Mercedes Sprinter Workshop Manual

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MERCEDES SPRINTER - WORKSHOP, SERVICE, REPAIR MANUAL

- English Workshop Manual to vehicles Mercedes Sprinter.

CONTENTS:

00 INTRO

01 WORKSHOP MANUAL

Foreword

Group tab locator

In-introduction 
- Vehicle identification number 
- Description 
- International symbols 
- Description 
- Fastener identification 
- Description 
- Fastener usage 
- Description - fastener usage 
- Threaded hole repair 
- Description - threaded hole repair 
- Metric system 
- Description 
- Torque references 
- Description

0-lubrication & maintenance 
- Fluid types 
- Description 
- Parts and lubricant recommendations 
- Automatic transmission fluid - nag1 
- Fluid additives 
- Axle fluid 
- Brake fluid 
- Hoat coolant 
- Coolant performance 
- Engine oil - diesel engines 
- Sae viscosity grade 
- Fuel requirements - diesel engine 
- Diesel fuels for use at very low temperature 
- Power steering fluid 
- Operation - automatic transmission fluid 
- Fluid capacities 
- Specifications - fluid capacities 
- Fluid fill / check locations 
- Inspection - fluid fill / check locations 
- Hoisting 
- Standard procedure - hoisting 
- Floor jack 
- Hoist 
- Jump starting 
- Standard procedure - jump starting 
- To jump start a disabled vehicle: 
- Disconnect cable clamps as follows: 
- Towing 
- Standard procedure - towing 
- If the engine is damaged 
- If the transmission is damaged 
- If the front axle is damaged 
- If the rear axle is damaged 
- Safety precautions 
- Ground clearance 
- Ramp angle 
- Towing when keys are not available 
- Maintenance schedules 
- Description 
- Maintenance - without assyst maintenance computer 
- Maintenance - with assyst maintenance computer 
- Regular check - ups 
- Special maintenance requirements 
- Engine oil change and filter replacement 
- Scope of work for maintenance service 
- Additional maintenance work 
- Additional maintenance work after years 
- International symbols 
- Description

2-suspension 
- Front 
- Front 
- Specifications - torque chart 
- Special tools 
- Front suspension 
- Bushings 
- Removal 
- Installation 
- Hub / bearing 
- Diagnosis and testing - 
- Removal 
- Installation 
- Knuckle 
- Removal 
- Installation 
- Lower ball joint 
- Removal 
- Installation 
- Lower control arm 
- Removal 
- Installation 
- Spring 
- Removal 
- Installation 
- Spring clamp plates 
- Removal 
- Installation 
- Spring stop plates 
- Removal 
- Installation 
- Stabilizer bar 
- Description 
- Operation 
- Removal 
- Installation 
- Stabilizer link 
- Removal 
- Installation 
- Strut 
- Removal 
- Installation 
- Rear 
- Rear 
- Description 
- Diagnosis and testing - spring and shock 
- Specifications - torque chart 
- Shock 
- Diagnosis and testing - shock 
- Removal 
- Installation 
- Spring 
- Description 
- Operation 
- Removal 
- Removal - (srw) 
- Removal - (drw) 
- Installation 
- Installation - (srw) 
- Installation - (drw) 
- Spring shackle 
- Removal 
- Installation 
- Stabilizer bar 
- Removal 
- Installation 
- Stabilizer link 
- Removal 
- Installation 
- Wheel alignment 
- Wheel alignment 
- Description 
- Diagnosis and testing - pre - alignment inspection 
- Standard procedure - toe adjustment 
- Specifications

3-differential & driveline 
- Propeller shaft 
- Propeller shaft 
- Diagnosis and testing 
- Propeller shaft 
- Propeller shaft vibration 
- Propeller shaft balance 
- Propeller shaft runout 
- Standard procedure 
- Propeller shaft angle 
- Two / three - piece propeller shaft 
- Specifications 
- Special tools 
- Propeller shaft 
- Removal 
- Installation 
- Center bearing 
- Removal 
- Installation 
- Rear axle 
- Rear axle 
- Diagnosis and testing 
- Gear noise 
- Bearing noise 
- Low speed knock 
- Vibration 
- Driveline snap 
- Standard procedure - drain and fill 
- Removal 
- Installation 
- Specifications 
- Special tools 
- Shaft - axle single rear wheel 
- Removal-single rear wheel 
- Installation - single rear wheel 
- Bearing / seal - axle 
- Removal 
- Installation 
- Shaft - axle dual rear wheels 
- Removal - dual rear wheel 
- Installation - dual rear wheel 
- Bearing / seal - axle hub 
- Removal 
- Installation 
- Differential 
- Removal 
- Disassembly 
- Disassembly - single rear wheel 
- Disassembly - dual rear wheel 
- Assembly 
- Assembly - single rear wheel 
- Assembly - dual rear wheel 
- Installation 
- Bearings - differential case 
- Removal 
- Installation 
- Seal - pinion 
- Removal 
- Installation 
- Gear - pinion / ring 
- Removal 
- Installation

5-brakes 
- Brakes - base 
- Brakes - base 
- Diagnosis and testing - base brake system 
- Preliminary brake check 
- Road testing 
- Brake noises 
- Standard procedure 
- Standard procedure - manual bleeding 
- Standard procedure - pressure bleeding 
- Hydraulic / mechanical 
- Specifications 
- Specifications - torque chart 
- Base brake 
- Special tools 
- Brakes 
- Brake lines 
- Standard procedure 
- Standard procedure - iso flaring 
- Standard procedure - double inverted flaring 
- Brake pads / shoes 
- Removal 
- Removal - front (srw) 
- Removal - front (drw) 
- Removal - rear (16  wheels) (srw) 
- Removal - rear (15  wheels) (srw) 
- Removal - rear (drw) 
- Installation 
- Installation - front (srw) 
- Installation - front (drw) 
- Installation - rear (16  wheels) (srw) 
- Installation - rear (16  wheels) (srw) 
- Installation - rear (drw) 
- Disc brake calipers 
- Removal 
- Removal - front (srw) 
- Removal - front (drw) 
- Removal - rear (srw) 
- Removal - rear (drw) 
- Installation 
- Installation - front (srw) 
- Installation - front (drw) 
- Installation - rear (srw) 
- Installation - rear (drw) 
- Disc brake caliper adapter 
- Removal 
- Removal - front 
- Removal - rear 
- Installation 
- Installation - front 
- Installation - rear 
- Fluid 
- Diagnosis and testing - brake fluid contamination 
- Standard procedure - brake fluid level 
- Specifications 
- Brake fluid 
- Fluid reservoir 
- Removal 
- Installation 
- Alb lever 
- Removal 
- Installation 
- Alb controller 
- Removal 
- Installation 
- Adjustments 
- Adjustment 
- Master cylinder 
- Diagnosis and testing - master cylinder / power booster 
- Power booster vacuum test 
- Power booster check valve test 
- Standard procedure - master cylinder bleeding 
- Removal 
- Installation 
- Pedal 
- Removal 
- Installation 
- Power brake booster 
- Description 
- Operation 
- Removal 
- Installation 
- Rotors 
- Removal 
- Removal - front (srw) 
- Removal - rear (srw) 
- Removal - front (drw) 
- Removal - rear (drw) 
- Installation 
- Installation - front (srw) 
- Installation - rear (srw) 
- Installation - front (drw) 
- Installation - rear (drw) 
- Support plate 
- Removal - rear 
- Installation - rear 
- Parking brake 
- Specifications 
- Torque chart 
- Special tools 
- Park brake 
- Cable tensioner 
- Removal 
- Installation 
- Cables 
- Removal 
- Removal - front 
- Removal - rear 
- Installation 
- Installation - front 
- Installation - rear 
- Adjustments 
- Adjustment - parking brake cables 
- Lever 
- Removal 
- Installation 
- Shoes 
- Removal 
- Removal - (srw) 
- Removal - (drw) 
- Cleaning - rear drum in hat brake 
- Installation 
- Installation - (srw) 
- Installation - (drw) 
- Adjustments 
- Adjustment 
- Brakes - abs 
- Brakes - abs 
- Specifications - torque chart 
- Electrical 
- Description 
- Operation 
- Front wheel speed sensor 
- Removal 
- Installation 
- Rear wheel speed sensor 
- Removal 
- Installation 
- Tone wheel 
- Removal 
- Installation 
- Steering angle sensor 
- Description 
- Removal 
- Installation 
- Lateral acceleration sensor 
- Description 
- Removal 
- Installation 
- Yaw rate sensor 
- Description 
- Removal 
- Installation 
- Hcu (hydraulic control unit) 
- Description 
- Removal 
- Installation

7-cooling 
- Cooling 
- Operation - cooling system 
- Diagnosis and testing 
- Diagnosis and testing - preliminary checks 
- Engine cooling system overheating 
- Cooling system 
- Accessory drive 
- Belt tensioners 
- Description 
- Operation 
- Drive belts 
- Diagnosis and testing - accessory drive belt 
- Visual diagnosis 
- Noise diagnosis 
- Removal 
- Removal 
- Removal 
- Installation 
- Installation 
- Installation 
- Engine 
- Coolant 
- Description 
- Diagnosis and testing 
- Cooling system leaks 
- Ultraviolet light method 
- Pressure tester method 
- Internal leakage inspection 
- Combustion leakage test - without pressure tester 
- Standard procedure 
- Adding additional coolant 
- Draining cooling system 
- Refilling cooling system 
- Coolant level sensor 
- Removal 
- Installation 
- Radiator fan 
- Removal 
- Installation 
- Engine block heater 
- Removal 
- Installation 
- Engine coolant temp sensor 
- Description 
- Removal 
- Installation 
- Engine coolant thermostat 
- Removal 
- Installation 
- Fan drive viscous clutch 
- Removal 
- Installation 
- Radiator 
- Removal 
- Installation 
- Radiator pressure cap 
- Description 
- Operation 
- Diagnosis and testing - radiator pressure cap 
- Water pump 
- Removal 
- Installation

8a-audio / video 
- Audio 
- Special tools 
- Audio 
- Antenna body & cable 
- Removal 
- Installation 
- Instrument panel antenna cable 
- Removal 
- Installation 
- Radio 
- Removal 
- Installation 
- Speaker 
- Removal 
- Installation

8b-chime / buzzer 
- Chime / buzzer 
- Description 
- Operation 
- Diagnosis and testing - chime warning system

8e-electronic control modules 
- Central timer module 
- Description 
- Operation 
- Diagnosis and testing - central timer module 
- Removal 
- Installation 
- Controller antilock brake 
- Description 
- Removal 
- Installation 
- Engine control module 
- Description 
- Removal 
- Installation 
- Transmission control module 
- Description 
- Operation 
- Tcm signals 
- Brake transmission shift interlock (btsi) 
- Shift schedules 
- Downshift safety 
- Adaptation 
- Controller modes of operation 
- Standard procedure - tcm adaptation

8f-engine systems 
- Battery system 
- Battery system 
- Description 
- Operation 
- Diagnosis and testing - battery system 
- Micro 420 battery tester 
- Abnormal battery discharging 
- Cleaning 
- Inspection 
- Special tools 
- Battery system special tools 
- Battery 
- Description 
- Operation 
- Diagnosis and testing - battery 
- Micro 420 battery tester 
- Standard procedure 
- Standard procedure - battery charging 
- Charging a completely discharged battery 
- Charging time required 
- Standard procedure - open - circuit voltage test 
- Standard procedure - ignition - off draw test 
- Standard procedure - using micro 420 battery tester 
- Battery testing 
- Standard procedure - checking battery electrolyte level 
- Removal 
- Under hood battery removal 
- Auxiliary battery removal 
- Installation 
- Under hood battery installation 
- Auxiliary battery installation 
- Battery holddown 
- Description 
- Removal 
- Installation 
- Battery cables 
- Description 
- Operation 
- Diagnosis and testing - battery cables 
- Removal 
- Installation 
- Battery tray 
- Description 
- Operation 
- Removal 
- Installation 
- Charging system 
- Charging system 
- Specifications 
- Torque   2.7l diesel 
- Special tools 
- Generator 
- Description 
- Operation 
- Removal 
- Installation 
- Generator decoupler pulley 
- Description 
- Operation 
- Diagnosis and testing - generator decoupler 
- Removal 
- Installation 
- Voltage regulator 
- Description 
- Removal 
- Installation 
- Starting system 
- Starting system 
- Description 
- Operation 
- Diagnosis and testing - starting system 
- Inspection 
- Testing 
- Specifications 
- Torque - starter - diesel 
- Specifications - starter motor - diesel 
- Starter motor 
- Diagnosis and testing - starter motor 
- Removal 
- Installation 
- Starter motor relay 
- Description 
- Removal 
- Installation

8g-heated systems 
- Heated glass 
- Heated glass 
- Description 
- Operation 
- Diagnosis and testing 
- Electric backlight (ebl) system 
- Rear window defogger relay 
- Description 
- Operation 
- Removal 
- Installation 
- Rear window defogger switch 
- Description 
- Operation 
- Diagnosis and testing 
- Rear window defogger switch 
- Removal 
- Installation 
- Rear window defogger grid 
- Standard procedure 
- Grid line and terminal repair 
- Heated mirrors 
- Heated mirrors 
- Description 
- Operation 
- Heated seats 
- Heated seats 
- Description 
- Operation 
- Diagnosis and testing - heated seats 
- Driver heated seat switch 
- Description 
- Operation 
- Diagnosis and testing - driver heated seat switch 
- Removal 
- Installation 
- Heated seat element 
- Description 
- Operation 
- Diagnosis and testing - heated seat element 
- Heated seat relay 
- Description 
- Operation 
- Diagnosis and testing - heated seat relay 
- Removal 
- Installation 
- Heated seat sensor 
- Description 
- Diagnosis and testing - heated seat sensor 
- Passenger heated seat switch 
- Description 
- Operation 
- Diagnosis and testing - passenger heated seat switch 
- Removal 
- Installation

8h-horn 
- Horn 
- Removal 
- Installation 
- Horn switch 
- Removal 
- Installation

8i-ignition control 
- Ignition control 
- Operation - glow plug 
- Pre - glowing 
- Glow output stage 
- After glow 
- Special tools 
- Glow plug 
- Removal 
- Installation 
- Glow plug relay 
- Description 
- Operation 
- Diagnosis and testing - glow plug relays

8j-instrument cluster 
- Instrument cluster 
- Description 
- Operation 
- Input and output circuits 
- Diagnosis and testing - instrument cluster 
- Standard procedure 
- Cluster programming 
- Removal 
- Installation 
- Abs indicator 
- Description 
- Operation 
- Adr indicator 
- Description 
- Operation 
- Airbag indicator 
- Description 
- Operation 
- Ambient temperature indicator 
- Description 
- Operation 
- Brake indicator 
- Description 
- Operation 
- Brake wear indicator 
- Description 
- Operation 
- Charging indicator 
- Description 
- Operation 
- Clock 
- Description 
- Operation 
- Coolant low indicator 
- Description 
- Operation 
- Engine temperature gauge 
- Description 
- Operation 
- Esp indicator 
- Description 
- Operation 
- Fuel filter clogged indicator 
- Description 
- Operation 
- Fuel gauge 
- Description 
- Operation 
- Gear selector indicator 
- Description 
- Operation 
- High beam indicator 
- Description 
- Operation 
- Low fuel indicator 
- Description 
- Operation 
- Low oil level indicator 
- Description 
- Operation 
- Maintenance indicator 
- Description 
- Operation 
- Malfunction indicator lamp (mil) 
- Description 
- Operation 
- Multi - function indicator 
- Description 
- Operation 
- Odometer 
- Description 
- Operation 
- Park brake indicator 
- Description 
- Operation 
- Seatbelt indicator 
- Description 
- Operation 
- Speedometer 
- Description 
- Operation 
- Tachometer 
- Description 
- Operation 
- Traction control indicator 
- Description 
- Operation 
- Traction control malfunction indicator 
- Description 
- Operation 
- Turn signal indicator 
- Description 
- Operation 
- Wait - to - start indicator 
- Description 
- Operation 
- Washer fluid indicator 
- Description 
- Operation 
- Water - in - fuel indicator 
- Description 
- Operation

8l-lamps 
- Lamps / lighting - exterior 
- Lamps / lighting - exterior 
- Description 
- Operation 
- Specifications - lamps / lighting - exterior 
- Backup lamp bulb 
- Removal 
- Installation 
- Brake lamp switch 
- Removal 
- Installation 
- Adjustments 
- Adjustment 
- Brake / park lamp bulb 
- Removal 
- Installation 
- Center high mounted stop lamp bulb 
- Removal 
- Installation 
- Center high mounted stop lamp un 
- Removal 
- Installation 
- Clearance lamp bulb 
- Removal 
- Installation 
- Clearance lamp unit 
- Removal 
- Installation 
- Daytime running lamp relay 
- Removal 
- Installation 
- Fog lamp bulb 
- Removal 
- Installation 
- Fog lamp relay 
- Removal 
- Installation 
- Fog lamp switch 
- Removal 
- Installation 
- Front lamp unit 
- Removal 
- Installation 
- Adjustments 
- Adjustment - front lamp unit 
- Vehicle preparation for front lamp unit alignment 
- Front lamp unit alignment 
- Front position lamp bulb 
- Removal 
- Installation 
- Front turn / park / side marker lamp bulb 
- Removal 
- Installation 
- Headlamp leveling motor 
- Removal 
- Installation 
- Headlamp leveling switch 
- Removal 
- Installation 
- High beam headlamp bulb 
- Removal 
- Installation 
- License plate lamp bulb 
- Removal 
- Installation 
- License plate lamp unit 
- Removal 
- Installation 
- Low beam headlamp bulb 
- Removal 
- Installation 
- Multi - function switch 
- Removal 
- Installation 
- Park brake switch 
- Removal 
- Installation 
- Rear side marker lamp bulb 
- Removal 
- Installation 
- Rear turn lamp bulb 
- Removal 
- Installation 
- Repeater lamp bulb 
- Removal 
- Installation 
- Repeater lamp unit 
- Removal 
- Small 
- Large 
- Installation 
- Small 
- Large 
- Tail lamp unit 
- Removal 
- Installation 
- Turn signal relay 
- Removal 
- Installation 
- Lamps / lighting - interior 
- Lamps / lighting - interior 
- Description 
- Operation 
- Interior lighting circuit 
- Exterior lighting circuit 
- Specifications - interior lighting 
- Ash receiver / cigar lighter lamp unit 
- Removal 
- Installation 
- Cargo / dome lamp bulb 
- Removal 
- Installation 
- Cargo / dome lamp unit 
- Removal 
- Installation 
- Cargo lamp switch 
- Removal 
- Removal - instrument panel

- Removal - bulkhead 
- Removal - rear pillar 
- Installation 
- Installation - instrument panel 
- Installation - bulkhead 
- Installation - rear pillar 
- Dome / reading lamp bulb 
- Removal 
- Installation 
- Dome / reading lamp unit 
- Removal 
- Installation 
- Dome lamp / intrusion sensor bulb 
- Removal 
- Installation 
- Dome lamp / intrusion sensor 
- Removal 
- Installation 
- Door jamb switch 
- Removal 
- Installation 
- Entry / exit lamp bulb 
- Removal 
- Installation 
- Entry / exit lamp unit 
- Removal 
- Installation 
- Time delay relay 
- Removal 
- Installation

8n-power systems 
- Power locks 
- Door lock motor 
- Removal 
- Installation 
- Remote keyless entry transmitter 
- Description 
- Master lock switch 
- Description 
- Diagnosis and testing - master lock switch 
- Removal 
- Installation 
- Power mirrors 
- Power mirrors 
- Description 
- Power mirror switch 
- Diagnosis and testing - power mirror switch 
- Removal 
- Installation 
- Power windows 
- Power windows 
- Description 
- Operation 
- Window switch 
- Window motor 
- Window motor 
- Removal 
- Power window switch 
- Diagnosis and testing - power window switch 
- Removal 
- Installation

8o-restraints 
- Restraints 
- Description 
- Active restraints 
- Passive restraints 
- Operation 
- Active restraints 
- Passive restraints 
- Warnings - restraint system 
- Diagnosis and testing - supplemental restraint system 
- Standard procedure 
- Standard procedure - handling non - deployed supplemental restraints 
- Supplemental restraint storage 
- Standard procedure - service after a supplemental restraint deployment 
- Cleanup procedure 
- Standard procedure - verification test 
- Airbag control module 
- Description 
- Operation 
- Removal 
- Installation 
- Clockspring 
- Description 
- Operation 
- Standard procedure - clockspring centering 
- Removal 
- Installation 
- Driver airbag 
- Description 
- Operation 
- Removal 
- Installation 
- Front seat belt & retractor 
- Removal 
- Installation 
- Front seat belt buckle 
- Removal 
- Installation 
- Passenger airbag 
- Description 
- Operation 
- Removal 
- Installation 
- Passenger airbag bracket 
- Removal 
- Installation 
- Rear seat belt & retractor 
- Removal 
- Installation 
- Rear seat belt buckle 
- Removal 
- Removal - inboard 
- Removal - outboard 
- Installation 
- Installation - inboard 
- Installation - outboard 
- Seat belt switch 
- Description 
- Operation 
- Seat belt tensioner 
- Description 
- Operation 
- Seat belt turning loop adjuster 
- Removal 
- Installation 
- Side curtain airbag 
- Description 
- Operation 
- Removal 
- Installation 
- Side impact sensor 
- Description 
- Operation 
- Removal 
- Installation

8p-speed control 
- Speed control 
- Description 
- Operation 
- Specifications 
- Torque 
- Cable 
- Description 
- Servo 
- Description 
- Switch 
- Removal 
- Installation

8q-vehicle theft security 
- Vehicle theft security 
- Description 
- Operation 
- Diagnosis and testing - vehicle theft security 
- Intrusion sensor 
- Removal 
- Installation 
- Security system module 
- Removal 
- Installation 
- Sentry key remote entry module 
- Description 
- Sentry key immobilizer 
- Remote keyless entry (rke) 
- Operation 
- Sentry key immobilizer 
- Remote keyless entry 
- Removal 
- Sentry key remote entry module 
- Sentry key remote entry module transponder ring 
- Installation 
- Sentry key remote entry module 
- Sentry key remote entry module transponder ring 
- Siren 
- Removal 
- Installation 
- Transponder key 
- Description 
- Operation

8r-wipers / washers 
- Wipers/washers 
- Description 
- Operation 
- Intermittent wipe system 
- Automatic wipe system 
- Operating modes 
- Diagnosis and testing - wiper & washer system 
- Intermittent wiper system 
- Automatic wiper system 
- Cleaning - wiper & washer system 
- Wiper system 
- Washer system 
- Inspection - wiper & washer system 
- Wiper system 
- Washer system 
- Check valve 
- Description 
- Operation 
- Removal 
- Installation 
- Rain sensor 
- Description 
- Operation 
- Standard procedure 
- Rain sensor bracket replacement 
- Removal 
- Installation 
- Rain sensor control module 
- Description 
- Operation 
- Removal 
- Installation 
- Washer fluid level switch 
- Description 
- Operation 
- Washer hoses / tubes 
- Description 
- Operation 
- Washer nozzle 
- Description 
- Operation 
- Removal 
- Installation 
- Washer pump / motor 
- Description 
- Operation 
- Removal 
- Installation 
- Washer reservoir 
- Description 
- Operation 
- Removal 
- Installation 
- Wiper arm 
- Description 
- Operation 
- Removal 
- Installation 
- Wiper blade 
- Description 
- Operation 
- Removal 
- Installation 
- Wiper linkage 
- Description 
- Operation 
- Removal 
- Installation 
- Wiper motor 
- Description 
- Operation 
- Removal 
- Installation 
- Wiper relay 
- Description 
- Operation 
- Removal 
- Installation

8w-wiring 
- 8w-01 wiring diagram information 
- Wiring diagram information 
- Description 
- How to use wiring diagrams 
- Symbols 
- Terminology 
- Circuit information 
- Section identification and information 
- Connector, ground, and splice information 
- Identification 
- Locations 
- Warnings - general 
- Diagnosis and testing 
- Wiring harness 
- Troubleshooting tools 
- Intermittent and poor connections 
- Troubleshooting wiring problems 
- Standard procedure 
- Electrostatic discharge (esd) sensitive devices 
- Testing for voltage potential 
- Testing for continuity 
- Testing for a short to ground 
- Testing components for a short to ground on a fuse powering several loads 
- Testing for a voltage drop 
- Connector 
- Removal 
- Installation 
- Diode 
- Removal 
- Installation 
- Terminal 
- Removal 
- Installation 
- Wire 
- Standard procedure 
- Wire splicing 
- 8w-02 component index 
- 8w-10 power distribution 
- 8w-11 fuse block 
- 8w-15 ground distribution 
- 8w-18 bus communications 
- 8w-20 charging system 
- 8w-21 starting system 
- 8w-30 fuel/ignition system 
- 8w-31 transmission control system 
- 8w-33 vehicle speed control 
- 8w-35 antilock brakes 
- 8w-39 vehicle theft security system 
- 8w-40 instrument cluster 
- 8w-41 horn/cigar lighter 
- 8w-42 air conditioning-heater 
- 8w-43 airbag system 
- 8w-44 interior lighting 
- 8w-45 central timer module 
- 8w-47 audio system 
- 8w-48 rear window defogger 
- 8w-50 front lighting 
- 8w-51 rear lighting 
- 8w-52 turn signals 
- 8w-53 wipers 
- 8w-54 trailer tow 
- 8w-55 navigation/telecommunications 
- 8w-60 power windows 
- 8w-61 power door locks 
- 8w-62 power mirrors 
- 8w-63 power seats 
- 8w-70 splice information 
- 8w-80 connector pin-outs 
- 8w-91 connector/ground/splice location 
- Connector/ground/splice location 
- Description 
- 8w-97 power distribution 
- Power distribution 
- Description 
- Operation 
- Cigar lighter outlet 
- Description 
- Operation 
- Diagnosis and testing - cigar lighter outlet 
- Removal 
- Circuit breaker 
- Description 
- Operation 
- Diagnosis and testing - circuit breaker 
- Fuse block #1 
- Description 
- Operation 
- Removal 
- Installation 
- Fuse block #2 
- Description 
- Operation 
- Power distribution center 
- Description 
- Operation 
- Power outlet 
- Description 
- Operation 
- Diagnosis and testing - power outlet 
- Removal 
- Installation 
- Relay 
- Description 
- Operation 
- Diagnosis and testing - relay 
- Diagnosis and testing - relay circuit test 
- Removal 
- Installation

9-engine 
- Engine 
- Description 
- Standard procedure 
- Standard procedure - compression testing engine 
- Standard procedure - cylinder leak down test 
- Inspecting 
- Standard procedure - determining cylinder pressure loss 
- Removal 
- Removal - engine cover 
- Removal 
- Installation 
- Installation - engine cover 
- Installation 
- Specifications - torque specifications 
- Special tools 
- Air cleaner element 
- Removal 
- Installation 
- Air cleaner housing 
- Removal 
- Installation 
- Cylinder head 
- Description 
- Standard procedure 
- Standard procedure - cylinder head bolt inspection 
- Standard procedure - measure cylinder head surface 
- Removal 
- Removal - cylinder head 
- Removal - cylinder head front cover 
- Removal - cylinder head guide rail 
- Installation 
- Installation - cylinder head 
- Installation - cylinder head front cover 
- Installation - cylinder head guide rail 
- Camshaft(s) 
- Standard procedure 
- Standard procedure - checking camshaft position 
- Standard procedure - inspecting tappet clearance 
- Removal 
- Installation 
- Cylinder head cover(s) 
- Removal 
- Installation 
- Valve stem seals 
- Description 
- Valve springs 
- Removal 
- Removal - valve springs 
- Removal - valves 
- Installation 
- Installation - valve springs 
- Installation - valves 
- Engine block 
- Standard procedure 
- Standard procedure - replacing engine core and oil gallery plugs 
- Standard procedure - measuring cylinder bores 
- Crankshaft 
- Description 
- Standard procedure - measure crankshaft and block journals 
- Assign crankshaft bearing shells 
- Removal 
- Installation 
- Crankshaft oil seal - rear 
- Removal 
- Installation 
- Crankshaft oil seal - front 
- Removal 
- Installation 
- Flywheel 
- Removal 
- Installation 
- Installation 
- Installation - crankshaft lock 
- Piston & connecting rod 
- Description 
- Standard procedure 
- Standard procedure - checking and repairing connecting rods 
- Connecting rod specifications 
- Standard procedure - measuring piston protrusion 
- Removal 
- Installation 
- Piston rings 
- Standard procedure - piston ring fitting 
- Vibration damper 
- Removal 
- Installation 
- Vacuum pump 
- Description 
- Operation 
- Removal 
- Installation 
- Left mount 
- Removal 
- Installation 
- Right mount 
- Removal 
- Installation 
- Oil 
- Removal - oil separator 
- Installation - oil separator 
- Oil cooler & lines 
- Removal 
- Installation 
- Oil filter 
- Removal 
- Installation 
- Oil jet 
- Description 
- Removal 
- Installation 
- Oil pan 
- Removal 
- Installation 
- Oil pump 
- Removal 
- Removal 
- Removal - oil pump chain 
- Installation 
- Installation 
- Installation - oil pump chain

- Oil sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Intake manifold 
- Removal 
- Installation 
- Exhaust manifold 
- Removal 
- Installation 
- Timing chain cover 
- Removal 
- Installation 
- Timing chain and sprockets 
- Removal 
- Removal - tensioning and slide rails 
- Removal - intermediate gear 
- Removal - timing chain tensioning rail 
- Removal - timing chain 
- Installation 
- Installation - tensioning and slide rail 
- Installation - intermediate gear 
- Installation - timing chain tensioning rail 
- Adjustments 
- Installation - timing chain 
- Timing chain tensioner 
- Removal 
- Installation

11-exhaust system 
- Exhaust system 
- Description - 2.7l diesel 
- Diagnosis and testing - diesel engine 
- Catalytic converter 
- Removal 
- Installation 
- Exhaust pipe 
- Removal 
- Installation 
- Tailpipe 
- Removal 
- Installation 
- Turbocharger system 
- Description 
- Operation 
- Charge air cooler and plumbing 
- Description 
- Operation 
- Diagnosis and testing - charge air cooler system - leaks 
- Removal 
- Cleaning 
- Inspection 
- Installation 
- Turbocharger 
- Description 
- Operation 
- Removal 
- Removal 
- Removal - vacuum transducer 
- Installation 
- Installation 
- Installation - vacuum transducer

13-frame & bumpers 
- Bumpers 
- Specifications - torque 
- Front bumper - steps 
- Removal 
- Installation 
- Front fascia 
- Removal 
- Installation 
- Rear bumper - step 
- Removal 
- Installation 
- Rear fascia 
- Removal 
- Installation 
- Frame 
- Specifications 
- Specifications - frame dimensions 
- Vehicle preparation 
- Specifications - torque 
- Engine cradle crossmember 
- Removal 
- Installation 
- Rear crossmember - transmission 
- Removal 
- Installation 
- Trailer hitch 
- Removal 
- Installation

14-fuel system 
- Fuel system 
- Warning 
- Warning - high fuel system pressure 
- Warning 
- Diagnosis and testing 
- Diagnosis and testing - high pressure fuel lines 
- Diagnosis and testing - air in fuel system 
- Diagnosis and testing - injector leak quantity 
- Cranking test 
- Running test 
- Standard procedure 
- Standard procedures - cleaning fuel system components 
- Standard procedures - draining water from fuel filter 
- Standard procedure - low pressure fuel pump test 
- Fuel delivery 
- Fuel delivery 
- Description 
- Operation 
- Start of actuation 
- Switching off main injection 
- Calculating main injection 
- Period of actuation 
- Deceleration mode 
- Full load injected quantity 
- Limiting maximum engine speed 
- Fuel quantity control 
- Boiling protection 
- Fuel tank protection 
- Standard procedure 
- Standard procedure - draining fuel tank - diesel 
- Fuel contamination 
- Specifications 
- Torque 
- Special tools 
- Fuel system 
- Fuel drain tubes 
- Diagnosis and testing - fuel supply restrictions 
- Low - pressure lines 
- High - pressure lines 
- Fuel filter 
- Description 
- Removal 
- Installation 
- Fuel lines 
- Removal - high pressure lines 
- Installation - high pressure lines 
- Fuel rail pressure sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel pump 
- Description 
- Description - high pressure pump 
- Description - low pressure pump 
- Operation 
- Operation 
- Low pressure side 
- High pressure side 
- Operation - low pressure pump 
- Removal - high pressure pump 
- Installation - high pressure pump 
- Fuel pump module 
- Description 
- Removal 
- Installation 
- Fuel quantity control valve 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel rail 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel tank 
- Description 
- Removal 
- Installation 
- Fuel level sending unit / sensor 
- Description 
- Removal 
- Installation 
- Water in fuel sensor 
- Description 
- Operation 
- Fuel injection 
- Accelerator pedal position sensor 
- Description 
- Removal 
- Installation 
- Boost pressure sensor 
- Description 
- Operation 
- Diagnosis and testing - boost pressure sensor 
- Removal 
- Installation 
- Camshaft position sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Crankshaft position sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel injector 
- Description 
- Fuel injector 
- Operation 
- Injector closed (with high pressure applied) 
- Injector opens (start of injection) 
- Injector opens fully 
- Injector closes (end of injection) 
- Standard procedure 
- Standard procedure - injector classification 
- Injector classification procedure 
- Cleaning fuel injectors 
- Removal 
- Installation 
- Fuel pressure sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel pressure solenoid 
- Description 
- Operation 
- Standard procedure - fuel pressure solenoid test 
- Removal 
- Installation 
- Fuel temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Intake air temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Intake air pressure sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Manifold air flow (maf) sensor 
- Description 
- Operation 
- Removal 
- Installation 
- O2 sensor 
- Description 
- Operation 
- Removal 
- Installation

19-steering 
- Steering 
- Description 
- Operation 
- Diagnosis and testing - power steering system 
- Column 
- Column 
- Specifications - torque chart 
- Intermediate shaft 
- Removal 
- Installation 
- Key / lock cylinder 
- Removal 
- Installation 
- Steering wheel 
- Removal 
- Installation 
- Gear 
- Gear 
- Description 
- Removal 
- Installation 
- Specifications - torque chart 
- Linkage 
- Linkage 
- Diagnosis and testing - outer tie rod end 
- Specifications - torque chart 
- Special tools 
- Front suspension 
- Tie rod end 
- Removal 
- Installation 
- Pump 
- Pump 
- Description 
- Operation 
- Diagnosis and testing - pump leakage 
- Standard procedure 
- Standard procedure - power steering pump - initial operation 
- Standard procedure - flushing power steering system 
- Removal 
- Installation 
- Specifications - torque chart 
- Fluid 
- Standard procedure 
- Power steering pump fill and bleed procedure 
- Fluid cooler tube 
- Removal 
- Installation 
- Hoses 
- Removal 
- Removal - pressure hose 
- Removal - return line from pump to cooler tube 
- Removal - return hose from gear to cooler tube 
- Installation 
- Installation - pressure hose 
- Installation - return line from pump to cooler tube 
- Installation - return hose from gear to cooler tube

21-transmission 
- Automatic transmission nag1 - service information 
- Automatic transmission nag1 - service information 
- Description 
- Transmission identification 
- Transmission gear ratios 
- Transmission housing 
- Mechanical section 
- Electrohydraulic control unit 
- Shift groups 
- Operation 
- Emergency running function 
- Clutch application 
- First gear powerflow 
- Second gear powerflow 
- Third gear powerflow 
- Fourth gear powerflow 
- Fifth gear powerflow 
- Reverse gear powerflow 
- Reverse gear powerflow - limp in 
- Shift groups/ shift sequence 
- Diagnosis and testing 
- Automatic transmission 
- Preliminary 
- Vehicle is drivable 
- Vehicle is disabled 
- Road testing 
- Automatic transmission 
- Standard procedure - aluminum thread repair 
- Removal 
- Disassembly 
- Assembly 
- Installation 
- Schematics and diagrams 
- Specifications - nag1 automatic transmission 
- Special tools - automatic transmission - nag1 
- Input clutches 
- Description 
- Operation 
- Input clutch k1 
- Disassembly 
- Assembly 
- Input clutch k2 
- Disassembly 
- Assembly 
- Input clutch k3 
- Disassembly 
- Assembly 
- Electrohydraulic unit 
- Description 
- Electrical control unit 
- Hydraulic control unit 
- Operation 
- Electrical control unit 
- Hydraulic control unit 
- Removal 
- Disassembly 
- Assembly 
- Installation 
- Fluid and filter 
- Description 
- Operation 
- Diagnosis and testing 
- Effects of incorrect fluid level 
- Causes of burnt fluid 
- Fluid contamination 
- Standard procedure 
- Check oil level 
- Transmission fill 
- Fluid / filter service 
- Freewheeling clutch 
- Description 
- Operation 
- Disassembly 
- Assembly 
- Gearshift cable 
- Diagnosis and testing 
- Gearshift cable 
- Removal 
- Installation 
- Holding clutches 
- Description 
- Operation 
- Holding clutch b1 
- Disassembly 
- Assembly 
- Holding clutch b2 
- Disassembly 
- Assembly 
- Input speed sensors 
- Description 
- Operation 
- Oil pump 
- Description 
- Operation 
- Disassembly 
- Inspection 
- Side clearance 
- Tip clearance 
- Assembly 
- Output shaft bearing 
- Removal 
- Installation 
- Output shaft seal 
- Removal 
- Installation 
- Park lock cable 
- Removal 
- Installation 
- Pistons 
- Description 
- Operation 
- Pressure

- Pressure on a confined fluid 
- Force multiplication 
- Piston travel 
- Planetary geartrain 
- Description 
- Operation 
- Disassembly 
- Assembly 
- Shift mechanism 
- Description 
- Operation 
- Removal 
- Installation 
- Solenoid 
- Description 
- Upshift / downshift solenoid valves 
- Modulating pressure control solenoid valve 
- Torque converter lockup clutch pwm solenoid valve 
- Shift pressure control solenoid valve 
- Operation 
- Upshift / downshift solenoid valves 
- Modulating pressure control solenoid valve 
- Torque converter lockup clutch pwm solenoid valve 
- Shift pressure control solenoid valve 
- Temperature sensor / park - neutral contact 
- Description 
- Park / neutral contact 
- Transmission temperature sensor 
- Operation 
- Park / neutral contact 
- Transmission temperature sensor 
- Torque converter 
- Description 
- Impeller 
- Turbine 
- Stator 
- Torque converter clutch (tcc) 
- Operation 
- Turbine 
- Stator 
- Torque converter clutch (tcc) 
- Removal 
- Installation 
- Torque converter hub seal 
- Removal 
- Installation

22-tires / wheels 
- Tires / wheels 
- Diagnosis and testing - tire and wheel runout 
- Method 1 (relocate wheel on hub) 
- Method 2 (relocate tire on wheel) 
- Standard procedure 
- Standard procedure - match mounting 
- Standard procedure - tire and wheel balance 
- Standard procedure - tire rotation 
- Specifications 
- Torque chart 
- Tires 
- Description 
- Description - tires 
- Tire identification 
- Tire chains 
- Description - radial   ply tires 
- Description - tire pressure for high speeds 
- Description - replacement tires 
- Description - tire inflation pressures 
- Diagnosis and testing 
- Diagnosis and testing - pressure gauges 
- Diagnosis and testing - tire noise or vibration 
- Diagnosis and testing - tread wear indicators 
- Diagnosis and testing - tire wear patterns 
- Diagnosis and testing - tire / vehicle lead 
- Standard procedure - repairing leaks

- Cleaning 
- Specifications 
- Tires 
- Spare tire carrier 
- Removal 
- Installation 
- Wheels 
- Description 
- Operation 
- Diagnosis and testing 
- Wheel inspection 
- Standard procedure 
- Standard procedure - wheel replacement 
- Standard procedure - dual rear wheel installation 
- Removal 
- Installation

23-body 
- Body 
- Warning 
- Safety precautions and warnings 
- Diagnosis and testing 
- Diagnosis and testing - water leaks 
- Visual inspection before water leak tests 
- Water leak tests 
- Water leak detection 
- Diagnosis and testing - wind noise 
- Visual inspection before tests 
- Standard procedure 
- Standard procedure - plastic body panel repair 
- Rigid plastics: 
- Semi - rigid plastics: 
- Flexible plastics: 
- Repair procedure: 
- Adhesion promoter / surface modifier: 
- Safety precaution and warnings 
- Rigid, semi-rigid, and flexible plastic parts types 
- Panel sectioning 
- Panel reinforcement 
- Visual inspection 
- Panel surface preparation 
- Patching panels 
- Panel patch fabrications 
- Panel patch installation 
- Patched panel surfacing 
- Standard procedure - buzz, squeak & rattle 
- Specifications 
- Door - front 
- Check 
- Removal 
- Installation 
- Door 
- Removal 
- Installation 
- Adjustments 
- Adjustment 
- Door glass 
- Removal 
- Installation 
- Exterior handle 
- Removal 
- Installation 
- Hinge 
- Removal 
- Installation 
- Latch 
- Removal 
- Installation 
- Latch striker 
- Removal 
- Installation 
- Lock cylinder 
- Removal 
- Installation 
- Trim panel 
- Removal 
- Installation 
- Window regulator - power 
- Removal 
- Installation 
- Window regulator - manual 
- Removal 
- Installation 
- Doors - rear 
- Check 
- Removal 
- Installation 
- Door 
- Removal 
- Disassembly 
- Right door 
- Left door 
- Assembly 
- Right door 
- Left door 
- Installation 
- Adjustments 
- Adjustment 
- Door glass 
- Removal 
- Installation 
- Exterior handle 
- Removal 
- Installation 
- Hinge 
- Removal 
- Installation 
- Inside handle actuator 
- Removal 
- Installation 
- Latch 
- Removal 
- Installation 
- Trim panel 
- Removal 
- Installation 
- Doors - sliding 
- Exterior handle 
- Removal 
- Installation 
- Inside handle actuator 
- Removal 
- Installation 
- Upper roller arm 
- Removal 
- Installation 
- Center roller arm 
- Removal 
- Installation 
- Lower roller arm 
- Removal 
- Installation 
- Center track 
- Removal

- Installation 
- Latch / lock control 
- Removal 
- Installation 
- Rear latch 
- Removal 
- Installation 
- Rear latch striker 
- Removal 
- Installation 
- Sliding door 
- Removal 
- Disassembly 
- Assembly 
- Installation 
- Adjustments 
- Adjustment 
- Gaps and ridge adjustment 
- Flush adjustment 
- Door stop bumper adjust 
- Stabilizer 
- Removal 
- Installation 
- Trim panel 
- Removal 
- Upper 
- Lower 
- Installation 
- Upper 
- Lower 
- Door glass 
- Removal

- Installation 
- Exterior 
- Fuel fill door 
- Removal 
- Installation 
- Grille 
- Removal 
- Installation 
- License plate bracket 
- Removal 
- Installation 
- Radiator crossmember 
- Removal 
- Installation 
- Side view mirror 
- Removal 
- Driver's side 
- Passenger side 
- Installation 
- Driver's side 
- Passenger side 
- Side view mirror - glass 
- Removal 
- Installation 
- Hood 
- Hinge 
- Removal 
- Installation 
- Hood 
- Removal 
- Installation 
- Adjustments 
- Adjustment 
- Latch 
- Removal 
- Installation 
- Latch release cable 
- Removal 
- Installation 
- Latch release handle 
- Removal 
- Installation 
- Prop rod 
- Removal 
- Installation 
- Safety latch 
- Removal 
- Installation 
- Instrument panel 
- Cluster bezel 
- Removal 
- Installation 
- Accessory switch bezel 
- Removal 
- Installation 
- Instrument panel center bezel 
- Removal 
- Installation 
- Ash receiver 
- Removal 
- Installation 
- Cup holder 
- Removal 
- Installation 
- Glove box 
- Removal 
- Installation 
- Instrument panel assembly 
- Removal 
- Installation 
- Top cover - cluster 
- Removal 
- Installation 
- Top cover - tray 
- Removal 
- Installation 
- Top cover 
- Removal 
- Installation 
- Steering column opening cover 
- Removal 
- Installation 
- Interior 
- Interior 
- Caution 
- A - pillar trim 
- Removal 
- Installation 
- Assist handle 
- Removal 
- Installation 
- B - pillar trim 
- Removal 
- Installation 
- Bulkhead trim panel 
- Removal 
- Installation 
- Carpets and floor mats 
- Removal 
- Cargo / passenger van - front 
- Passenger van - rear 
- Cargo van - rear 
- Installation 
- Cargo / passenger van - front 
- Passenger van - rear 
- Cargo van - rear 
- Cowl trim 
- Removal 
- Installation 
- D - pillar trim 
- Removal 
- Installation 
- Headliner 
- Removal 
- Cab section 
- Number 2 section 
- Number 3 section 
- Number 4 section 
- Installation 
- Cab section 
- Number 2 section 
- Number 3 section 
- Number 4 section 
- Quarter trim panel 
- Removal 
- Passenger van 
- Cargo van 
- Installation 
- Passenger van 
- Cargo van 
- Rear view mirror 
- Removal 
- Installation 
- Installation 
- Installation - rear view mirror support bracket 
- Stepwell scuff pads 
- Removal 
- Installation 
- Sun visor 
- Removal 
- Installation 
- Paint 
- Paint 
- Specifications - paint codes 
- Basecoat / clearcoat finish 
- Description 
- Paint touch - up 
- Description 
- Standard procedure - paint touch - up 
- Finesse sanding / buffing & polish 
- Description 
- Seats 
- Armrest 
- Removal 
- Installation 
- Headrest 
- Removal 
- Installation 
- Seat - front 
- Removal 
- Installation 
- Seat back - front 
- Removal 
- Installation 
- Seat cushion - front 
- Removal 
- Installation 
- Seat adjusters - front 
- Removal 
- Installation 
- Seat - rear 
- Removal 
- Installation 
- Rear seat back shield 
- Removal 
- Installation 
- Seat back cushion / cover - rear 
- Removal 
- Installation 
- Seat cushion / cover - rear 
- Removal 
- Installation 
- Stationary glass 
- Backlite - bulkhead trim panel 
- Removal 
- Installation 
- Quarter window 
- Removal 
- Installation 
- Windshield 
- Warning 
- Windshield safety precautions 
- Removal 
- Installation 
- Windshield preparation - installing a previously installed windshield 
- Windshield preparation - installing a new windshield 
- Windshield opening preparation 
- Windshield installation 
- Weatherstrip / seals 
- Front door inner belt weatherstrip 
- Removal 
- Installation 
- Front door outer belt weatherstrip 
- Removal 
- Installation 
- Door opening seals 
- Removal 
- Installation 
- Body structure 
- Gap and flush 
- Specifications 
- Opening dimensions 
- Specifications

24-heating & air conditioning 
- Heating & air conditioning 
- Description 
- Operation 
- Diagnosis and testing 
- A / c performance 
- A / c performance test 
- Heater performance test 
- Maximum heater output 
- Possible locations or cause of obstructed coolant flow 
- Possible locations or cause of insufficient heat 
- Temperature control 
- Atc function test 
- Specifications 
- Heating - a / c system 
- Controls - front 
- A / c compressor clutch 
- Description 
- Operation 
- Standard procedure 
- A / c compressor clutch air gap 
- A / c compressor clutch break - in 
- Removal 
- Inspection 
- Installation 
- A / c compressor clutch coil 
- Diagnosis and testing 
- A / c compressor clutch coil 
- A / c heater control 
- Description 
- Operation 
- Removal 
- Installation 
- A / c pressure transducer 
- Description 
- Operation 
- Diagnosis and testing

- A / c pressure transducer 
- Removal 
- Installation 
- Air outlet temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Ambient temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Blower motor resistor 
- Description 
- Operation 
- Diagnosis and testing 
- Blower motor resistor 
- Removal 
- Installation 
- Blower motor switch 
- Description 
- Operation 
- Diagnosis and testing 
- Blower motor switch 
- Evaporator temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- In - car temperature sensor 
- Description 
- Operation 
- Diagnosis and testing 
- In - car temperature sensor 
- Mode door cables 
- Removal 
- Installation 
- Recirculation door actuator 
- Description 
- Operation 
- Removal 
- Installation 
- Controls - rear 
- A / c clutch relay 
- Description 
- Operation 
- Removal 
- Installation 
- A / c condenser fan relay 
- Description 
- Operation 
- Removal 
- Installation 
- A / c control module 
- Description 
- Operation 
- Removal 
- Installation 
- A / c high pressure switch 
- Description 
- Operation 
- Removal 
- Installation 
- A / c low pressure switch 
- Description 
- Operation 
- Removal 
- Installation 
- Blower motor relay 
- Description 
- Operation 
- Removal 
- Installation 
- Blower motor switch 
- Description 
- Operation 
- Diagnosis and testing 
- Rear blower motor switch 
- Removal 
- Installation 
- Evaporator temperature sensor 
- Description 
- Operation 
- Removal 
- Installation 
- Temperature control 
- Description 
- Operation 
- Diagnosis and testing 
- Rear a / c temperature control 
- Removal 
- Installation 
- Temperature sensor 
- Description 
- Operation 
- Diagnosis and testing 
- Rear temperature sensor 
- Removal 
- Installation 
- Suppressor filter - rear blower motor 
- Description 
- Operation 
- Removal 
- Installation 
- Suppressor filter - rear condenser fan 
- Description 
- Operation 
- Removal 
- Installation 
- Distribution - front 
- Air filter 
- Removal 
- Installation 
- Air outlets 
- Removal 
- Installation 
- Blower motor 
- Removal 
- Installation 
- Defroster ducts 
- Removal 
- Installation 
- Floor distribution ducts 
- Removal 
- Installation 
- Hvac housing 
- Removal 
- Disassembly 
- Assembly 
- Installation 
- Instrument panel ducts 
- Removal 
- Installation 
- Distribution - rear 
- A / c condenser cover 
- Removal 
- Installation 
- A / c condenser housing 
- Removal 
- Installation 
- A / c evaporator cover 
- Removal 
- Installation 
- A / c evaporator housing 
- Removal 
- Installation 
- Air filter 
- Removal 
- Installation 
- Blower motor 
- Removal 
- Installation 
- Plumbing 
- Plumbing 
- Description 
- Operation 
- Warnings 
- Cautions 
- Diagnosis and testing 
- Refrigerant system leaks 
- Standard procedure 
- Refrigerant system service equipment 
- Manifold gauge set connections 
- Refrigerant system recovery 
- Refrigerant system evacuate 
- Refrigerant system charge 
- Partial charge method 
- A / c compressor 
- Description 
- Operation 
- Diagnosis and testing 
- A / c compressor noise 
- Removal 
- Denso 7sbu16c a / c compressor 
- Denso 10s17 a / c compressor 
- Installation 
- Denso 7sbu16c a / c compressor 
- Denso 10s17 a / c compressor 
- A / c condenser 
- Description 
- Operation 
- Removal 
- Installation 
- A / c discharge line 
- Removal 
- Installation 
- A / c evaporator 
- Description 
- Operation 
- Removal 
- Installation 
- A / c expansion valve 
- Description 
- Operation 
- Diagnosis and testing 
- A / c expansion valve 
- Removal 
- Installation 
- Electric coolant pump 
- Description 
- Operation 
- Removal 
- Installation 
- Heater core 
- Description 
- Operation 
- Removal 
- Installation 
- Liquid line 
- Removal 
- Installation 
- Receiver / drier 
- Description 
- Operation 
- Removal 
- Installation 
- Refrigerant 
- Description 
- Operation 
- Refrigerant oil 
- Description 
- Operation 
- Standard procedure 
- Refrigerant oil level 
- Suction line 
- Removal 
- Installation 
- Water valve 
- Removal 
- Installation 
- Rear a / c condenser fan 
- Removal 
- Installation 
- Rear a / c evaporator 
- Removal 
- Installation 
- Rear a / c expansion valve 
- Description 
- Operation 
- Removal 
- Installation 
- Rear discharge line 
- Description 
- Removal 
- Installation 
- Rear liquid line 
- Description 
- Removal 
- Installation 
- Rear receiver / drier 
- Removal 
- Installation 
- Rear refrigerant reservoir 
- Removal 
- Installation 
- Rear suction line 
- Description 
- Removal 
- Installation 
- Refrigerant line coupler 
- Description 
- Operation 
- Removal 
- Installation 
- Underbody lines 
- Removal 
- Installation 
- Cabin heater 
- Cabin heater 
- Description 
- Operation 
- Diagnosis and testing 
- Supplemental cabin heater 
- Exhaust tube 
- Removal 
- Installation 
- Fuel dosing pump 
- Description 
- Operation 
- Removal 
- Installation 
- Fuel line 
- Standard procedure 
- Cleaning 
- Removal 
- Installation 
- Heater unit 
- Removal 
- Heater unit 
- Wire harness 
- Installation 
- Heater unit 
- Wire harness 
- Inlet hose 
- Removal 
- Installation

25-emissions control 
- Evaporative emissions 
- Crankcase ventilation heater 
- Removal 
- Installation 
- Crankcase ventilation breather 
- Description 
- Removal 
- Installation 
- Exhaust gas recirculation 
- Exhaust gas recirculation 
- Description 
- Valve 
- Description 
- Operation 
- Removal 
- Installation 
- Valve cooler 
- Description

Index

Comments

02 POWERTRAIN

Table of contents

1.0 introduction 
- 1.1 system coverage 
- 1.2 six-step troubleshooting procedure

2.0 identification of system

3.0 system description and functional operation 
- 3.1 general description 
- 3.2 functional operation 
- 3.2.1 ecm on-board diagnostics 
- 3.2.2 ecm operating modes 
- 3.2.3 monitored circuits 
- 3.2.4 skreem overview 
- 3.2.5 skreem on-board diagnostics 
- 3.2.6 skreem operation 
- 3.3 diagnostic trouble codes 
- 3.3.1 hard code 
- 3.3.2 intermittent code 
- 3.3.3 ecm diagnostic trouble codes 
- 3.3.4 handling no trouble code problems 
- 3.4 using the drbiii 
- 3.4.1 drbiii does not power up 
- 3.4.2 display is not visible

4.0 disclaimers, safety, warnings 
- 4.1 disclaimers 
- 4.2 safety 
- 4.2.1 technician safety information 
- 4.2.2 vehicle preparation for testing 
- 4.2.3 servicing sub-assemblies 
- 4.2.4 drbiii safety information 
- 4.3 warnings and cautions 
- 4.3.1 road test warnings 
- 4.3.2 vehicle damage cautions

5.0 required tools and equipment

6.0 glossary of terms

7.0 diagnostic information and procedures 
- Communication 
- *no response from engine control module 
- *no response from sentry key remote entry module 
- Driveability - diesel 
- P-1105 atmospheric pressure sensor plausibility with boost pressure sensor 
- P1105-atmospheric pressure sensor signal voltage too high 
- P1105-atmospheric pressure sensor signal voltage too low 
- P1617- ecm read/write error 
- P1617- ecm write error 
- P1617-ecm incorrect value 
- P1617-ecm read error 
- P2122-internal error counter fault 
- P2122-internal error engine shut off 
- P2122-internal error engine voltage monitoring 
- P2122-internal error engine voltage monitoring 
- P2123-injector bank error 
- P2124-injector bank error 
- P2139-ecm injector output stage #1 
- P2139-ecm injector output stage #1 short circuit 
- P2140-ecm injector output stage #2 
- P2140-ecm injector output stage #2 short circuit 
- P2149-ecm a/d converter high 
- P2149-ecm a/d converter low 
- P2149-ecm a/d converter plausibility 
- P2153-starter relay circuit ecm thermal overload 
- P2197-fuel quantity solenoid ecm thermal overload 
- P2214-can message error 
- P2319-ecm internal error 1 
- P2319-ecm internal error 2 
- P2319-ecm internal error 3 
- P2319-ecm internal error 4 
- P2321-ecm internal error 5 
- P2323-ecm internal error 
- P2324-ecm injector monitoring 1 
- P2324-ecm injector monitoring 2 
- P2324-ecm injector monitoring 3 
- P2324-ecm injector monitoring 4 
- P2324-ecm injector undervoltage 
- P2325-ecm internal error 1 
- P2325-ecm internal error 2 
- P2325-ecm internal error 3 
- P2325-ecm internal error 4 
- P2329-ecm internal error 1 
- P2330-ecm internal error 1 
- P2340-ecm injection quantity error 
- P2342-ecm internal error 1 
- P2342-ecm internal error 2 
- P2350-internal voltage error 
- P2352-injection fault - excessive temperature 
- P2352-injection fault - quantity error 
- P2352-injection fault - torque limit 
- P2352-injection fault excessive engine speed 
- P2354-ecm internal fault 
- P2356-ecm internal error 
- P2357-ecm internal error 
- P2358-ecm internal error 
- P2500-fuel pressure solenoid circuit excessive current 
- P2514-crankcase vent heater excessive current 
- P2526-boost pressure servo motor excessive current 
- P2527-egr valve excessive current 
- P0100-mass air flow sensor signal voltage too low 
- P0100-mass air flow sensor signal voltage too low 
- P2011-mass air flow sensor plausibility air mass too high 
- P2011-mass air flow sensor plausibility air mass too low 
- P2024-mass air flow sensor signal voltage too high 
- P2024-mass air flow sensor signal voltage too low 
- P2065-mass air flow sensor supply voltage too high 
- P2065-mass air flow sensor supply voltage too low 
- P2067-mass air flow sensor signal circuit open or shorted 
- P2067-mass air flow sensor signal voltage too high 
- P2067-mass air flow sensor signal voltage too low 
- P2068-mass air flow sensor plausibility signal ratio error 
- P2633-maf sensor signal plausibility 
- P0105-intake pressure sensor can message error 
- P0105-intake pressure sensor plausibility 
- P0105-intake pressure sensor signal voltage too high 
- P0105-intake pressure sensor signal voltage too low 
- P0110-intake air temp sensor signal voltage too high 
- P2063-intake air temp sensor circuit signal voltage too high 
- P0110-intake air temp sensor signal voltage too low 
- P2063-intake air temp sensor circuit signal voltage too low 
- P0115-engine coolant temp sensor circuit plausibility 
- P2012-engine coolant temp sensor circuit plausibility 
- P0115-engine coolant temp sensor circuit plausibility with engine oil sensor 
- P0115-engine coolant temp sensor circuit signal voltage too high 
- P2054-engine coolant temp sensor circuit signal voltage too high 
- P2054-engine coolant temp sensor circuit signal voltage too low 
- P0115-engine coolant temp sensor circuit signal voltage too low 
- P0180-fuel temperature sensor circuit - signal voltage too high 
- P0180-fuel temperature sensor circuit - signal voltage too low 
- P2625-fuel temperature sensor plausibility 
- P0190-fuel press sensor circuit malf signal voltage too high 
- P2008-fuel pressure sensor circuit signal voltage too high 
- P0190-fuel press sensor circuit malf signal voltage too low 
- P2008-fuel pressure sensor circuit signal voltage too low 
- P0201-cylinder 1-injector circuit excessive current 
- P0201-cylinder 1-injector circuit open or shorted to ground 
- P0201-cylinder 1-injector circuit shorted to ground 
- P0201-cylinder 1-injector circuit shorted to voltage 
- P0202-cylinder 2-injector circuit excessive current 
- P0202-cylinder 2-injector circuit open or shorted to ground 
- P0202-cylinder 2-injector circuit shorted to ground 
- P0202-cylinder 2-injector circuit shorted to voltage 
- P0203-cylinder 3-injector circuit excessive current 
- P0203-cylinder 3-injector circuit open or shorted to ground 
- P0203-cylinder 3-injector circuit shorted to ground 
- P0203-cylinder 3-injector circuit shorted to voltage 
- P0204-cylinder 4-injector circuit excessive current 
- P0204-cylinder 4-injector circuit open or shorted to ground 
- P0204-cylinder 4-injector circuit shorted to ground 
- P0204-cylinder 4-injector circuit shorted to voltage 
- P0205-cylinder 5-injector circuit excessive current 
- P0205-cylinder 5-injector circuit open or shorted to ground 
- P0205-cylinder 5-injector circuit shorted to ground 
- P0205-cylinder 5-injector circuit shorted to voltage 
- P2123-injector circuit fault 
- P2123-injector circuit low side shorted to ground 
- P2123-injector circuit shorted to ground or voltage

- P2124-injector circuit fault 
- P2124-injector circuit low side shorted to ground 
- P2124-injector circuit shorted to ground or voltage 
- P2141-cylinder #1 injector open circuit 
- P2142-cylinder #2 injector open circuit 
- P2143-cylinder #3 injector open circuit 
- P2144-cylinder #4 injector open circuit 
- P2145-cylinder #5 injector open circuit 
- P0300-misfire detected 
- P2113-misfire cylinder #1 
- P2114-misfire cylinder #2 
- P2115-misfire cylinder #3 
- P2116-misfire cylinder #4 
- P2117-misfire cylinder #5 
- P2567-leakage cylinder #1 
- P2567-misfire cylinder #1 
- P2568-leakage cylinder #2 
- P2568-misfire cylinder #2 
- P2569-leakage cylinder #3 
- P2569-misfire cylinder #3 
- P2570-leakage cylinder #4 
- P2570-misfire cylinder #4 
- P2571-leakage cylinder #5 
- P2571-misfire cylinder #5 
- P2573-general leakage 
- P2574-injector 1 injection time above limit 
- P2574-injector 1 injection time below limit 
- P2575-injector 2 injection time above limit 
- P2575-injector 2 injection time below limit 
- P2576-injector 3 injection time above limit 
- P2576-injector 3 injection time below limit 
- P2577-injector 4 injection time above limit 
- P2577-injector 4 injection time below limit 
- P2578-injector 5 injection time above limit 
- P2578-injector 5 injection time below limit 
- P0500-wheel speed sensor plaus - can bus message from abs 
- P0600-can data bus - bus circuit fault 
- P1222-acc pedal position sensor 1 ckt plausibility 
- P1222-acc pedal position sensor 1 ckt signal voltage too high 
- P1222-acc pedal position sensor 1 ckt signal voltage too low 
- P1234-acc pedal position sensor 2 circuit plausibility 
- P1234-acc pedal position sensor 2 ckt signal voltage too high 
- P1234-acc pedal position sensor 2 ckt signal voltage too low 
- P2327-app sensor plausibility 
- P1480-glow plug indicator error 
- P1482-glow plug module - communication error 
- P2537-glow plug control circuit preglow fault 
- P2537-glow plug control circuit preglow short to ground 
- P2537-glow plug control circuit preglow short to voltage 
- P1482-glow plug module - excess current 
- P2133-glow plug #1 circuit excessive current 
- P2133-glow plug #1 circuit open circuit 
- P2133-glow plug #1 circuit short to ground 
- P2133-glow plug #1 circuit short to voltage 
- P2134-glow plug #2 circuit excessive current 
- P2134-glow plug #2 circuit open circuit 
- P2134-glow plug #2 circuit short to ground 
- P2134-glow plug #2 circuit short to voltage 
- P2135-glow plug #3 circuit excessive current 
- P2135-glow plug #3 circuit open circuit 
- P2135-glow plug #3 circuit short to ground 
- P2135-glow plug #3 circuit short to voltage 
- P2136-glow plug #4 circuit excessive current 
- P2136-glow plug #4 circuit open circuit 
- P2136-glow plug #4 circuit short to ground 
- P2136-glow plug #4 circuit short to voltage 
- P2137-glow plug #5 circuit excessive current 
- P2137-glow plug #5 circuit open circuit 
- P2137-glow plug #5 circuit short to ground 
- P2137-glow plug #5 circuit short to voltage 
- P1482-glow plug module - incorrect timer 
- P1482-glow plug module - internal fault 
- P2538-glow plug module communication error 
- P2538-glow plug module excessive current error 
- P2538-glow plug module timer error 
- P1610-engine control relay plausibility 
- P1610-engine control relay shuts off too early 
- P1610-engine control relay shuts off too late 
- P1611-sensor supply 1 voltage is too high 
- P1611-sensor supply 1 voltage is too low 
- P1612-ignition voltage - voltage error 
- P1615-ecm voltage supply is too high 
- P1615-ecm voltage supply is too low 
- P1630-immobilizer 
- P1630-immobilizer 
- P1630-immobilizer 
- P1630-immobilizer 
- P2201-immobilizer can message error 
- P2243-no message received from skreem 
- P1681-acm circuit fault 
- P1681-acm circuit short to voltage 
- P2009-water in fuel sensor - water in fuel 
- P2009-water in fuel sensor signal error 
- P2010-mass air flow sensor negative deviation 
- P2010-mass air flow sensor positive deviation 
- P2068-mass air flow sensor plausibility signal ratio too large 
- P2068-mass air flow sensor plausibility signal ratio too small 
- P2013-ambient air temperature signal voltage too high 
- P2013-ambient air temperature signal voltage too low 
- P2014-engine oil sensor oil temperature plausibility 
- P2014-engine oil sensor signal plausibility 
- P2014-engine oil sensor signal voltage is too high 
- P2014-engine oil sensor signal voltage is too low 
- P2040-engine oil sensor circuit invalid level 
- P2040-engine oil sensor circuit level out of range 
- P2040-engine oil sensor circuit level out of range 
- P2041-engine oil sensor poor oil quality 
- P2041-engine oil sensor quality measurement error 
- P2041-engine oil sensor quality plausibility 
- P2042-engine oil sensor water contamination 
- P2061-engine oil sensor open circuit 
- P2062-engine oil sensor signal error 
- P2062-engine oil sensor synchronization error 
- P2015-fuel rail pressure malfunction maximum fuel flow exceeded 
- P2016-fuel rail pressure malfunction deceleration error 
- P2016-fuel rail pressure malfunction fuel flow below minimum quantity 
- P2017-fuel rail pressure malfunction rail pressure is too low 
- P2018-fuel rail pressure malfunction rail pressure is too high 
- P2019-fuel rail pressure malfunction maximum fuel pressure exceeded 
- P2019-fuel rail pressure malfunction rail pressure is too low 
- P2020-fuel rail pressure malfunction rail pressure is too low 
- P2020-fuel rail pressure malfunction rail pressure too high 
- P2021-fuel rail pressure malfunction rail pressure too low 
- P2023-fuel rail pressure malfunction rail pressure too high 
- P2047-fuel rail pressure malfunction maximum fuel pressure exceeded 
- P2049-fuel rail pressure malfunction deceleration error 
- P2051-fuel rail pressure malfunction maximum fuel pressure exceeded 
- P2052-fuel rail pressure malfunction plausibility with fuel pressure solenoid 
- P2025-intake pressure sensor plausibility 
- P2025-intake pressure sensor signal voltage too high 
- P2030-intake pressure sensor circuit fault 
- P2030-intake pressure sensor open circuit 
- P2030-intake pressure sensor signal voltage too high 
- P2025-intake pressure sensor signal voltage too low 
- P2030-intake pressure sensor signal voltage too low 
- P2026-o2 sensor circuit fault 
- P2026-o2 sensor circuit open circuit 
- P2026-o2 sensor circuit signal voltage too high 
- P2026-o2 sensor circuit signal voltage too low 
- P2028-o2 sensor circuit fault 
- P2028-o2 sensor circuit open circuit 
- P2028-o2 sensor circuit signal voltage too high 
- P2028-o2 sensor circuit signal voltage too low 
- P2032-o2 sensor plausibility 
- P2032-o2 sensor plausibility 
- P2032-o2 sensor plausibility 
- P2057-o2 sensor signal circuit signal voltage too high 
- P2058-o2 sensor signal circuit signal voltage too high 
- P2059-o2 sensor signal circuit signal voltage too high 
- P2090-o2 sensor plausibility 
- P2090-o2 sensor signal fault 
- P2091-o2 sensor low o2 concentration 
- P2091-o2 sensor signal plausibility 
- P2195-o2 sensor heater circuit fault 
- P2353-o2 sensor plausibility 
- P2366-o2 circuit fault 
- P2034-o2 sensor circuit calibration value too high 
- P2034-o2 sensor circuit calibration value too low 
- P2036-o2 sensor circuit calibration value too high 
- P2036-o2 sensor circuit calibration value too low 
- P2038-o2 sensor circuit calibration value too high 
- P2038-o2 sensor circuit calibration value too low 
- P2043-camshaft position sensor circuit open circuit 
- P2043-camshaft position sensor circuit open or short circuit 
- P2045-crankshaft position sensor circuit lost signal 
- P2045-crankshaft position sensor circuit signal plausibility 
- P2322-crankshaft position sensor plausibility 
- P2343-ckp plausibility 
- P2062-engine oil sensor monitoring error 
- P2066-mass air flow sensor plausibility 
- P2355-egr flow rate is too high 
- P2355-egr flow rate is too low 
- P2066-mass air flow sensor plausibility air mass too high 
- P2066-mass air flow sensor plausibility air mass too low 
- P2087-intake pressure sensor intake restriction 
- P2100-fuel pump relay circuit open circuit 
- P2100-fuel pump relay circuit shorted to ground 
- P2100-fuel pump relay circuit shorted to voltage 
- P2100-fuel pump relay excessive current 
- P2104-starter relay circuit short circuit 
- P2152-starter relay circuit short to ground 
- P2153-starter relay circuit open or shorted to voltage 
- P2110-boost pressure servo motor circuit short circuit 
- P2112-boost pressure servo motor circuit excessive current 
- P2526-boost pressure servo motor short to voltage 
- P2111-boost pressure servo motor circuit short to ground 
- P2112-boost pressure servo motor circuit open circuit 
- P2510-boost pressure servo motor short to ground 
- P2526-boost pressure servo motor open circuit 
- P2526-boost pressure servo motor short to ground 
- P2132-glow plug control module circuit open circuit 
- P2132-glow plug control module circuit shorted to ground 
- P2132-glow plug control module circuit shorted to voltage or open 
- P2132-glow plug control module fault 
- P2151-fuel press solenoid signal plausibility high 
- P2151-fuel press solenoid signal plausibility low 
- P2500-fuel pressure solenoid circuit open circuit 
- P2501-fuel pressure solenoid circuit shorted to ground or b+ 
- P2197-fuel quantity solenoid open circuit 
- P2198-fuel quantity solenoid short to voltage 
- P2199-fuel quantity solenoid short to ground 
- P2502-fuel quantity solenoid short to ground 
- P2203-torque reduction message from abs - can plausibility 
- P2203-torque reduction message from abs - message error 
- P2203-torque reduction message from abs - messages missing 
- P2203-torque reduction message from abs - no communiocation 
- P2203-torque reduction message from abs - plausibility #1 
- P2203-torque reduction message from abs plausibility #2 
- P2208-abs brake signal can message implausible 
- P2208-abs can brake signal plausibility 
- P2209-abs can message missing or incorrect 
- P2253-steering angle sensor plausibility 
- P2204-torque reduction message from tcm - can plausibility 
- P2204-torque reduction message from tcm - engine stop 
- P2204-torque reduction message from tcm - message error 
- P2204-torque reduction message from tcm - messages missing 
- P2204-torque reduction message from tcm - plausibility 
- P2204-torque reduction message from tcm - tcm dtc #1 
- P2204-torque reduction message from tcm - tcm dtc #2 
- P2210-esm can message missing or incorrect 
- P2234-abs dtc external quantity control fault present 
- P2252-lateral accelerator sensor plausibilty 
- P2211-etc can message missing or incorrect 
- P2258-tcm message error 
- P2258-tcm no can message 
- P2217-tcm dtc internal fault present 
- P2218-tcm dtc 1-2 and 4-5 shift solenoid fault present 
- P2219-tcm dtc 2-3 shift solenoid fault present 
- P2220-tcm dtc 3-4 shift solenoid fault present 
- P2221-tcm dtc torque converter clutch solenoid fault present 
- P2222-tcm dtc modulating pressure solenoid fault present 
- P2223-tcm dtc shift pressure solenoid fault present 
- P2224-tcm dtc valve voltage supply fault present 
- P2225-tcm dtc speed sensor voltage fault present 
- P2226-tcm dtc ewm can message fault present 
- P2227-tcm dtc right rear wheel speed implausible fault present 
- P2228-tcm dtc transmission ratio error fault present 
- P2229-tcm dtc can msg implausible fault present 
- P2230-tcm dtc tcc excessive power consumption fault present 
- P2231-tcm dtc not unequivocal fault present 
- P2232-tcm dtc negative gear comparison fault present 
- P2240-abs steering angle sensor can message implausible 1 
- P2240-abs steering angle sensor can message implausible 2 
- P2242-abs brake message plausibility 1 
- P2242-abs brake message plausibility 2 
- P2244-instrument cluster message plausibility 
- P2259-torque reduction message from hvac- parity error 
- P2259-torque reduction message from hvac- switch signal error 
- P2259-torque reduction message from hvac- switch signal plausibility 
- P229-instrument cluster message - ambient temperature signal plausibility 
- P2306-sensor supply 2 voltage is too high 
- P2306-sensor supply 2 voltage is too low 
- P2332-sensor supply 3 voltage is too low 
- P2332-sensor supply 3 voltage is too high 
- P2333-s/c vehicle speed plausibility 
- P2338-s/c excessive acceleration 
- P2338-s/c excessive deceleration 
- P2339-ecm checksum error #1 
- P2339-ecm checksum error #2 
- P2339-ecm invalid coding 
- P2339-ecm invalid data 
- P2344-kickdown switch plausibility 
- P2347-automatic transmission coded as manual transmission 
- P2347-can bus circuit interuption 
- P2347-manual transmissio coded as auto transmission 
- P2347-write error to eeprom 
- P2351-ecm supply voltage too low 
- P2359-boost pressure too high 
- P2359-boost pressure too low 
- P2511-egr valve signal circuit shorted to ground 
- P2527-egr valve signal circuit open circuit 
- P2527-egr valve signal circuit shorted to ground 
- P2514-crankcase vent heater open circuit 
- P2514-crankcase vent heater shorted to ground 
- P2514-crankcase vent heater shorted to voltage 
- P2521-improper start attempt 
- P2527-egr valve signal circuit shorted to voltage 
- P2531-fuel injector 1 read too large 
- P2531-fuel injector 1 read too large 
- P2531-fuel injector 1 read too small 
- P2531-fuel injector 1 read too small 
- P2532-fuel injector 2 read too large 
- P2532-fuel injector 2 read too large 
- P2532-fuel injector 2 read too small 
- P2532-fuel injector 2 read too small 
- P2533-fuel injector 3 read too large 
- P2533-fuel injector 3 read too large 
- P2533-fuel injector 3 read too small 
- P2533-fuel injector 3 read too small 
- P2534-fuel injector 4 read too large 
- P2534-fuel injector 4 read too large 
- P2534-fuel injector 4 read too small 
- P2534-fuel injector 4 read too small 
- P2535-fuel injector 5 read too large 
- P2535-fuel injector 5 read too large 
- P2535-fuel injector 5 read too small 
- P2535-fuel injector 5 read too small 
- P2606-cmp/ckp synchronization error 
- *checking the fuel pressure sensor circuits 
- *checking the fuel pressure solenoid circuits 
- *checking the fuel quantity solenoid circuits 
- *checking the power and grounds 
- *engine cranks but will not start 
- *engine will not crank 
- Verification tests 
- Verification tests

8.0 component locations 
- 8.1 control modules 
- 8.2 controls and solenoids 
- 8.3 data link connector 
- 8.4 sensors 
- 8.5 switches

9.0 connector pinouts 
- Accelerator pedal position sensor (obd) 
- Airbag control module - yellow 
- Boost pressure sensor (obd) 
- Boost pressure servomotor (obd) 
- Camshaft position sensor - black 
- Controller antilock brake 
- Crankcase heater - black 
- Crankshaft position sensor - black 
- Data link connector - black 
- Egr valve - black 
- Engine control module c1 (obd) 
- Engine control module c2 (obd) 
- Engine coolant temperature sensor - black 
- Engine oil sensor - black 
- Fuel injector no. 1 - black 
- Fuel injector no. 2 - black 
- Fuel injector no. 3 - black 
- Fuel injector no. 4 - black 
- Fuel injector no. 5 - black 
- Fuel pressure sensor - black 
- Fuel pressure solenoid 
- Fuel pump (obd) 
- Fuel pump relay (obd) 
- Fuel quantity control valve (obd) 
- Fuel temperature sensor 
- Engine control relay (fuse block no. 1) 
- Fuses (fuse block no. 1) 
- Fuses (fuse block no. 2) 
- Fuses (fuse/relay block) 
- Starter motor relay (fuse/relay block) 
- Glow plug control module c1 - black 
- Glow plug control module c2 - black 
- Intake air pressure sensor (obd) 
- Intake air temperature sensor - black 
- Kick down switch - black 
- Mass air flow sensor - black 
- Oxygen sensor (obd) 
- Fused ignition switch run-start relay (relay block) 
- Speed control switch 
- Water in fuel sensor - black

10.0 schematic diagrams 
- 10.1 engine control module 
- 10.2 engine control module

11.0 charts and graphs

Comments

03 BODY

Table of contents

1.0 introduction 
- 1.1 system coverage 
- 1.2 six-step troubleshooting procedure

2.0 identification of system

3.0 system description and functional operation 
- 3.1 airbag system 
- 3.1.1 driver airbag 
- 3.1.2 clockspring 
- 3.1.3 passenger airbag 
- 3.1.4 seat belt tensioners 
- 3.1.5 special tools 
- 3.1.6 diagnostic trouble codes 
- 3.1.6.1 active codes 
- 3.1.6.2 stored codes 
- 3.2 communication 
- 3.2.1 communication k-lines 
- 3.2.2 can bus 
- 3.3 heating & a/c system 
- 3.3.1 automatic temperature control (atc) 
- 3.3.1.1 system controls 
- 3.3.1.2 system diagnostics 
- 3.3.2 cabin heater module (chm) & heater booster module (hbm) 
- 3.3.2.1 system description 
- 3.3.2.2 venting the heater's exhaust 
- 3.3.2.3 system diagnostics 
- 3.4 instrument cluster 
- 3.5 power door locks/rke 
- 3.5.1 central locking 
- 3.5.2 remote keyless entry (rke) 
- 3.5.3 auto door locks 
- 3.5.4 accident response 
- 3.6 vehicle theft security system (vtss) 
- 3.7 using the drbiii 
- 3.8 drbiii error messages 
- 3.9 drbiii does not power up (blank screen) 
- 3.10 display is not visible

4.0 disclaimers, safety, warnings 
- 4.1 disclaimers 
- 4.2 safety 
- 4.2.1 technician safety information 
- 4.2.2 vehicle preparation for testing 
- 4.2.3 servicing sub-assemblies 
- 4.2.4 drbiii safety information 
- 4.3 warnings 
- 4.3.1 vehicle damage warnings 
- 4.3.2 road testing a complaint vehicle

5.0 required tools and equipment

6.0 glossary of terms

7.0 diagnostic information and procedures 
- Airbag 
- Airbag warning indicator - driver high 
- Airbag warning indicator - driver low 
- Driver seat belt tensioner - incorrect feedback 
- Driver squib 1 - incorrect feedback 
- Internal 1 
- Internal 2 
- Internal 3 
- Passenger seat belt tensioner - incorrect feedback 
- Passenger squib 1 - incorrect feedback 
- Stored energy firing 1 
- Stored energy firing 2 
- Driver seat belt tensioner circuit open 
- Driver seat belt tensioner circuit short 
- Driver seat belt tensioner short to battery 
- Driver seat belt tensioner short to ground 
- Driver squib 1 circuit open 
- Driver squib 1 circuit short 
- Driver squib 1 short to battery 
- Driver squib 1 short to ground 
- Loss of ignition run - start 
- Passenger seat belt tensioner circuit open 
- Passenger seat belt tensioner circuit short 
- Passenger seat belt tensioner short to battery 
- Passenger seat belt tensioner short to ground 
- Passenger squib 1 circuit open 
- Passenger squib 1 circuit short 
- Passenger squib 1 short to battery 
- Passenger squib 1 short to ground 
- *airbag warning indicator flashing 
- Cabin heater 
- A. Heater pre-test 
- Circ pump control open 
- Circ pump control shorted 
- Combust fan shorted 
- Combust fan speed incorrect 
- Combustion fan open 
- Control unit faulty 
- Dosing pump open 
- Dosing pump shorted 
- Fan stage 1 relay control open 
- Fan stage 1 relay control shorted 
- Flame detect prior to combust 
- Flame out 
- No start 
- Flame sensor open 
- Flame sensor shorted 
- Glow pin open 
- Glow pin shorted 
- Heater in lockout mode 
- Heater overheated 
- Successive overheating 
- Over voltage 
- Overheating sensor open 
- Overheating sensor shorted 
- Temp sensor open 
- Temp sensor shorted 
- Under voltage 
- Communication 
- *no response from airbag control module 
- *no response from automatic temperature control 
- *no response from cabin heater module 
- *no response from central timer module 
- *no response from controller antilock brake 
- *no response from engine control module 
- *no response from heater booster module 
- *no response from instrument cluster 
- *no response from radio 
- *no response from security system module 
- *no response from sentry key remote entry module 
- *no response from shifter assembly 
- *no response from transmission control module 
- Heating & a/c 
- A/c compressor control high or open (active) 
- A/c compressor control high or open (stored) 
- A/c compressor control shorted low (stored) 
- Air outlet temp sensor high or open (stored) 
- Air outlet temp sensor shorted low (stored) 
- Aux fan relay control high or open (stored) 
- Aux fan relay control shorted low (stored) 
- Blower stage 1 high or open (stored) 
- Blower stage 1 shorted low (stored) 
- Cabin heater control high or open (stored) 
- Cabin heater control shorted low (stored) 
- Circ pump control high or open (stored) 
- Circ pump control shorted low (stored) 
- Evap temp sensor high or open (stored) 
- Evap temp sensor shorted low (stored) 
- No communication bus (stored) 
- No communication with ecm (stored) 
- No communication with ic (stored) 
- Recirc air solenoid control high or open (stored) 
- Recirc air solenoid control shorted low (stored) 
- Refrig press sensor high or open (stored) 
- Refrig press sensor shorted low (stored) 
- Water cycle valve control high or open (stored) 
- Water cycle valve control shorted low (stored) 
- A/c compressor control shorted low (active) 
- Air outlet temp sensor high or open (active) 
- Air outlet temp sensor shorted low (active) 
- Atc function test cool failure 
- Atc function test failure 
- Atc function test heat failure 
- Aux fan relay control high or open (active) 
- Aux fan relay control shorted low (active) 
- Blower stage 1 high or open (active)

- Blower stage 1 shorted low (active) 
- Cabin heater control high or open (active) 
- Cabin heater control shorted low (active) 
- Circ pump control high or open (active) 
- Circ pump control shorted low (active) 
- Evap temp sensor high or open (active) 
- Evap temp sensor shorted low (active) 
- No communication bus (active) 
- No communication with ecm (active) 
- No communication with ic (active) 
- Recirc air solenoid control high or open (active) 
- Recirc air solenoid control shorted low (active) 
- Refrig press sensor high or open (active) 
- Refrig press sensor shorted low (active) 
- Water cycle valve control high or open (active) 
- Water cycle valve control shorted low (active) 
- Instrument cluster 
- Ambient temp sensor open/short to battery 
- Ambient temp sensor short to ground 
- Fuel level sensor open/short to battery 
- Fuel level sensor short to ground 
- Instrument cluster internal failure b1043 
- Instrument cluster internal failure b1053 
- Instrument cluster overvoltage 
- No can communication with abs 
- No can communication with ecm 
- No can communication with tcm 
- Preglow indicator lamp failure 
- Srs indicator lamp failure 
- Power door locks/rke 
- Driver door ajar indicator driver circuit short to ground 
- Passenger door ajar indicator driver circuit short to ground 
- Replace control module 
- Rke interface circuit short to ground - ctm 
- Rke interface circuit short to ground - skreem 
- Rke interface circuit short to voltage - ctm 
- Rke interface circuit short to voltage - skreem 
- The acm has unlocked the doors 
- Unknown trouble code unknown dtc type 2 
- *rke inoperative 
- *rke poor range 
- Vehicle theft/security 
- Driver cylinder lock switch circuit short to ground 
- Driver cylinder unlock switch circuit short to ground 
- Front door jamb switch circuit short to ground 
- Internal error - ssm 
- Towing inclination sensor beyond limits 
- Towing inclination sensor value is invalid 
- Towing inclination sensor value is missing 
- Intrusion sensor 1 circuit open/short to ground 
- Intrusion sensor 1 ground circuit open 
- Intrusion sensor 2 circuit open/short to ground 
- Intrusion sensor 2 ground circuit open 
- Intrusion sensor 3 circuit open/short to ground 
- Intrusion sensor 3 ground circuit open 
- Rear or sliding door jamb switch circuit short to ground 
- Rke interface circuit failure - ssm 
- Security system interface failure - ssm 
- Siren circuit open/shorted to ground 
- Siren internal failure 
- Siren signal control circuit short to ground 
- Windshield wiper & washer 
- Checking the rain sensor/wiper operation 
- Verification tests 
- Verification tests

8.0 component locations 
- 8.1 airbag system 
- 8.2 airbag control module 
- 8.3 driver airbag squib 
- 8.4 clockspring 
- 8.5 seat belt tensioner 
- 8.6 heating & a/c 
- 8.6.1 automatic temperature control (atc) system components 
- 8.6.2 cabin heater & heater booster system components 
- 8.6.3 auto temp control, cabin heater, & heater booster fuses & relays 
- 8.6.4 evap temp sensor & air outlet temp sensor 
- 8.7 instrument cluster 
- 8.7.1 ambient temperature sensor 
- 8.8 power door locks/rke 
- 8.8.1 central timer module 
- 8.8.2 sentry key remote entry module 
- 8.8.3 door lock motor/ajar switch 
- 8.8.4 contact plates 
- 8.8.5 door lock motor/ajar switch connectors 
- 8.9 vehicle theft security system 
- 8.9.1 security system module 
- 8.9.2 intrusion sensors 
- 8.9.3 switches 
- 8.9.4 siren

9.0 connector pinouts 
- A/c auxiliary fan 
- Air outlet temperature sensor 
- Airbag control module - yellow 
- Airbag squib-driver - yellow 
- Airbag squib-passenger - yellow 
- Ambient temperature sensor 
- Automatic temperature control module c1 - brown 
- Automatic temperature control module c2 
- Auxiliary heater control 
- Blower motor resistor block 
- Blower motor-front - black 
- C205 - yellow (dash side) 
- C205 - yellow (main body side) 
- Central timer module c1 - pink 
- Central timer module c2 - lt. Green 
- Circulation pump (cabin heater module) 
- Circulation pump (rest system) 
- Circulation pump diode 
- Clockspring c2 - yellow 
- Controller antilock brake 
- Cylinder lock switch-driver 
- Data link connector - black 
- Door lock motor/ajar switch assembly-driver c1 
- Door lock motor/ajar switch assembly-driver c2 
- Door lock motor/ajar switch assembly-left sliding c1 
- Door lock motor/ajar switch assembly-left sliding c2 
- Door lock motor/ajar switch assembly-passenger c1 
- Door lock motor/ajar switch assembly-passenger c2 
- Door lock motor/ajar switch assembly-rear c1 
- Door lock motor/ajar switch assembly-rear c2 
- Door lock motor/ajar switch assembly-right sliding c1 
- Door lock motor/ajar switch assembly-right sliding c2 
- Dosing pump 
- Engine control module c1 (except obd) - black 
- Engine control module c2 (except obd) - black 
- Engine control module c2 (obd) 
- Engine control module c3 (except obd) - black 
- Evaporator temperature sensor 
- Fuel level sensor 
- Fuses (fuse block no. 1) 
- Fuse block no. 1 c1 
- Fuse block no. 1 c2 
- Fuse block no. 1 c3 - black 
- Fuse block no. 1 c4 - black 
- Fuse block no. 1 c5 - black 
- Fuses (fuse block no. 2) 
- Fuses (fuse block no. 3) 
- Fuses (fuse/relay block) 
- Hood ajar switch - black 
- Horn (vtss) 
- Ignition lock switch - black 
- Instrument cluster c1 
- Instrument cluster c2 - white 
- Intrusion sensor no. 1 - black 
- Intrusion sensor no. 2 - black 
- Intrusion sensor no. 3 - black 
- Master door lock switch 
- Panic alarm switch - black 
- Fuses (pdc) 
- Radio c1 - black 
- Radio c2 
- Recirculated air solenoid valve 
- Refrigerant pressure sensor 
- A/c auxiliary fan relay (relay block) 
- Circulation pump relay-cabin heater module (relay block) 
- D+ relay no. 2 (relay block) 
- Fan stage 1 relay (relay block) 
- Optional equipment relay (relay block) 
- Remote keyless entry antenna 
- Seat belt switch 
- Seat belt tensioner-driver - yellow 
- Seat belt tensioner-passenger - yellow 
- Security system module c1 - brown 
- Security system module c2 - lt. Green 
- Sentry key remote entry module (skreem) 
- Shifter assembly - black 
- Siren - black 
- Steering angle sensor 
- Towing/intrusion sensor on/off switch 
- Transmission control module c1 - black 
- Transmission control module c2 - black 
- Water cycle valve 
- Window defogger-left rear 
- Window defogger-right rear

10.0 schematic diagrams 
- 10.1 airbag system 
- 10.2 communication 
- 10.2.1 communication k-lines 
- 10.2.2 can bus network 
- 10.3 heating & a/c 
- 10.3.1 automatic temperature control (atc) 
- 10.3.2 cabin heater module (chm) 
- 10.3.3 heater booster module (hbm) 
- 10.4 instrument cluster 
- 10.5 power door locks/rke 
- 10.5.1 front doors 
- 10.5.2 sliding and rear doors 
- 10.5.3 switch and miscellaneous circuits 
- 10.6 vehicle theft security system 
- 10.7 rain sensor system

11.0 charts and graphs 
- 11.1 evap temp sensor resistance to temperature specifications 
- 11.2 air outlet temp sensor resistance to temperature specifications 
- 11.3 wiper switch/washer switch voltage signals

Comments

04 CHASSIS

Table of contents

1.0 introduction 
- 1.1 system coverage 
- 1.2 six-step troubleshooting procedure

2.0 indentification of system

3.0 system description and functional operation 
- 3.1 esp 
- 3.2 abs 
- 3.3 brake assist system (hba) 
- 3.4 tcs (asr) 
- 3.5 electronic brake distribution (ebd) 
- 3.6 vehicle controlling (fzr) 
- 3.7 system components 
- 3.7.1 abs and tcs (asr) indicators 
- 3.7.2 controller antilock brake (cab) 
- 3.7.3 hydraulic control unit (hcu) 
- 3.7.4 switches/sensors 
- 3.7.5 self tests 
- 3.8 using the drbiii 
- 3.9 drbiii error messages 
- 3.9.1 drbiii does not power up (blank screen) 
- 3.9.2 display is not visible

4.0 disclaimers, safety, warnings 
- 4.1 disclaimers 
- 4.2 safety 
- 4.2.1 technician safety information 
- 4.2.2 vehicle preparation for testing 
- 4.2.3 servicing sub-assemblies 
- 4.2.4 drbiii safety information 
- 4.3 warning 
- 4.3.1 vehicle damage warnings 
- 4.3.2 road testing a complaint vehicle 
- 4.4 diagnosis

5.0 required tools and equipment

6.0 glossary of terms

7.0 diagnostic information and procedures 
- Brakes (cab) 
- Anti-lock brake module internal 
- Cab internal 
- Brake fluid level 
- Brake pressure sensor circuit 
- Brake switch circuit 
- Cab check sum 
- Cab option 
- Can communication error 
- Drive test completed successfully 
- Drive test error 
- Incorrect tone wheel 
- Lateral acceleration sensor circuit 
- Lateral acceleration sensor implausible 
- Lateral acceleration sensor internal fault 
- Left front inlet solenoid 
- Left front outlet solenoid 
- Left front, right rear inlet solenoid 
- Left front, right rear outlet solenoid 
- Left rear inlet solenoid 
- Left rear outlet solenoid 
- Right front inlet solenoid 
- Right front outlet solenoid 
- Right front, left rear inlet solenoid 
- Right front, left rear outlet solenoid 
- Right rear inlet solenoid 
- Right rear outlet solenoid 
- Left front wheel speed sensor circuit 
- Left rear wheel speed sensor circuit 
- Right front wheel speed sensor circuit 
- Right rear wheel speed sensor circuit 
- Left front wheel speed sensor signal 
- Left rear wheel speed sensor signal 
- Right front wheel speed sensor signal 
- Right rear wheel speed sensor signal 
- Wheel speed sensor signal error 
- No communication with bus 
- No communication with ecm 
- No communication with ic 
- Parameterization error 
- Pump motor 
- Relay output voltage 
- Solenoid relay 
- Steering angle sensor calibration error 
- Steering angle sensor greater than 720 degrees 
- Steering angle sensor implausible can signal 
- Steering angle sensor implausible value 
- Steering angle sensor implausible wheel speed 
- Steering angle sensor internal fault 
- System overvoltage 
- System undervoltage 
- Verification tests 
- Verification tests

8.0 component locations 
- 8.1 dlc   indicators 
- 8.2 cab   wss

9.0 connector pinouts 
- Brake fluid level switch 
- Brake lamp switch c1 (except esp) 
- Brake lamp switch c2 (except esp) - black 
- Controller antilock brake 
- Instrument cluster c2 - white 
- Steering angle sensor 
- Tcs switch (asr) - black 
- Wheel speed sensor-left front 
- Wheel speed sensor-left rear 
- Wheel speed sensor-right front 
- Wheel speed sensor-right rear

10.0 schematic diagrams 
- 10.1 bosch 5.7 antilock brake system   abs

Comments

05 TRANSMISSION

Table of contents

1.0 introduction 
- 1.1 system coverage 
- 1.2 six -step troubleshooting procedure

2.0 identification of system

3.0 system description and functional operation 
- 3.1 general description 
- 3.2 functional operation 
- 3.2.1 controller modes of operation 
- 3.2.2 mil illumination 
- 3.2.3 solenoids 
- 3.2.4 transmission component descriptions 
- 3.2.5 transmission operation and shift scheduling 
- 3.2.6 transmission adaptives - initialize and store 
- 3.3 diagnostic trouble codes 
- 3.3.1 active (hard) code 
- 3.3.2 stored (intermittent) code 
- 3.3.3 trouble code erasure 
- 3.4 using the drbiii 
- 3.5 drbiii error messages 
- 3.5.1 drbiii does not power up (blank screen) 
- 3.5.2 display is not visible

4.0 disclaimers, safety, and warnings 
- 4.1 disclaimers 
- 4.2 safety 
- 4.2.1 technician safety information 
- 4.2.2 vehicle preparation for testing 
- 4.2.3 servicing sub-assemblies 
- 4.2.4 drbiii safety information 
- 4.3 warnings 
- 4.3.1 vehicle damage warnings 
- 4.3.2 road testing a complaint vehicle 
- 4.4.4 bulletins and recalls

5.0 required tools and equipment

6.0 glossary of terms 
- 6.1 acronyms 
- 6.2 definitions

7.0 diagnostic information and procedures 
- Communication 
- *no response from shifter assembly 
- *no response from transmission control module 
- Shift lever assembly

- Backup lamp ckt short to ground 
- Backup lamp ckt short to voltage or open 
- Backup lamp supply circuit open 
- Can bus circuit 
- Incorrect can message from abs 
- Internal controller 
- Lr wheel spin can message not valid 
- Over voltage

- Rr wheel spin can message not valid 
- Under voltage 
- Transmission - nag1 
- 1-2/4-5 solenoid circuit 
- 1-2/4-5 solenoid circuit short to ground 
- 2-3 solenoid circuit 
- 2-3 solenoid circuit short to ground 
- 3-4 solenoid circuit 
- 3-4 solenoid circuit short to ground 
- Abs brake message 
- Abs can message incorrect 
- Abs can message missing 
- Abs lf sensor message 
- Abs lr sensor message 
- Abs rf sensor message 
- Abs rr sensor message 
- Accel pedal sensor can message incorrect 
- Can bus circuit 
- Can message from ecm from sla 
- Control module tcm is not coded 
- Engine can message incorrect 
- Engine can message missing 
- Engine overspeed 
- Engine rpm message 
- Engine temp message 
- Engine torque message incorrect 
- Engine torque reduction 
- Ic can message incorrect 
- Ic/atc can message missing 
- Improper gear 
- Improper ratio 
- Input sensor mismatch 
- Input sensor overspeed 
- Internal controller 
- Invalid control module version 
- Modulating pressure solenoid circuit 
- N2 input speed sensor circuit 
- N3 input speed sensor circuit 
- Sensor supply voltage 
- Shift lever position invalid 
- Shift pressure solenoid circuit 
- Sla can message incorrect 
- Solenoid supply voltage 
- Solenoid supply/watchdog 
- System overvoltage 
- System undervoltage 
- Tcc over temp 
- Tcc solenoid circuit 
- Tcc stuck on 
- Trans temp sensor - p/n switch circuit 
- Trans temp sensor erratic 
- Trans temp sensor shorted 
- Transmission slipping 
- Verification tests 
- Verification tests

8.0 component locations 
- 8.1 engine control module 
- 8.2 transmission control module 
- 8.3 transmission solenoid assembly

9.0 connector pinouts 
- Electrohydraulic control unit - black 
- Shifter assembly - black 
- Transmission control module c1 - black 
- Transmission control module c2 - black 
- Transmission relay (relay block)

10.0 schematic diagrams

11.0 charts and graphs 
- 11.1 5 volt square wave   typical pattern 
- 11.2 transmission temp sensor 
- Comments