With the DRBIII connected to the vehicle, select terhold and tighten the connection to specification Engine and the select Sensor Display. Page down to then perform this procedure again (Refer to 14 - view Fuel Pressure Set Point and Actual Fuel Pres- FUEL SYSTEM...
  • Page 135 FUEL SYSTEM 14 - 3 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 fuel system com-...
  • Page 136 14 - 4 FUEL SYSTEM Fig. 3 WATER IN FUEL SENSOR Fig. 4 FUEL GAUGE CONNECT AT HIGH PRESSURE PUMP 1 - WIF SENSOR 2 - WIF DRAIN 1 - FUEL SUPPLY FITTING 3 - FUEL FILTER 2 - ADAPTOR 4 - FUEL SUPPLY FROM TANK 3 - FUEL GAUGE HOSE 5 - FUEL SUPPLY TO HIGH PRESSURE PUMP...
  • Page 137 FUEL SYSTEM 14 - 5 move the gauge to the fuel filter input line and re- test. (Fig. 6). Fig. 6 FUEL PRESSURE TEST AT FILTER 1 - FUEL SUPPLY FROM FUEL TANK 2 - FUEL FILTER ASSEMBLY (6) If the fuel pressure is still below specification, replace the fuel pump.
  • Page 138 14 - 6 FUEL DELIVERY FUEL DELIVERY TABLE OF CONTENTS page page FUEL DELIVERY OPERATION DESCRIPTION ......6 OPERATION .

  • Page 139: Steering

    STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING COLUMN ....... . 4 DESCRIPTION .
  • Page 140 19 - 2 STEERING STEERING NOISE CONDITION POSSIBLE CAUSES CORRECTION OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash 1. Check and repair seal at dash WHISTLE panel seal. panel. 2. Noisy valve in power steering gear. 2. Replace steering gear. RATTLE OR CLUNK 1.
  • Page 141 STEERING 19 - 3 INSUFFICIENT ASST. OR POOR RETURN TO CENTER CONDITION POSSIBLE CAUSE CORRECTION HARD TURNING OR MOMEN- 1. Tire pressure. 1. Adjust tire pressure. TARY INCREASE IN TURNING 2. Low fluid level. 2. Fill to proper level. EFFORT 3.

  • Page 142: Specifications - Torque Chart

    19 - 4 COLUMN COLUMN TABLE OF CONTENTS page page COLUMN INSTALLATION ......6 SPECIFICATIONS - TORQUE CHART .

  • Page 143: Installation

    COLUMN 19 - 5 Fig. 2 STEERING COLUMN BOLTS Fig. 3 TRANSPONDER 1 - BOLT 1 - TRANSPONDER 2 - COLUMN BOLT 2 - STEERING COLUMN (13) Remove the steering shaft with the universal (4) Insert the key into the ignition lock. joint off the steering gear drive shaft (Fig.

  • Page 144: Installation

    19 - 6 COLUMN STEERING WHEEL REMOVAL (1) Disconnect the ground 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.

  • Page 145: Transmission

    TRANSMISSION 21 - 1 TRANSMISSION TABLE OF CONTENTS page AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION......1 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION TABLE OF CONTENTS...
  • Page 146 21 - 2 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION INSPECTION ......155 REMOVAL ......169 ASSEMBLY .
  • Page 147 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 3 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION DESCRIPTION Fig. 1 NAG1 Automatic Transmission 1 - TORQUE CONVERTER 11 - PARKING LOCK GEAR 2 - OIL PUMP 12 - INTERMEDIATE SHAFT 3 - DRIVESHAFT 13 - FREEWHEEL F2 4 - MULTI-DISC HOLDING CLUTCH B1 14 - REAR PLANETARY GEAR SET...
  • Page 148 21 - 4 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION • Increased service life and reliability. ELECTROHYDRAULIC CONTROL UNIT • Lower maintenance costs. The electrohydraulic control unit comprises the shift plate made from light alloy for the hydraulic TRANSMISSION IDENTIFICATION control and an electrical control unit. The electrical The transmission can be generically identified control unit comprises of a supporting body made of visually by the presence of a round 13-way connector...
  • Page 149 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 5 • Stop the vehicle. flexible adaptation to different vehicle and engine variants. • Move selector lever to “P”. • Switch off engine. EMERGENCY RUNNING FUNCTION • Wait at least 10 seconds. In order to ensure a safe driving state and to pre- •...
  • Page 150 21 - 6 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION FIRST GEAR POWERFLOW Fig. 2 First Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...

  • Page 151: Tires/Wheels

    TIRES/WHEELS 22 - 1 TIRES / WHEELS TABLE OF CONTENTS page page TIRES/WHEELS DIAGNOSIS AND TESTING - TIRE WEAR DIAGNOSIS AND TESTING - TIRE AND PATTERNS ......9 WHEEL RUNOUT .
  • Page 152 22 - 2 TIRES/WHEELS Radial runout of more than 1.5 mm (.060 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral runout of more than 2.0 mm (.080 inch) measured near the shoulder of the tire may cause the vehicle to shake.
  • Page 153 TIRES/WHEELS 22 - 3 marked permanently on the inside of the rim in the tire well. This permanent mark may be a paint dot or line, a permanent label or a stamped impression such as an X. An optional location mark is a small spherical indentation on the vertical face of the out- board flange on some non styled base steel wheels.
  • Page 154 22 - 4 TIRES/WHEELS Fig. 6 Remount Tire 90 Degrees In Direction of Arrow 1 - 2ND HIGH SPOT ON TIRE 2 - 1ST HIGH SPOT ON TIRE STANDARD PROCEDURE - TIRE AND WHEEL BALANCE It is recommended that a two plane service dynamic balancer be used when a tire and wheel assembly require balancing.
  • Page 155 TIRES/WHEELS 22 - 5 Fig. 7 Static Unbalance & Balance 1 - HEAVY SPOT 4 - CORRECTIVE WEIGHT LOCATION 2 - CENTER LINE OF SPINDLE 5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP 3 - ADD BALANCE WEIGHTS HERE...
  • Page 156 22 - 6 TIRES/WHEELS Fig. 8 Dynamic Unbalance & Balance 1 - CENTER LINE OF SPINDLE 3 - CORRECTIVE WEIGHT LOCATION 2 - ADD BALANCE WEIGHTS HERE 4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION STANDARD PROCEDURE - TIRE ROTATION CAUTION: 3500 Dual rear tires have a new tire rota- tion pattern.

  • Page 157: Body

    BODY 23 - 1 BODY TABLE OF CONTENTS page page BODY DOOR - FRONT ......13 WARNING DOORS - REAR .
  • Page 158 23 - 2 BODY aligned and sealed. If component alignment or seal- also be used to deflect light to a limited-access area ing is necessary, refer to the appropriate section of to assist in locating a leak point. this group for proper procedures. BRIGHT LIGHT LEAK TEST METHOD WATER LEAK TESTS Some water leaks in the luggage compartment can...
  • Page 159 RESIN, PETROLEUM, OR ALCOHOL BASED SOL- an adhesion promoter for repair. These types of plas- VENTS. PERSONAL INJURY CAN RESULT. tic are used extensively on DaimlerChrysler Motors • DO NOT VENTURE UNDER A HOISTED VEHI- vehicles. Always follow repair material manufactur- CLE THAT IS NOT PROPERLY SUPPORTED ON er’s plastic identification and repair procedures.
  • Page 160 23 - 4 BODY CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN, DOOR PANELS, GRILLES, CYCLOVIN TRIM BULK MOLDING COM- FENDER EXTENSIONS POUND EHTYLENE METHYL ACRY- SURLYN, EMA, IONOMER BUMPER GUARDS, PADS LATE/IONOMER METTON METTON METTON GRILLES, KICK PANELS,...
  • Page 161 BODY 23 - 5 CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION EMPP ETHYLENE MODIFIED EMPP BUMPER COVERS POLYPROPYLENE EPDM ETHYLENE/PROPROPY- EPDM, NORDEL, VISTALON BUMPERS LENE DIENE MONOMER ETHYLENE/PROPROPY- FENDERS LENE CO-POLYMER FOAM POLYURETHANE SPOILERS POLYETHYLENE ALATHON, DYLAN, LUPOLEN, MARLEX POLYPROPYLENE NORYL, AZDEL, MARLOX, INNER FENDER, SPOILERS,...
  • Page 162 23 - 6 BODY When bonding plastic panels, Follow repair mate- rial manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured.
  • Page 163 HEATING & AIR CONDITIONING 24 - 1 HEATING & AIR CONDITIONING TABLE OF CONTENTS page page HEATING & AIR CONDITIONING CONTROLS-FRONT ......8 DESCRIPTION .

  • Page 164: Heating & Air Conditioning Description

    24 - 2 HEATING & AIR CONDITIONING A heater booster is used to aid in warming the engine coolant. The heater booster system can be switched on while the vehicle is being driven to help the engine reach its normal operating temperature quickly and will help aid in heating up the air within the passenger compartment quickly when requested by the operator (Fig.

  • Page 165: Diagnosis And Testing A/C Performance

    HEATING & AIR CONDITIONING 24 - 3 When the outside air contains smoke, odors, high trouble with the A/C system. The ambient air tem- humidity, or if rapid cooling is desired, interior air perature in the location where the vehicle will be can by recirculated by selecting the Recirculation tested must be a minimum of 21°...
  • Page 166 24 - 4 HEATING & AIR CONDITIONING (4) With the A/C compressor clutch engaged, duct by performing the ATC Function Test (Refer to 24 - temperature should not be less than 2° C (35° F) or HEATING & AIR CONDITIONING - DIAGNOSIS more than 12°...

  • Page 167: Heater Performance Test

    HEATING & AIR CONDITIONING 24 - 5 Condition Possible Causes Correction The low side pressure is 1. Low refrigerant system 1. See Refrigerant System Leaks in this normal or slightly low, and charge. group. Test the refrigerant system for leaks. the high side pressure is too Repair, evacuate and charge the refrigerant low.

  • Page 168: Atc Function Test

    24 - 6 HEATING & AIR CONDITIONING • Mode control in the floor heat position pare the test thermometer reading to the Tempera- ture Reference chart. • Blower motor control in the highest speed posi- tion Using a test thermometer, check the temperature of the air being discharged at the floor outlets.

  • Page 169: Emissions Control

    EMISSIONS CONTROL 25 - 1 EMISSIONS CONTROL TABLE OF CONTENTS page page EVAPORATIVE EMISSIONS ....1 EXHAUST GAS RECIRCULATION ... . . 4 EVAPORATIVE EMISSIONS TABLE OF CONTENTS page...
  • Page 170 25 - 2 EVAPORATIVE EMISSIONS (4) Connect the wiring harness connector to the CCV heater (Fig. 1). (5) Install the turbocharger heat shield. (6) Connect the negative battery cable. CRANKCASE VENTILATION BREATHER DESCRIPTION The crankcase ventilation breather is a three staged, filtered, oil separating breather with a oil return passage into the cylinder head cover (Fig.
  • Page 171 EVAPORATIVE EMISSIONS 25 - 3 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...
  • Page 172 25 - 4 EXHAUST GAS RECIRCULATION EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page page EXHAUST GAS RECIRCULATION REMOVAL ......6 DESCRIPTION .
  • Page 173 EXHAUST GAS RECIRCULATION 25 - 5 Fig. 1 EGR AND COOLER 1 - EGR VALVE 3 - COOLING FINS 2 - COOLANT PASSAGE 4 - EXHAUST GAS PASSAGE VALVE DESCRIPTION Exhaust gas recirculation reduces the quantity of fresh air supplied to the cylinders per stroke without having to throttle the air supply.
  • Page 174 25 - 6 EXHAUST GAS RECIRCULATION (5) Disconnect the EGR cooler hose. (6) Remove the EGR fasteners and EGR with cooler assembly (Fig. 3). Fig. 2 EXHAUST GAS RECIRCULATION 1 - EGR VALVE 2 -CHARGE AIR PRESSURE SENSOR 3 - EXHAUST MANIFOLD Fig.
  • Page 175 INDEX Description Group-Page Description Group-Page Description Group-Page INDEX ABS INDICATOR ..... . . 8J-9 CENTER TRACK ..... . 23-37 FOG LAMP BULB .
  • Page 176 INDEX Description Group-Page Description Group-Page Description Group-Page INSIDE HANDLE ACTUATOR ..23-33, 23-36 PUMP ......19-11 STARTER MOTOR .

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