Mercedes Sprinter Service Manual / Repair Manual View larger

Mercedes Sprinter Service Manual / Repair Manual

English Service Manual / Repair Manual to vehicles Mercedes Sprinter.

--------- INSTANT DOWNLOAD ---------

LANGUAGE: English.
FORMAT: PDF file
PAGES: 2301
COMPATIBILITY: All Versions of Windows, Mac, iOS, BB, Android, etc..
PRINTABLE: Yes

No shipping costs, instant downloadable manual!

More details

9,95 €

More info

MERCEDES SPRINTER - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual to vehicles Mercedes Sprinter.

 

CONTENTS:


00 INTRO

01 SERVICE 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