Utilimaster Vehicle Body Service Manual

Transcription

Body
Service
Manual
Utilimaster
Vehicles
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Call 800-237-7806 (or 574-862-3219).
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Fax to 574-862-7637.
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Mail to the following address:
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Utilimaster
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Attn: Customer
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65528 State
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P.O. Box
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Wakarusa,
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U.S.A.
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Utilimaster VehiclesBody Service Manual
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Revision
Print Date
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Rev.llA
October 2002
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The latest updates and other information
about parts and service
it o will be available for viewing and downloading
Bo
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at www.utilimaster.com. —
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ImportantVeNotices
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©2002, Utilimaster.
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Printedm
in U.S.A.
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ut Service Manual
Title:
c
U Utilimaster VehiclesBody
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eh
io that is accurate,Vcomplete,
Un to provide information
Utilimaster Corporation attempts
and useful. All information
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contained in this manual is based on the latestoproduct information available
at the time of publication. However,
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because of the Utilimaster policy of continual
r product improvement,
as Utilimaster reserves the right to amend the
information in this document at any timeowithout prior notice.mShould you find inadequacies in the text, pleasew
Caddress:
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send your comments to the following
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U When phoning Utilimaster, be aware bthat our
Utilimaster
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NOTE:
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Attn: Designer of Technical Publications
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219
telephone
area
code
changed
to
574
in
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i January
65906 State Road 19,
it li P.O. Box 585
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2002. The 800 numbers were unaffected.
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Wakarusa, Indiana,
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U 465730585, U.S.A.
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This material is confidential
and
the
property
of
Utilimaster.
It
is
for the sole purpose
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of helping you
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ig makes no warranty of any kind with regard
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dshall not be liable for errors
it purpose. Utilimaster
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Utilimaster expressly disclaims all responsibility
and liability forizthe installation, use, performance,
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and support of third-party products.
oto make their independent
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No part of this documentemay be photocopied, reproduced,
or translated to another
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written consent of Utilimaster.
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Utilimaster, Aeromaster
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Browseathe award-winning web site www.utilimaster.com for
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Contentsv
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Important
Notices .......................................................................................................................
3
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Introduction ...............................................................................................................................
10
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Vehicle Types ...........................................................................................................................
10
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Aeromaster h
(Walk-in) Vans .....................................................................................................................
10
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Parcel Delivery
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V Vans .................................................................................................................................
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TrucktBodies
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Exterior Overview
......................................................................................................................
11
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VIN,tiBody
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Part
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Ordering Parts ..........................................................................................................................
14
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14
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Returns ............................................................................................................................................
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Customizable Parts Order Form
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Faxable Parts Order Forms............................................................................................................... 15
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Filing Warranty Claimsi.............................................................................................................
16
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Reporting Safety Defects
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More Information
18
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Utilimaster2Quick Reference Parts Guide ........................................................................................
18n
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Utilimaster
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Vehicle Access Control System (VACS)h.........................................................................................
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Contact Utilimaster ...........................................................................................................................
18
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Safety Considerations ..............................................................................................................
19
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Notes, Cautions, and Warnings
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Reporting Safety Defectsd(U.S. Only) ..............................................................................................
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Towing ..............................................................................................................................................
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Emergency Repairs .........................................................................................................................
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Service Information
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Manufacturers
Recommendations ..................................................................................................
21
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Body Lubrication
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21
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Body Maintenance Checklist ........................................................................................................... 22
Pre-Trip Inspection .................................................................................................................................... 22
Routine Body Maintenance ........................................................................................................................ 22
Seats and Belts .................................................................................................................................. 22
Interior Driver Conveniences ............................................................................................................... 22
Wipers ................................................................................................................................................ 22
Hood ................................................................................................................................................... 23
Bumpers ............................................................................................................................................. 23
Doors, General .................................................................................................................................... 23
Doors, Roll-up ..................................................................................................................................... 24
Doors, Swing ...................................................................................................................................... 25
Other Body Parts ................................................................................................................................ 26
Tools and Fasteners ......................................................................................................................... 27
Common Tools .......................................................................................................................................... 27
Fastener Replacement .............................................................................................................................. 28
BOM® Fastener ................................................................................................................................... 28
Buck Rivet (Solid Brazier-Head) .......................................................................................................... 28
Locknuts ............................................................................................................................................ 29
Torque Values and Metric Equivalents ................................................................................................ 29
MONOBOLT®, Magna-Bulb®, and Magna-Lok® Rivets ......................................................................... 30
Nutsert ................................................................................................................................................ 30
Pin-and-Collar Fastener (Magna-Grip®) ................................................................................................ 31
POP® Rivet ......................................................................................................................................... 31
Tape (Double-Faced Adhesive) ........................................................................................................... 31
Tape (Vinyl Barrier) ............................................................................................................................. 32
Thread Adhesive ................................................................................................................................. 32
Torque Seal ........................................................................................................................................ 32
Sealants .................................................................................................................................................... 33
Service Procedures ......................................................................................................................... 34
Batteries ................................................................................................................................................... 34
Body Mount Bolts ...................................................................................................................................... 36
Bumpers ................................................................................................................................................... 37
STANDARD Bumper Replacement ...................................................................................................... 37
Bumper Channel and Extension Replacement ..................................................................................... 38
SHOCK ABSORBING Bumper Replacement ...................................................................................... 39
Decals ....................................................................................................................................................... 41
DoorBulkhead ........................................................................................................................................ 42
Door Replacement .............................................................................................................................. 42
Door Latch Adjustment ....................................................................................................................... 42
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DoorRear Roll-Up ................................................................................................................................... 43
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Cable Replacement
Procedure (with Tension
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Spring
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e Winding Procedure ..................................................................................................................
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Door Panel Replacement
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Roller Change .....................................................................................................................................
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Checking Roller Play
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Pull Strap Replacement
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Door SealhReplacement
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V Sliding ....................................................................................................................................
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a Side Sliding Door Catch Adjustment
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61
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ULower Guide Replacement
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62
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Drains .......................................................................................................................................................
64
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Echovision Back-Up Alarm .......................................................................................................................
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End Cap Replacement ..............................................................................................................................
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Fan (Auxiliary) ...........................................................................................................................................
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Grab Handle Replacement
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72
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Heater (Only)2System ................................................................................................................................
73
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0 Controls Overview ..................................................................................................................
System
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CABLE (Manual) Control Operation .....................................................................................................
74
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ELECTRONIC Control Module Replacement
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77
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Blower Motor Replacement ..................................................................................................................
78
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Resistor Replacement .........................................................................................................................
78
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Defrost Duct Upgrade .........................................................................................................................
79
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ELECTRONIC Control
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Control Module Switch Testn.........................................................................................
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d Ventilation, and Air-Conditioning) System ........................................................................
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Principles
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System Components ..........................................................................................................................
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Operation ............................................................................................................................................ 43
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System Controls Overview .................................................................................................................. 92
CABLE (Manual) Control Operation ..................................................................................................... 92
ELECTRONIC Control Operation ........................................................................................................ 93
Refrigerant Precautions ...................................................................................................................... 95
Lines and Fittings Precautions ............................................................................................................ 97
Maintaining Chemical Stability ............................................................................................................ 97
Diagnosis and Testing ......................................................................................................................... 99
Overview (Refrigerant System) ............................................................................................................ 99
Proper Use of Manual Valves .............................................................................................................. 99
Attaching the Manifold Gauge Set ....................................................................................................... 99
Checking for Leaks ........................................................................................................................... 100
Electronic Leak Detector ................................................................................................................... 100
Expansion Valve Test ........................................................................................................................ 100
Measuring Temperature ...................................................................................................................... 102
Measuring Pressure ........................................................................................................................... 103
Receiver/Drier Test ............................................................................................................................ 104
Magnetic Clutch Test ......................................................................................................................... 104
Excess Moisture ................................................................................................................................ 104
Voltage Tests (Temperature Control) .................................................................................................. 105
Blower Motor Power ............................................................................................................................ 105
Blower Control .................................................................................................................................... 105
A/C Clutch Control ............................................................................................................................. 105
ELECTRONIC Control Module Switch Test ........................................................................................ 106
ELECTRONIC Control Module Tests .................................................................................................. 108
Torque, Voltage, and Charge Specifications ....................................................................................... 111
Connectors ........................................................................................................................................ 113
Hood ........................................................................................................................................................ 116
RIM Hood Adjustment ........................................................................................................................ 118
Grille (Stone Guard) Replacement ...................................................................................................... 119
Gas Spring (Strut) Replacement ........................................................................................................ 120
Hood Replacement ............................................................................................................................ 120
RIM Fender Replacement .................................................................................................................. 122
RIM Fender Repair ............................................................................................................................. 123
Fiberglass Repair ............................................................................................................................... 123
RIM Fender Reinforcement ................................................................................................................ 124
Hood Stops Upgrade .......................................................................................................................... 129
Keys ......................................................................................................................................................... 132
Abloy® Keys ....................................................................................................................................... 132
VACS (Vehicle Access Control System) ............................................................................................ 132
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Lights ....................................................................................................................................................... 133
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HeadlightrAdjustment .........................................................................................................................
133
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FronteTurn Signal Replacement ..........................................................................................................
134
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ig Clearance and IdentificationSLight
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Replacement ........................................................................................
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License Plate Light Replacement
.......................................................................................................
137
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B Replacement (RemovabletLens)
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Cab/Cargo Light Bulb
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Cab/Cargo Light
Mount) ............................................................
138
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ro(Grommet Mount) ...............................................................
hiLight Assembly Replacement
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Matting (Cab
139
V Floor) Replacement .............................................................................................................
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MirrortReplacement
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140
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Overhead
Shelf Cover Replacement
141
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U Positive Pressure Systema ........................................................................................................................
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Roof .........................................................................................................................................................
148
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Rear Corner Casting Replacement .....................................................................................................
149
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Exterior Roof Panel Replacement
149
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Exterior Panel Repair .........................................................................................................................
150
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Interior Roof Liner Replacement
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Seats and Seat Belts ...............................................................................................................................
152
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154
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Maintenance t......................................................................................................................................
154
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Pedestal2Seat Belt Replacement .......................................................................................................
155
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Jump0Seat Belt Replacement ............................................................................................................
156
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Pedestal Seat Replacement ..............................................................................................................
158
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Co Shelving ...................................................................................................................................................
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Shelf Operation, Spring-Loaded Bolt Latches .....................................................................................
160
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Shelf Operation, Rubber Jeep
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161
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Vent .........................................................................................................................................................
162
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Two-Way Hingeless
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162
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Roof ...................................................................................................................................................
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Visor Replacement
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Headlight Replacement ...................................................................................................................... 133
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Windows .................................................................................................................................................. 165
Windshield/Quarter Window Tools and Materials ................................................................................ 165
Bonded Glass Replacement .............................................................................................................. 166
Sliding Side Window Replacement ..................................................................................................... 170
LEXAN® Window Replacement (Bonded) ........................................................................................... 170
Window (Rubber Mounted) ................................................................................................................. 172
LEXAN Window Cleaning .................................................................................................................. 173
Crank-up Window Replacement ......................................................................................................... 174
Window Regulator Replacement ......................................................................................................... 176
Trim Molding Installation .................................................................................................................... 177
Wiper System .......................................................................................................................................... 179
Troubleshooting Procedure ................................................................................................................ 180
Coupler Addendum for 78.5"-Wide Vehicles (Troubleshooting) ........................................................... 182
Motor Replacement ............................................................................................................................ 183
Link Assembly Replacement ............................................................................................................. 184
Wiper Blade Replacement ................................................................................................................. 185
Wiper Arm Replacement .................................................................................................................... 186
Pivot Assembly Replacement ............................................................................................................ 187
Index ...................................................................................................................................... 188
9
Introduction d
l
w
a
a
e
l
u
v and maintenance procedures
This manual includesrservice
n for truck and van bodiesy manufactured by
a
e
b of the information will
Utilimaster Corporation.
While
it
focuses
on
Model
s
M Years 2000 and later,d much
e
r built earlier. It contains cdrawings
also apply to units
to aid in servicing theevehicle, and it may include
e
t
iUtilimaster.
i
maintenancetsinformation on some items installed
but
not
manufactured by
Items such as chassis and
b
v
i
h
r
drive train
h manufacturer-supplied
efurnishings are covered byoseparate
ig components or certain interior
S
r
r
information.
Information provide here
l
y is intended to assist Utilimaster
ll
p customers and is no way meant to replace
a
or A
supercede instructions provideddby other suppliers of their products.
n
o
nu
o
i
B
a
t this manual are based on the latest product M
All information, specifications, and illustrations containedcin
—
u because of Utilimasters policy of continualeproduct
information available at the
le time of publication. However,
d
c
c
i
o
improvement, the information
contained in this document
is subject to change without notice. vi
r
r
p information about ordering replacement
ehbody parts manual for more
e
e
See the appropriate
V
r
S parts. For
r
wiring schematics,
appropriate body
wiring manual. (See the Customer Service
te seeorthe
dy page on
ed Service.)
s
z
www.utilimaster.com
contact
Customer
o
i
a
r
B
o
m
i
—
l
h
i
t
t
le
u
c
U
Vehicle
Types a
i
n
n
h
o
e
i
U
t
Your Utilimaster vehicle is one of the following types:
V
a
r
r
te
Aeromaster (Walk-in) Vans
po
s
r
a
o
w
Also known as step vans, these custom-built
walk-in
bodies
have
m
a
C
i
l
l
r cabs. From the outside,
walk-through doorways to custom-built
ti the
e
t
U
by
driver steps up or walks intosthe extra tall cab of our Aeromaster.
a the cargo area through the bulkhead
d
Once inside, the driver can access
e
m
t
door without having to exit
ilithe vehicle. Many possible chassis and body
bi
t
i
combinations exist. (See
U Illustration OV-5 and OV-10.)
oh
2
r
w
0Vans
p
Parcel Delivery
la
0
n
2
n
Also knownhast PDVs or high cubes, these versatile vehicles
o
by are not just tio
i
t
d service vehicles. uc
for delivering
a
ig packages. PDVs are also popular as utility
e
r
r
These custom-built
bodies have (optional) walk-through
it doorways to the od
y
o
b
p
p
i
r
r
original
van
cabs.
Drivers
can
access
the
cargo
area
through
the
bulkhead
h
o
Cowithout having to exit the vehicle. Popular
ep
o
door
PDVs manufactured by
C
r
r
r
p Metromaster , thed
Utilimaster include the compact and economical
e
t
e
n Trademaster lines.
s
larger-capacity Utilivan , and the tool-carrying
iz
io
a
r
t
o
c
im
Truck Bodies
h
u
l
t
i
t
odwith original truck cabs.au
U
Custom-built bodies on chassis
r
ed
n
p
2
v
Bodies can be of DuraPlate
e , aluminum, or FRP U
r
er
00
construction. The custom
bodies
have
rear
swing
or
rolls
2
d
t
e
re
up door options. Lift
gates, side stepwell doors,
h
z
i
r liners, ramps, and cabovers are
ts
translucent roofs,
ig
r
o
h
y
h other options.
among the many
ig
t
p
u
OV5 l r
o
a
l and Truck Body)
C Vehicle Types (Aeromaster, APDV,
n
U
®
®

®

®
10
NOTE: Your type
l determine the relevance
w of the
d of vehicle and installed options
a
a
e
l
various sections
u
v of this manual.
n
r
y
Some sections
(e.g., stop and licenseaplate lights) are common b
to most Utilimaster
e
s
M
vehicles.
d
re sections (e.g., side sliding
edoors, heater, HVAC, hood,
e
t
Other
c
i cab floor matting, overs
i
t
b
v
i
head
shelf
cover,
positive
pressure
system,
visor)
pertain
only to Aeromaster walk-in
h
r
h
e
ir g vans since PDVs and truck
S bodies have the originalrochassis cabs with original hoods,
l
l
y
l
HVAC, wipers, and other
cab-related equipment. p
a
d
A
n depend on what options are
Still other sectionso(e.g., overhead vs. swing doors)
nu
o
i
B
a
installed in a particular vehicle.
ct
M
—
u Details in illustrations and procedurese
e
l
d
NOTE: This cservice information is generic.
ic
i
o
v
r
h those in your vehicle.p Because Utilimaster manufactures many r
may differ from
e
e in
e cannot list and illustrate every possibleSpart
customized
vehicle bodies, this manual
V
r
r
y Use this
everytevehicle.
Nevertheless, the most
d common body options are describeddhere.
e
s
z
information
as a guideline where
o
i it applies.
a
r
B
o
m
ili
Exterior
Overviewuth
e—
t
l
U
aIdentification
ic High Rear Vision Identification
n
Clearance
Supplemental
n
Positive Pressure
h
eStop Light Camera
U Lights
Mount
Lights
Intake Scoop
tio Lights
V
a
r
r
Rear Door
Side
e
o
t
Mirrors
p
r
as
o
w
m
a
C
i
l
l
ti Stop/
y
er
Tail/
t
U
b
Turn
as
dVACS
Grab
Lights
Headlights
e
m
Handle
t
i Sensor
Turn Signals
Back-up
ili
b
t
i
Lights
h
U
Hood
Reflector
Hood
o
2
Safety
r
w
Straps
p
Rear
a
CablelLatch
00
Bumper
n
2
n
y
o
t
i
o
b
Block
Heater
License
Pull
Block
Heater
Step
i
t
h
t
(Rear Mount) c
Plate Lights
Strap
d
a
ig (Front Mount) Rings
u
e
r
r
d Side Marker Light poRear
it
y
Crosswalk
Sidewall
o
b
p
i
r
r
o
h
p
o Mirror
C
e
o
C
r
r
pr
d
e
Cab Vent
Cargo
t
e
n
s
z
o
Vent
i
a
r
ti
VACS
o
c
Sensor
h
u
lim
t
i
Grab
d
t
u
Side Marker
o
Handle d
U
a
r
Light
n
p
2
ve
r
U
e
0
r
0
Reflector
se
2
d
e
t
e
r
h
ir z
s
t
ig
r
o
h
Fuel
Fill
Door
Side
Sliding
Rubrails
y
h
g Reflector
i
t
p
(or Fuel
Fill Port)
Door
r
o
au
ll
OV10 C
n
A
Typical (Aeromaster) Body Components
U
11
VIN, Body Serial
Order Numbers
l
w
d Number, andaWork
a
e
l
u
The chassis Vehicle Identification
Number (VIN) isnthe legal identifier for this vehicle
rv
y and is the number
a
e
b
recorded in the license
plate
registration.
The
VIN
appears
on
a
small
metal
plate
on the dash on the drivers
s
M
e
d
r the VIN if you look through
side. You can read
window. (See Illustration LA
ethe windshield or quarter-panel
ite (See Illustration LA4.)
sThe number is also recordedvon
ic the Federal CertificationbLabel.
5 and LA6.)
t
i
h
r
h
e
ir g
Sfront corner of the dash on the
ro drivers side or on the left-hand side of l
lThe
l plate may be mounted on the
y
p
a
dfacing the quarter-panel window.
A the instrument panel assembly
u
n
o
The number is also recorded
io Decal. (See Illustrations LA15 and LA20.)
B on the Federal Certification
an
t
c
M
—
u
e
e
l
d
The Utilimaster Body c(or Unit) Serial Number is recorded
on the Federal Certification Label. iThis
c label is a
i
o
v
r
plastic decal (about 11"
variety of manufacturing information (including
the
r
ptheaquarter
eh long and 2" high) that contains
e
e
VIN). This label V
is found on the B-post, between
window
and
door,
on
Aeromasters
(see
r
S
r and on the B-post (see dIllustration
y
Illustration LA15),
LA20)
on
Truck
Body
and
PDV
body
styles.
e
t
d
e
s
z
o
i
a
r
B
A Work
Order
Number
appears
below
the Unit Serial Number on the Federal Certification
Label and is
o
m
i
—
l
h
i
t
also tstamped on the left-hand base rail of Truck Body and PDV units. This number
le can be used when the body
u chassis. (See Illustrations LA4 and LA10.)
c
U longer mounted on the original
a
is no
i
n
h
e
it o
Un
V
a
r
r
te
po
s
r
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
LA4
la
0
n
2
Federal Certification
Label
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
LA5
LA6 ig
t
p
r Number
u
Vehicle Identification Number
Vehicle Identification
o
l
a
l
C
Aeromaster
PDV and Truck
A Body
Un
12
l
l
A
ts
h
rig
ed
v
r
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
ti e
ib
h
o
pr
by
w
la
ce
i
rv
e
S
l
a
u
an
M
Right Hand
Left Hand
y
er
t
d
ed
s
z
o LA20
LA15
a Illustration LA10 ri
B
Label
on
A-post
Body Number
m
— Label on B-post
ho
ili
t
e
t
l
u
c
U
a
i
n
n
h
e
io
Part Numbers U
t
V
a
r
r
othat can be ordered directly
te from the Utilimaster Customer Service
This manual lists some parts and kit numbers
p
s
r
a see the relevant Utilimaster parts manuals. w
Department. For more comprehensive illustrations
and parts lists,
o
m
C
(See the Customer Service page onrwww.utilimaster.com
la
lori contact Customer Service.)
i
t
y
te
U
b
s
Some parts or procedures maya be dependent on which side of the vehicle they are located.
Front
d
m (LH) is based upon the position of the driver while facing ite
Right Hand (RH) or Left Hand
i
l
i sometimes called Curb Side, and Left Hand is sometimes
forward. Right Hand is talso
ib
h
U
called Road Side. 2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
b
Rear tio
t
h
c
d
ig
u
e
ra
r
t
d
i
y
o
p
ib
ro
rp
o
h
p
o
C
e
o
C
r
r
r
p
d
te
e
n
s
z
a
ri
tio
o
c
m
u
th
ili
d
t
u
d
U
a
ro
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
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h
ig
t
p
r
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o
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ll
C
n
A
U
13
Ordering Parts
l
w
d
a
a
e
l
u
n
How to Order rv
a
e
by
s
M
e this vehicle, gather the following
To order partsrfor
information:
d
e
e
t
c
Modeltand
name).
i
s year of vehicle (200x-Customer
b
vi
h
r
Chassis
VIN or Utilimaster Body
Number
(see page 12). hi
e
g
Complete
shipping address. S
ri
ro
l
l
y
l
p
a
method of shipping.
d
A Preferred
n relevant parts
o the parts necessary (seeiothe
nu
Complete description of all
B
a
t
manual).
c
M
—
u
e
e
Method of payment.
l
d
c Service prefers payment
ic
i
o
NOTE: Customer
by
Visa,
MasterCard,
v
r
r
p Purchase Orders from customers with
ehAmerican Express creditecards.
e
Discover,Vor
r
S
r open accounts are alsodaccepted.
established
y
e
t
d
e by using one of the following methods:
s
o
Then contact
iz
a Utilimaster CustomerrService
B
o
m your order to [email protected].
Email
(See Customizable Parts—
Order Form below.)
i
l
h
i your order to 574-862-7637.
t
tFax
le
u
c
U Call 800-237-7806 (574-862-3219)
a
i
and ask for
n the Parts Department.
h
e
it o
Unyour order to the following
Mail or express service
address:
V
a
r
Utilimaster Corp.
r
NOTE: Whentephoning Utilimaster, be aware that our
Attn: Parts Department
po
r
as area code changed to 574 in January w
219 telephone
65528 State Road 19
o
m 800 numbers were unaffected.
C
2002.liThe
la
P.O. Box 585
r
i
t
y
Wakarusa, IN 46573-0585
te
U
b
s
U.S.A.
a
d
m
te
i
i
l
i
ib
Returns
h
Ut
2 call the Customer Service Departmentwfor prior authorization. pAllroreturns must be
To return parts for credit,
0
la
0
shipped prepaid2freight. A restocking fee will be charged toyall returns. Special-ordernparts are not returnable. n
t
io
b
io
t
h
t
c
g
d
Customizable
Parts Order Form te
u
ra
ri
d
i
y
o
o Then one of the copies
b
p Order Form on the next page can beiphotocopied
r
rp can be
TheoParts
from this manual.
h
p
o
C in with the relevant information and thenrofaxed or mailed to Utilimaster
filled
re Customer Service. r C
p
d
te
eUtilimaster
n template file from the
You can also download a customizableoform
web
site
www.utilimaster.com.
s
z
a with your name
rai header that you can customize
ti the next page, but it has
That template is similar to the formcon
o
m
i
uyou only have to enter the
th specific information about
and address. Then, to order parts,
il the vehiclesaving
d
t
u
U the file can be emailed
retyping the same address information
repeatedly. Afteracompleting the form information,
ro
ed
n
p
2
v
as an attachment. That form
U or faxing.
re can also be used for mailing
er
00
s
2
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15
Filing Warranty
l
w
d Claims
a
a
e
l
u
If a problem on the Utilimaster
body is caused by a defect
n in materials or
rv
y
a
e
workmanship, it will
be
covered
by
our
Limited
Warranty.
Chassis, engine, tires,b
s
M
d
re are covered by the individual
and battery failures
e manufacturers.
e
t
c
i
s
t
vi
ib
h
r
Claims must
meet
the
requirements
listed
below.
Failure
to
meet
these
requirements
h
e
g
i
S
ro
maylresult
l
l r in a denied or delayed claim.
y
p
a
d
A
o following information:ion
nu
Complete a repair order with
Bthe
a
t
c
M
—
Owners and/or service
facilitys name.
u
e
e
l
Service center representatives
signature. d
c
ic
i
o
v
r
Chassis VIN orhUtilimaster Body Serial p
Number (see page 12).
r
e
e
e
Date vehicleVwas repaired.
r
S
r
y
Mileageteat time of failure.
d
d
e
Itemized
o
iz
as description of the problem.
r
B
o
m Complaint
i
—
l
h
i Cause of failure (if known)
t
t
le
u
c
U
a
i
Correction (describe
in detail)
n
n
h
Service center laborU
rate and total time of
e
it orepair.
V charges, and sales tax (if applia labor, miscellaneous
Total claim amount, including cost of rparts,
r
te
cable).
po
s
r
a
Your claim or repair order number.
o
w
m
a
C
i
NOTE: The claim or repair order
number is the number
used to match Utilimaster payl
l
ti payment.
y
erIt will be noted onUyour
ment with the work done.
t
b
s
Utilimaster authorization
a number (for repairs costing over $150 U.S.).
d
e
m
t
i
ilifaxed, emailed, or performed on-line on our web site (assumingiball
The claim can be mailed,
required
t
h
U
information is included).
2 should be mailed to:
ro
w
0
p
Warranty claims
a
l
0
n
2
Utilimaster
n
y
o
t
i
o
b
i
t
h
Attn:
Warranty Department
NOTE:
When phoning Utilimaster,
be aware that our
t
c
d
a
ig State Road 19
u
65528
e
r
r
219
telephone
area
code
changed
to
574
in
January
d
it 2002. The 800 numbers
yP.O. Box 585
o
o
b
p
were unaffected. rp
i
r
h
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Co Wakarusa, IN 46573-0585
ep
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U.S.A.
p
d with the above information
er to 574 Alternately, you can fax your claimn(if no photographs are involved)
t
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s to mail your
ioreceived copies must berizacceptable, or you will beaasked
862-7637. (The resolution of the
t
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hard copies.)
im
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Or you can email your claim
(You can
u to [email protected].
od with the above information
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ed
download a customizable
Warranty
Claim
Form
template
from
the
Utilimaster
web
site
n
p
2
v
U that you can customize
www.utilimaster.com.
re The template has a header
er
00 with your name and address.
s
2
d you only have to enter the specific information about
Then, to file a claim,
the vehiclesaving retyping
e
re asthe
ht
same address
the file can be emailed
an
ir zinformation repeatedly. After completing the formiginformation,
s
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attachment.
y
ho This form can also be used for mailing or faxing.)
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Un
16
Other claim requirements:
l
d
a
aw from Utilimaster,
e
l
Any repairs overv$150 U.S. or for structural warranty
require prior authorization
u
n
r must appear on the repair order.
y
and that number
a
e
b
s
Any claimethat is not legible and completeM
will be returned for completion.
d
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e
t
All paint
claims
require
pictures,
estimates,
and
prior
authorization.
c
ts damage claims also require
biauthorization. The damage must also
vipictures, estimates, and prior
i
Shipping
h
r
h signature of the carrier driver.
e form. This form requiresothe
ignoted on the Delivery Acceptance
be
S
r
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l
y repair order attached to the
p
llSublet work must have the sublet
service facilitys repair order that is being a
d
A submitted.
n
o
nu
o
i
B
a
t is completed.
Claims must be submitted within 30 days after thecrepair
M
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l
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cgoods
c
i
o
If the return of a failedi part is requested, contact a Utilimaster
warranty
representative
for
a
return
r
h Please reference that number
rvthe repair
p
e
authorization (RGA).
with
the
returned
part
and
enclose
a
copy
of
e
e
V
S
order. Shippingr charges should be entered onrthe same repair order that is submitted for warranty
payment.
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d
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t
COD charges
for a returned parts will notebe accepted, and the part will be returned. d
o
iz
as
r
B
Claims
— If you do not have our tax
limare paid semimonthly. Utilimaster
ho generally does not pay sales tax on claims.
i
t
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t
l
u
exemption
number on file, please call 800-528-3454 or 574-862-4561 and ask
U
a
ic for the accounting department
n
n
to obtain the number.
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tio
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o
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WARNING: Unauthorized alteration
or repair can result in possible
p or improper amaintenance
s
r
dangerous driving conditions.
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CAUTION: Theseavehicles are designed to specific specifications. Improper use or d
m cause damage to equipment and void warranty.
te
overloading can
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Reporting
Safety
Defects
(U.S.
Only)
i
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c
d
a
ig
u
e
r
r
If youybelieve that your vehicle has a defect that could
it cause a crash, injury,oord death, you should immediately
o
b
p
p
i
r
inform
the
National
Highway
Traffic
Safety
Administration
(NHTSA),
in
addition
to
notifying
Utilimaster.
r
o
Co
epif it finds that a safety defect
ohopen an investigation, and
C
r
r
If NHTSA receives similar complaints, it may
r exists in a
p
d
e
group of vehicles, it may order a recall n
and remedy campaign. However,
NHTSA cannot become
t involved in
e
s
z
o
i
individual problems between you, your
a
ti dealer, or Utilimaster.or
c
m
u call the Auto Safety Hotline
th toll-free at 1-800-424-9393;
To contact NHTSA, you may either
in the
ili
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u
d
o
U
a
Washington, D.C., area callr202-366-0123 or write to:
e
n
p
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re
NHTSA
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2
d of Transportation
U.S. Department
es
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iz Street
400 Seventh
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Washington,
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20590
y
h
ig
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You canaalso obtain other information about motor vehicle safety from the Hotline.
ll
C
n
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17
More Information
l
w
d
a
a
e
l
u
rv Reference PartsanGuide
Utilimaster Quick
e
by
s
M
d
Easily find commonly
vehicles in the
re replaced parts for mostcUtilimaster
e
e
t
i
s
UtilimastertQuick Reference Parts Guide. This
illustrated document includes
vi electrical
ibwindow
h
r
more partgnumbers
for bumpers, door hardware,
components,
h
e
S sun visors, vents, mud flaps,
ri air conditioner, hood, mirrors,
glass,l heater,
ro roll-up
l
y
l
p
a
door
other parts. It also includes sealants, window
d
A parts, seats, wiper, and many
u
n
replacement, and other repair kits.
it o
Bo
an
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M
Utilimaster Glossary
u
e— of Terms
e
l
ic
ic
od
v
If you are not familiarhwith some of the terminologyrused in this manual, you can
r
p and definitions in the
e and industry associated terms
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e
find many Utilimaster
V
r
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r
Utilimaster Glossary
of TermsBody Information
Guide.
y
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s
o
iz
a Files
Download
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B
o
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i
—
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i download the above guides
t (as Adobe Acrobat PDF files) from ourle
Youtcan
u
U site at www.utilimaster.com
a (click on the Customer
ic
web
Service button). To
n
n
h
e
view a guide you must haveUthe Adobe Acrobat Reader
io version 3.0 or higher
t
V
a
installed on your computer. Acrobat readers are
r
r available free for alleleading
o
t
computer operating systems on the Adobe web
site
(www.adobe.com).
rp
as
o
w
Vehicle Access Control System
(VACS) im
a
C
l
l
tiand Service Manual
er System Operation
t
To obtain the Vehicle Access Controls
U
by
s
d
(P/N 03102103) refer to your aVACS Operators Guide or contact Utilimasters
e
m
t
Customer Service Department.
ili
bi
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Contact Utilimaster
oh
2
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w
0
la its products or n p
Browse our site 0for more information about Utilimaster and
2
n
t
contact Utilimaster
Customer Service by using one of
io
o
bythe following
i
t
h
t
c
methods:ig
d
a
u
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r
r
Cally800-237-7806 (or 574-862-3219).
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it
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p
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i
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Fax
to
574-862-7637.
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o
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ep
CEmail to [email protected]. ro
C
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p
Mail to the following address:
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Utilimaster
s
on
iz
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t
Attn: Customer Service Department
o
c
im
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65528 State Road 19
t
i
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u When phoning Utilimaster,
od
P.O. Box 585
NOTE:
be aware that ed
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p
2
Wakarusa, IN 46573-0585
code changed to 574 in rv
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e
0
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0 numbers were unaffected.
U.S.A.
January 2002. The 2800
s
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Safety Considerations
d
a
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u
rv and Warnings an
y
Notes, Cautions,
e
b
s
M
d and
re the procedures, you willcecome across NOTES, CAUTIONS,
e
As you read through
t
ts Each one is there for a specific
WARNINGS.
bi
vi purpose.
i
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r
h
e that will help you to complete
ig give you additional information
o
S
NOTES
the procedure.
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y
l
p
a
d
A CAUTIONS warn you against
ndamage the vehicle.
o making an error that could
nu
o
i
B
a
ta risk of personal injury.
WARNINGS remind —
you to be careful when there is
c
M
u
e
e
l
d heed when you work on the vehicle: ic
Below are some basic
c WARNINGS that you should
i
o
r
h
rv
p
e
e
Always wear
safety
glasses.
V
re
S
r
y
d
e
Use tsafety stands and/or wheel blocks
d
e whenever you are underneath the vehicle.
s
z
o
i
a
B
Be sure that the ignition switchr is Off unless otherwise required by the procedure.
o
m
i
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l
h
e the vehicle.
t
i Put the transmission in Park
lon
ut and set the parking brake before working
c
U
a
i
n
h
Operate the engine only
e
io area.
Un in a well-ventilated
t
V and any moving parts when the
a the radiator fan, belts,
r
Keep yourself and your clothing awayrfrom
o
te
engine is running.
p
s
a
or
w
Avoid contact with hot metalC
parts, such as the radiator
or exhaust system.
m
a
i
l
l
y
er on the vehicle. Uti
Do NOT smoke while working
t
b
s
awatches,
d Tie
Always remove rings,
hanging jewelry, and loose clothing before working on a vehicle.
e
m
t
i
long hair securely
your head.
ilbehind
bi
t
i
h
U
o
Keep hands2and other objects clear of the radiator fan blades. The electric fan can
start at any time
r
0 the ignition is Off. Disconnect the fan when
p
awworking under the hood.
even though
l
0
n
2
t recommends that a licensed automotive
io work on the vehicles tair Utilimaster
on
byair-conditioning specialist
i
t
h
c
d
conditioning
(HVAC) system.
ig
u
e
ra
r
t
d
i
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o
p Avoid breathing A/C refrigerant and lubricant
ib vapor or mist. Exposure
ro may irritate eyes, nose,
rpand
o
h
p
o
certified to meet the requireC throat. To remove R-134a from therA/C
e
o system use service equipment
C ventilate
r
ments of SAE J2210 (R-134a recycling
equipment).
If
accidental
system
discharge occurs,
r
p
dsafety information may beteobtained from
e
n
work area before resuming service.
Additional health and
s
z
i
io
a
r
refrigerant and lubricant manufacturers.
t
o
c
h
u
lim
t
i
Become familiar with all
warning labels.
d
t
u
d
o
U
a
r
e
Always maintain firm
footing and control of n
tools.
p
2
rv
U
e
0
r
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Always weardproper protective equipment when appropriate to the
2 process.
es
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iz
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C
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19
Reporting Safety Defects (U.S. Only)
l
d
a
aw should immediately
e
u
If you believe that yourvvehicle has a defect that could cause
a crash, injury, or death,lyou
n (NHTSA), in addition toynotifying Utilimaster.
r
a
inform the National e
Highway Traffic Safety Administration
b
s
M
e
d
r similar complaints, it maycopen
e an investigation, and iftitefinds that a safety defect exists in a
If NHTSA receives
i
s
i
t
group of vehicles,
it may order a recall andrvremedy campaign. However,
cannot become involved in
bNHTSA
i
h
h
e
g
individual
ri problems between you, yourSdealer, or Utilimaster. ro
l
l
l NHTSA, you may eitherdycall the Auto Safety Hotline ptoll-free at 1-800-424-9393; in the
a
ToAcontact
u
n
Washington, D.C., area call 202-366-0123
or write to:
it o
Bo
an
c
M
NHTSA
u
e—
e
l
c of Transportation rod
ic
U.S. Department
i
v
r
400 Seventh
p
ehStreet
e
e
V
r
S
Washington,
r DC 20590
y
d
e
t
d
e
You can alsosobtain other information about
iz motor vehicle safety from the Hotline. Bo
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ho
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Towing
n
n
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io information on Ve
U
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See the Chassis Operators Manual for more complete
ra
er
towing procedures.
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t
rp
as
Utilimaster recommends the following: o
w
m
a
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i
l
l
ti of towing.
A wheel lift or flatbed equipment
y
er is the preferredUmethod
t
b
s
Unload the vehicle to reduce stress on the chassis during towing.
a
d
e
Be sure to place the transmission
in Neutral and fully release the
m
t
ili
parking brake if towing.
bi
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2
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Emergency
Repairs
n
2
t the Utilimaster body are unlikely to disablebayvehicle enough to make
ioit undrivable. See the tion
t
Problems with
h
c
d for emergency information.
ig
Chassis Operators
Manual and the Engine Service Manual
u
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ra
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d
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C
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20
l
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Service Information
d
a
a
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l
u
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rv Recommendations
y
a
Manufacturers
e
b
s
M
d
re instructions providedcwith
e sealants, adhesives, and other
e
Safety and application
t
ts always supersede information
products should
vi provided by Utilimaster.ibi
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e
ig
o
S
r
r
l
l Lubrication
Body
y
l
p
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A
u
n Hinges, latches,
The engine is not the only partBofoyour vehicle that needs lubrication.
it o
an
seals, and locks also require—occasional lubrication.
c
M
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l
d
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ic
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v
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S
r V Do NOT power-wash
d
CAUTION:
for the first 90 days. Wash and wax the y
body periodically to
e
t
d washes.
e
preserve the body finish, but
s
o
ir z avoid harsh cleaning solutions or high-pressure
a
B All deviations from
o recommended by the chassis manufacturer.
m Only use engine coolant(s)
i
—
l
h
i
the recommended coolant
all cooling system additives must
t
le be approved by the chassis
ut andCorporation.
manufacturer andaUtilimaster
c
U
i
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io
Un
t
V
a
r
Rear Door Locks,
r
e
o
t
Catches,
p
s
r
Latches,
a
o
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and
Hinges
m
a
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Side Door Track li
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b
as
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Door Locks,
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Catches,
i
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and Latches
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Co
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pFill Hinge
d
e
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t
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n
s
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it o
a
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Illustration MC5
o
c
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lim
Body Lubrication
Points
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h 14,000 lbs GVWR. s
CAUTION:
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r
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ig
th
p
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C
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21
Body Maintenance Checklist
l
w
d
a
a
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l
u
By design, the Utilimaster
body
is
low-maintenance.
However,
Utilimaster
recommends
the following items
v
n
r
y
a otherwise stated. For moreb detailed information, check
should be checked every
e three to four months, unless
s
M
the relevant sections
d
re of the manual.
e
e
t
c
i
s
t
vi
ib
h
r
h
e
g
Pre-Trip
ri Inspection (daily) S
ro
l
l
y
l
p
a
The
checks each day:
d
Adriver should perform the following
n
o
nu
o
i
B
a
t
o Adjust the drivers seat
position.
c
M
—
u
e
e
l
d
o Adjust all mirrors.
c
ic
i
o
v
r
h
r
p
eadjust
e
o Fasten and
the safety belt.
e
V
r
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r
y
d lights on the instrument panel.
o Whentestarting the engine, check allewarning
d
s
z
o
i
a
r
o Check all switches on the dash and the steering column to see that they workBproperly.
o
im
l
h
io
t
e—
Check the heater and defroster
controls.
t
l
u
U
a
ic
n
n
h
o Check the wiper operation.
e
io
U
t
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a
o Check the washer operation and sprayrpattern.
er
o
t
rp
o Check the washer fluid level.
as
o
w
m
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C
i
l
o Check all exterior and interior
lights.
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t
U
by
o Check the operation of all
doors.
s
a
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m
t
ili
bi
t
i
(every three to four months)
Routine Body Maintenance
h
U
o
2
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w
Utilimaster recommends
0 that a technician do the above pre-triplainspection before performing
p the following body
0
maintenance checks:
n
2
n
y
o
t
i
o
b
i
t
h
t
Seats andgBelts
c
d
a
i
u
e
r
r
d
o
o yCheck tightness of the bolts for the seat beltitand pedestal.
o
b
p
p
i
r
r
h of fraying or wear. ep
o
Coo Check the seat belt for operation androsigns
C
r
Catch
r
p
d
Interior Driver Conveniences
e
Plate
t
e
n
s
iz
a
o Check the heating system fortio
operation and ease of use.
r
o
c
im
h
u
1/8"
l
t
o Check all switches for operation.
i
d
t
u
U
rooperation and tightnessnofa mounting.
ed
o Check the cab fan for
p
2
v
r
U
re
e
00
s
Wipers
2
Latch
d
t
e
re
Tongue
h
o Check tightness
ir z of the wiper linkage connections.
ts
ig
Illustration MC10
r
o
h
yCheck Latch Tongue and Catch
o Check
h that the blades wipe clean.
ig Plate for Wear
t
p
r
u
o
a
ll
C
n
A
U
22
l
w
d
a
a
e
l
u
o Check the hold-down
straps for alignment and
n excessive
rv
y
a
e
wear.
b
s
M
e
d
e excessive wear.
e
o Checkrthe hood guides for alignmentcand
t
s
bi
vi
i
ht the hood struts for propereroperation.
o g
Check
h
i
o
S
r
r
l
l
Bumpers
y
l
p
a
d
A o Check bolts on the bumper
u
n
it o
Bo and brackets for tightness.
an
M
o Check for damaged
e—or bent components. duc
e
l
c absorbing bumper fittingrowhen
ic
Illustration MC15
i
o Grease rear shock
v
h
Check Roll-Up Door LatchrDeadbolt for Wear
p
e
applicable.
e
e
V
r
S
y
er
Doors, General
t
d
ed
s
z
o
a the window operation. ri
o Check
B
m
hoand close tightly.
ili Check that doors open easily
t
e—
o
t
l
u
U
a handles for tightness.
ic
n
n
h
o Check interior and exterior
e
U
tio
V
a
o Check alignment of latches and catches.
r (See Illustration er
o
MC10.)
p
st
r
a
oand sliding door catch
w
o Check for wear on the bulkhead
m
a
C
i
l
l
rleast 1/8" of the Kasonti latch
plates and latch tongue. At
y
e
t
U
Illustration MC20 b
tongue needs to engagesthe catch plate.
a
Rear Door Dead Bolt
d
e
t
o Check operation ofim
the locks.
il
bi
t
i
o Check condition
h
U of the pull-down strap on the rear door.
o
2
r
0rear door is centered in the opening. law
p
o Check that
0
n
2
n
t the (non-VACS) ABLOY lock cylinders
o Lubricate
io
o
by with a
i
t
h
t
c
lightweight
oil. (ABLOY recommends Exxon d
Hydraulic oil
a
ig
u
e
r
r
d
itcylinders.)
y type NUTO 68, or equivalent, for the lock
o
o
b
p
p
i
r
r
h use ZEP 45 ep
o
dirty,
Coo If the ABLOY lock cylinders become
o
C
r
r
penetrating lubricant to clean the cylinders
before applying
r
p
d
e
t
the NUTO 68.
n
s
ze
o
i
i
a
r
t
Illustration
MC25
o On the VACS rear door dead
o zerk
c bolt, lubricate the three
mSide Door
i
Bulkheadlor
Dead Bolt
h
u
t
i
fittings with #2 grease at
six-month intervals or three-month
d
t
u
d
U
a MC
intervals in hot, dusty
roconditions. (See Illustration
e
n
p
2
20.)
rv
U
0
re
e
0
2
d bulkhead and (both) side door dead bolts,
o On the VACS
es
t
e
r
h
z side of the slide bolt with dry graphite
lubricaterieach
g
ts
i
r
o
h
lubrication
at six-month intervals or as needed. (See
y
h MC25.)
ig
t
p
Illustration
r
u
o
a
ll
C
n
A
U
Hood
®
®
®
®
®
23
l
w
d
a
a
e
l
u
n
rv
a
e
by
s
M
e
d
e
e
Doors, Roll-up r
t
c
i
s
t roll-up door with a (Utilimaster
vi P/N 04202540, or equivalent)
ib light oil (see Illustration MC30):
h
Lubricate rear
r
h
e
g
i
S off excess oil (#1, #3). ro
o
l
ll r Roller drums and shaftswipe
y
p
a
d
Ao Springslubricate bothosprings
u
n
along their entire length
it o to prevent rusting (#2).
B
an
c
M
o Hinges (center ande—
end)wipe off excess oil (#5).
u
e
l
d(#1, #3).
c shaftswipe off excess oil
ic
i
o
o Roller drums and
v
r
h
r
p
e#7).
e
e
V
o Rollers (#6,
r
S
r
y
d
e
t (NS).
d
e
o Latches
s
o
iz
a
r
B
o im
Clean and lubricate track (#4).
o
—
l
h
i
t
t
le
u
c
U
a
i
n
h
e
it o
Un
V
ra
Counterbalanceo
Shaft
Springer
Drum Roller
Track
t
p
r
as
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
Hinges
m
t
ili
bi
t
i
h
U
o
2
r
w
Roller Shaft
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h Roller Bracket
ig
t
p
r
u
Illustration MC30
o
a
ll
CRoll-Up Door
Lubrication Points on Rear
n
A
U
CAUTION: Do NOT use grease on doors. Do NOT get oil on rubber seals. Wipe up any drips
immediately.
24
l
w
d
a
a
e
l
u
o Hingeslubricate
v the zerk fittings with #2 grease
n in
rintervals
y
a
e
at six-month
or three-month intervals
b
s
M
d
hot, dusty
MC35.)
re conditions. (See Illustration
e
e
t
c
ts
o Handlesuse
ZEP 45 penetrating
bi
vilubricant to
i
h
r
h
e oil. (Exxon
igclean before applying a lightweight
o
S
r
r
l
l Hydraulic oil type NUTO y68, or equivalent.)
l
p
a
d
A
o ZEP 45 penetrating ion
nu
o Interior door catchesuse
B
a
t
lubricant to clean before
applying a lightweight oil.
c
M
—
e oil type NUTO 68, or du
e
(Exxon Hydraulic
l
ic
ic Illustration MC40.) ro
equivalent.)h(See
v
r
p
e
Illustration MC35
e
e
V door catchescleanrand check
o Rubberrexterior
S Hinges
Grease Swing Door
y
d
e
for loose
t fasteners. (See Illustration
d
e MC45.)
s
z
o
Do
NOT
use
petroleum
jelly
on
rubber
door
i
a
B
orbecome abrasive
mcatches. It will attract dirt and
i
—
l
h
i to the fittings.
t
le
ut
c
U
a
i
n
n
h
o Steel exterior door catcheslubricate
theozerk
e
i
U
t
V
fittings with #2 grease at six-month intervals
a or
r
r
three-month intervals in hot, dusty conditions.
o
te
p
s
r
a
NOTE: The information in this
o
w
m
a
C
i
l
illustration is generic. Details
may
l
r
ti
y
differ from your vehicle.teUse this
U
b
information as a guideline
as where it
d
e
m
t
applies.
ili
bi
t
i
h
U
o
2
r
Illustration
0
p MC40
aw
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
IllustrationrMC45
u
o
a
ll Catches
Clean Rubber
C
n
A
U
Doors, Swing
®
®
Lubricate Swing Door Catches
25
Other Body Parts
d
l
a of body
o On Truck Bodies
e and PDVs, check the alignment
u
v
r and tighten mounting boltsanafter the first 30,
mounting spacers
e
60, and 90
esdays of operation and everyesixMmonths after that.
r
(See s
Illustration MC50.)
c
by
w
la
d
e
t
i
t
b
vi
h
r
o On
Aeromasters,
check
for
loose
fasteners
underneath the hi
e
g
i
o
S
bolts on the outsiderof
l
ll r chassis, particularly the bodyymounting
p
a
d chassis rails and the boltsnon the
A the riser on either side ofothe
u
crossmember plate. (See
it o
B Illustration MC55 and Body
an
Mount Bolts section.)
c
M
u
e—
e
l
d
c floor surface.
ic
o Sweep debris from
i
o
v
r
r
p could result.
eh down wooden floors as ewarpage
e
o Do NOT V
wash
r
S
r
y
d
e
o Check
t that all reflective tape is securely
d
e attached.
s
z
o
i
a
r
B
o m
Clean rear threshold drains and
o drain troughs. (See also the
i
—
l
h
i Drains section.)
t
t
le
u
c
Uo Check grab handle mounting
a
i
n (See also the h
bolts for tightness.
n
o
e
i
U
Grab Handle section.)
t
V
a
r (See also the er
o
o Check mirror mounting bolts for tightness.
p
st
Illustration MC50
r
Mirror section.)
a
o
w
Body
Mounting Bolts
m
a
C
i
l
l
ti
er
t
U
by
s
a Frame Rail
d
e
Chassis
m
t
ili
bi
t
i
Riser
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
Crossmember Plate
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
Illustration
u MC55
od
U
a
r
ed
Check for Loose
Bolts on Chassis
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
26
l
w
a
a
e
l
u
n
Common Tools rv
y
a
e
b
s
Below are tools,eincluding recommended brandsMand models, commonly used
d in van repairs.
r
e
e
it
s and flat-blade screwdrivervset
icincluding Torx bit
Phillips
t
b
i
h
r
h
e
ig
Metric and standard box and open-end
wrench set
o
S
r
r
l
l
l Metric and standard socketysets
p
a
d
A
u
n
3/8" drill (Dewalt DW221
it o
Bo recommended)
an
M
1/2" drill (Dewalte—
DW231 recommended) uc
e
l
dor #11 bit)
c
ic
Drill bit set (including
1/4" or F-bit and 3/16"
i
o
v
r
h
r
p
e
e
Screw gun
(Dewalt
DW281
recommended)
e
r
S
r V (Emhart PRG 540 recommended
POP eriveter
as it does both POP rivet and y
MONOBOLT
d
t
d
e
s
installation)
o
ir z
a
B consists of Jaws PRG
o with 1/4" nose assemblythis nose assembly
imMonobolter (Emhart PRG 540
—
l
h
i 540-44, Jaw Pusher PRG
t
ut 740-7A, and 1/4" Nose Tip BRN-811) icle
U Air hammer with a buck
a
n riveter attachment
hAjax rivet set #1620) and buck bar
on(Sioux 270 with 3/16"
e
i
U
t
Huck riveter (Huck 229 with 1/4" nose
a assembly 99-1458)r V
r
Saber saw (Porter Cable 548) po
te
s
r
a
DVOM (Digital Voltmeter)
o
w
m
a
C
i
l
l
Terminal tool kit (Snap-OnrTT600 recommended)ti
y
e
t
U
b
Locking pliers (VISE-GRIP
recommended,
9"
or
10"
[23
or
25
cm]
long)
as
d
e
Multigrips pliers (any
standard
model
about
9"
or
10"
[23
or
25
cm]
long)
m
t
ili
bi
t
i
Needle-nose pliers
h
U
o
2
Torque wrenches
(any quality sets with inlb and ftlb [or
Nm]
measurements)
r
0
p
aw
l
0
Drill stop
n
2
n
t punch or an air hammer with a punch attachment
io
o
by
Hand
i
t
h
t
c
d
a
ig
u
e
r
yrDisk Air sander with 220-, 320-, and 600-grit
sandpaper
d
it
o
o
b
p
p
i
r

Tape
measure
r
o
Co Fine-pointed marker
ep
oh
C
r
r
r
p
d
e
Rubber mallet
t
e
n
s
iz
it o
a
r
Razor knife
o
c
h
u
lim
Pry bar or large screwdriver
t
i
d
t
u
d
o
U
a
Safety glasses
r
e
n
p
2
rv
U
0
Memory saver re
e
0
2
dtool (Sioux 02107TL recommended)
es
Nutsert insert
t
e
r
h
z
igun
g
r
Caulking
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Tools and Fasteners
d
®
®
®
®
®
®
®
®
®
®
®
27
Fastener Replacement
l
w
d
a
a
e
l
u
BOM Fastener
n
rv
a
e
by
Removal
s
M
remust be cut off with a die grinder.
e Punch out the center ted
A BOM fastener
c
i
s
i
t
b
v
pin. The remaining
ring may need to be drilled
out.
(See
Illustration
i
h
h
er
ig
FR10.)
Illustration FR10
o
S
r
r
l
l
BOM Fastener
y
l
p
a
Replacement
d
A
u
n
o
n
o
i
B
a
A BOM fastener should be replaced per original specifications.
be
t However, in some applications it may M
c
— 8 bolt, and a Grade 8 locknut
able to be replaced with aeGrade
of
like
diameter.
If
replacing
with
a
nut
and
u
e
l
d
c
c use flat washers against allroaluminum surfaces.
bolt, always rememberito
i
v
h
r
e
ep
Buck Rivet (SolidVBrazier-Head)
r
Se
r
Removal
te
dy
ed
s
z
o
i off the head of the rivet, starting at the B
r
Use a #11 a(3/16" or 5 mm) drill bit to drill
o
m
—
dimple
ililocated in the center. Continue
th to drill the rivet until the head pops off. lTake
e
t
u
a punch
U and knock out the stems.
a (See Illustration FR15.)
ic
Illustration FR15
n
n
h
o rivet head in ordere to get a
Buck Rivet
U can be used ontithe
NOTE: A center punch
V
a
good start for the drill bit.
r
er
o
t
rp buck rivets of varying
NOTE: Brazier-head 3/16" [5 mm]
as lengths are used on most
o
w
locations on the body.
m
a
C
i
l
l
ti
er
Installation
t
U
by
s
a
d
Use an air hammer with a buck-riveter
attachment and bucking bar to replace the rivet. In most applications
e
m
t
li used to replace a buck rivet. Do NOT replace buck rivets with POP
a MONOBOLT can also ibe
bi rivets.
t
i
UMetric Equivalents
Buck Rivets Lengths and
oh
2
r
w
0 vehicle was designed using English (S.A.E.)
p
la measurements.nUtilimaster
0
NOTE: This
2
n
provides
t metric conversion equivalents as a courtesy
io be used,
o
by if metric toolstmust
i
h
but
c
d given in this manual.
at
ig Utilimaster does not warrant metrictvalues
u
e
r
r
dNo. #11
i [4.85 mm], Drill Bit
y
o
RivetpDiameter
3/16" [4.76 mm], Hole Diameterb.191"
o
p
i
r
r
h
o
CoRivet Length
ep
o
C
r
r
Metal Rivet
Grips
Metal
Thickness
r
p
d
e
t
e
7/16" [11.1 mm]
.244" on[6.2 mm]
3/16"
s
iz to 15/64" [4.8 to 6.0 mm]
i
a
r
t
1/2" [12.7 mm]
.305"
1/4"
o to 19/64" [6.4 to 7.5lmm]
c [7.7 mm]
im
h
u
t
i
t mm]
9/16" [14.3 mm]
od.364" [9.2 mm] au 5/16" to 23/64" [7.9 toU9.1
r
ed
5/8" [15.9 mm] p .424" [10.8 mm] n
3/8" to 27.64" [9.52to 10.7 mm]
v
U
e
0
er
0[11.1
3/4" [19.1 mm] r
.545" [13.8 mm]
7/16" to 17/32"
to 13.5 mm]
s
2
d
t [13.9 to 16.7 mm] re
e
7/8" [22.2 imm]
.665" [16.9 mm]
35/64" to 21/32"
h
z
r
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
28
l
w
d
a
a
e
l
u
Removal
n
rv
y
a
e
b
Locknuts can be s
removed with an appropriate open-end
or
box-end
wrench.
M
e
d
r
e
e
t
c
Replacements
t
bi
vi
i
h
r
Utilimaster
h threads. These locknuts and the bolts
etype locknuts, which distortothe
ig commonly uses center-lock
S
r
r
should
with new. Nylon insert nuts and KEPS nuts are reusable. If
l
l always be discarded and replaced
ywashers
l
p
a
d
locknuts
are
not
available,
use
lock
and
a
thread
adhesive
like
Loctite.
Flange
head
nuts
and
bolts
A
u
n
can be used in place of flat washers.
it oagainst aluminum surfaces.
Bo Always use flat washers
an
c
M
u
e—
e
Torque Values and Metric
Equivalents
l
d
c
ic
i
o
v
r
6$(%ROW7KUH
0H WULF7RUTXH (TXLYD OHrQWV
pVGH eh *UD GH D GVD QG7RUTXH
eGH e
6$( V
*UD
*UD
GH *UD
r
S
%ROW
0LQ
0D [ 0LQ
0D [ 0LQ
0D [ 0LQ
0D [ y
d
eGr 7RUTXH
t
d
e
7KUH
D
7RUTXH
7RUTXH
7RUTXH
7RUTXH
7RUTXH
7RUTXH
7RUTXH
o
iz
as
r
3RXQG,QFKH
VLQOE
1H Z WRQ0H WH UV1P
B
o m
h
—
ili
t
e
t
l
u
c
U a
i
n
n
h
e
U
tio V
a
r
r
e
o
t
p
s
r
a
o w
C
m a
i
l
l
r
3RXQG)H H WIWOE
ti 1H Z WRQ0H WH UV1P y
e
t
U
b
as d
e
m
t
li
i i
t
ib h U
o
2
r
w
0 p
la 20
n
n
y t
b
io o
i
t
h
t
c
g
d
a
i
u
e
r
r
d
it y
o
o
ib
p
p
r
r
h
p o
Co e o
C
r
r
r
p
d
e t
e
n o
z
i
i
as r
t
o c
m
i
th
u
l
i d
t
u
d
o U
a
e
pr
n
2
v
e
0
U er
r
0
8WLOLPDVWHUSURYLGHVPHWULFFRQYHUVLRQRQO\DVDFRXUWHV\0
HWULFYDOXHVJLYHQDUHQRWZDUUDQWHG
2
d
es
t
e
r
h
z vehicle was designed using English (S.A.E.)gmeasurements.
NOTE:riThis
Utilimaster
ts
i
r
o
h
provides
metric
conversion
equivalents
as
a
courtesy
if
metric
tools
must
be
used,
but
y
h
g
i
t
p
Utilimaster
does not warrant metric values givenoin this manual.
r
u
l
a
l
C
A
Un
Locknuts
®
®
29
NOTE: Torque values listed are suggested values on parts carrying residual oil of manul otherwise lubricated parts.wThey apply to
d do not apply to plated or
facture. Theseevalues
a
lacalled out in a
v and should be supercedednuby any torque specifications
general purposes
r
a
by
specific process.
se
M
ts
h
rig
re
ce
i
rv
e
S
d
te
i
ib
h
o
pr
CAUTION: Utilimaster uses center-lock-type locknuts, which distort the threads of the nut and
bolt. This type, should NOT be reused after disassembly. Always replace the locknut and
bolt with new.
l
y
ll
a
d
A
MONOBOLT , Magna-Bulb , and
o Magna-Lok Rivets ion
nu
B
a
t
Removal
c
M
—
u
e air hammer with a punch attachment),
e
1. With a punch (or lan
d
cout of the fasteners. (See Illustrations
ic
i
o
knock the stems
FR20
v
r
Illustration rFR20
p
eh
and FR25.)
e
V
Magna-Bulb
r
Se
r
y
e the head of the rivet usingead#11 (3/16" or 5 mm) or F
2. Drill toff
d
s
z
o
(1/4"
i on fastener size). The back
a or 6 mm) drill bit (depending
r
B
o
stem
should
fall
off.
m
i
—
l
h
i
t
t
le
Replacement
u
c
U
a
i
Illustration FR25
n
h
Use a MONOBOLT rivet gunnto replace it.
e
Magna-Lok
it o
U
V
a
r
er
o
t
rp thread locker on the
as threads of a nutsert.
CAUTION: Do NOT use Loctite
o
w
m
a
C
i
l
l
ti
er
t
U
by
Nutsert
s
a
d
e
NOTE: A nutsert iisma threaded insert that is crimped
t
il need only to be removed if it is
bi
into place. A nutsert
t
i
damaged and U
the threads cannot be retapped.
oh
2
r
w
0
p
Removal
la
0
n
2
n
io
o
by
Cut off withhatdie grinder. (See Illustration FR30.)
i
t
t
c Illustration FR30
d
a
ig
u
e
r
r
Replacement
d
it
y
Nutsert
o
o
b
p
p
i
r
r
Using
a
nutsert
insert
tool,
replace
the
nutsert
with
one
meeting
h
o
Co specifications. Do NOT use Loctiterothread
ep of a nutsert.
original
locker on the threads
C
r
r
p
d
e
t
If a nutsert of original specifications or the
tool
to
install
nutserts
is
not
available,
the
nutsert
may
be replaced
e
n
s
z
o
i
i
with another form of threaded inserttor a nut and bolt. This depends
r upon application andashould be approved
o
im to use flat washers on
by Utilimaster Customer Service.ucIf it is to be replaced with
a
nut and bolt, it is important
h
l
t
i
t
u
both sides of the material. od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
®
®
®
®
30
l
w
d
a
a
e
l
u
Removal
rv
y
an drill bit (3/16"
e
b
a. From theshead side, using the appropriate-size
(With Collar)
M
d
re1/4" [6 mm], or 3/8" [10 mm]),
e
[5 mm],
drill off the head of
c
ite
s Punch out the center of theviremaining
thetpin.
pin. (See
b
i
h
r
h
e
ir gIllustration FR35.)
ro
l
lb. From the collar side, usingytheS appropriate-size drill bit p(3/16"
l
a
d
A [5 mm], 1/4" [6 mm], oro 3/8" [10 mm]), drill out thencenter
nu
o
(With
Flanged
Collar)
i
B
a
t pin.
of the collar. Punch out the center of the remaining
c
M
—
Illustration FR35 e
u
e
l
d the steel pin
NOTE: Be extremely
careful not to overheat
c
Magna-Grip ic
i
o
r
and collar. h
Use low-RPM drill speed. p
rv
e
e
Vcollar side, the rivet can alsorebe cut off with a die grinder or a reciprocating
S saw. Punch
c. From the
r
y
d
e
out the
t center and the remaining zring.
d
e
s
o
i
a
B
Replacement
or
m
i
—
l
h
t
Usetia Huck rivet gun to replaceuit.
le
c
U
a
i
n replace the fastener
h of like diameter and a Grade 8
If a Huck rivet gun is not available,
on with a Grade 8 bolt
e
i
U
t
locknut. For additional locking capacity, use Loctite
a thread locker. r V
r
NOTE: Flat washers are requiredoagainst aluminum surfaces.
te
p
s
r
a
o
w
POP Rivet
m
a
C
i
l
l
ti
Removal
y
er
t
U
b
Drill off the head of the rivet using
as a #11 or 3/16" [5 mm] drill bit. The
d
e
m
t
back stem should fall off. l(See
Illustration
FR40.)
ii
bi
t
i
Replacement
h
U
o
2
Illustration
FR40
r
Use a POP rivet gun
0 to replace it.
p POP Rivet
aw
l
0
n
2 Adhesive)
n
y
o
Tape (Double-Faced
t
i
o
b
i
t
h
t
c
d
a
Removal ig
u
e
r
r
d
it pulling apart the joined
y
o
o
b
p
Withpa razor knife, cut along the length of the tape
while
flat surfaces. Scraperoff
i
r
o
remnants
Co as much as possible. Clean with arsolvent.
ep
oh
C
r
r
p
Replacement
d
e
t
e
n
s is in the proper
iz paper until the other surface
it o Do NOT remove the rtape
Apply to one surface from a fresh roll.
a
o to reposition it without
position. Once the tape sticks touacsurface, you will not behable
limstarting over.
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Pin-and-Collar Fastener (Magna-Grip®)
®
®
®
31
Tape (Vinyl Barrier)
l
d
w
a mate in order to prevent
White vinyl tape is usedewherever steel and aluminum u
surfaces
la corrosion of the
v
n
r
y
surfaces.
a
e
Removal
s
re
M
d
te
i
ib
h
o
pr
b
ce
s
i
t
Peel or scrape
h off.
rv
e
g
i
Replacement
S
l
ll r
y
a
d roll.
Apply
A to mating surfaces from a ofresh
n
nu
o
i
B
a
t part numbers:
NOTE: Tape rolls can be ordered with the following
c
M
—
e roll........P/N 12303707du
1" [25.4 mm]-wide
2" [50.8 mm]-wide roll........P/N 12303706
e
l
c roll........P/N 12303705
ic12605947
i
o
3" [76.2 mm]-wide
4" [101.6 mm]-wide roll......P/N
v
r
r
p
eh
e
e
V
r
S
r
y
d
e
t
d
e
s
o
iz or any other thread locker on the threads
CAUTION:
Do NOT use Loctite
of a nutsert.
a
r
B
o
m
ili
th
e—
t
l
u
U Adhesive
a
ic
Thread
n
n
h
e
io
U
t
Removal
V
a
r
er if any residue from the seal is present
o
Bolts with thread adhesive cannot be reused.
After
the
bolt
is
removed,
t
rp
on a reusable surface, scrape off the residue.
as
o
w
m
a
C
i
l
l
Replacement
ti
y
er
t
U
b
s
Slowly torque the new bolt to the appropriate value. (Using a power tool to spin the fastener quickly may lower
a
d
e
the effectiveness of the seal.)m
t
i
ili
b
t
i
Torque Seal
U
oh
2
r
w
The torque seal appears
0 as a small painted line across a bolt thread
p and washer seam.
a and nut or across a bolt
l
0
If the seal line is2broken (out of alignment), the fastener hasyloosened.
n
n
o
t
i
o
b
i
t
h
Removal g
t
c
d
a
i
u
e
r
r
dsurface, scrape off the residue.
it is present on a reusable
y bolt is removed, if any residue from the bseal
o
After the
o
p
p
i
r
r
h
o
Replacement
Co
ep
o
C
r
r
r the new bolt
When the fastener installation is complete,papply a small bead of torque
seal or paint stick across
d
e
t
e
threads, nut, head, and/or washer. on
s
iz
i
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
32
l
w
d
a
a
e
l
u
CAUTION:v Always wear proper protective equipment when appropriate for the process.
n
r
y
a
e
b
s
M
e
d
r
e
e
t
Sealants s
c
t
bi
vi
i
h
r
One-compound
polyurethanes are veryeeffective sealants. They remain
h permanently elastic (less cracking due
ig
o
S
r
r
to shrinkage),
they can be painted, and
require no mixing. They bond as well as seal, thus reducing the l
l
y they
l
p
a
d
number
of
mechanical
fasteners
needed,
and
they also reducennoise and corrosion.
A
u
o
io
B provided with sealants,tadhesives,
an
Safety and application instructions
and
other
products
should
always
c
M
u
e— by Utilimaster.
supersede information provided
e
l
d
c
ic
i
o
v
r
h provide an overview ofpwhat to look for when working with polyurethane
The following statements
r sealants:
e
e
e
1. Manufacturers
Recommendations:r Always follow manufacturers cautions andSrecommendations
rV
y
e
t
d
forsprotective
equipment, application,
ed and cleanup.
z
o
i
a
r
B
2.imConditions: Recommended
application
temperatures
are
40º
[5º
C]
to
100º
F [37º C]. For coldo
—
h
it l weather applications, store
leremove them just prior to using.
ut sealants at approximately 70º F [21º C] and
c
U Make sure joint is frost-free.
a
i
n
n
h
o
e
i
U
t
3. Surface: Clean the surface with a strong
jet of compressed air,Vsandblast, or solvent. Remove all
r free of grease or rust, and of sound
ra must be clean,edry,
loose particles and old sealant. Theosurface
t
p
quality.
r
as
o
m type and uniformity can vary, a pretest islaw
i
4. Priming: Usually no primingCis required. Since substrate
l
ti when substrates require them. Since compatibility
y
er
recommended. Sealant manufacturers
have primers
t
U
b
among manufacturersaissin question, do not mix and match different manufacturers primers and
d sealants.
e
m
t
5. Application: Cut
ilithe tip of the plastic nozzle to joint size. Puncture the airtight seal. Install
bi with a
t
i
hand- or power-operated
caulking gun. For best performance, sealant should be gunned
h in the joint
U
o
2 slot is at the midpoint of its designed expansion
r
where the0joint
and
contraction.
Dip
the Poly-stick in a
w
p
a
l
0
soapy solution
to ease spreading the adhesive to seal any gaps.
n
2
n
y
o
t
i
o
b
i
t
Limitations:h
t
c
d
a
ig
u
e
r
r
t
y Since the system is moisture-cured, permitisufficient
exposure to air.d
o
o
b
p
p
i
r
r
hpresence of curing silicones.
p
o
Co Do NOT apply over silicones or in the
e
o
C
r
r
During cure, avoid contact with alcohol
solvents.
r
p and alcohol-containing
d
e
t
n in the same day. ize
For best results, use open cartridges
s
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
33
Service Procedures
Batteries
d
e
rv
e
s
re
l
a
u
n
a
M
by
w
la
d
e
e
t
c
i
Always remove thei Negative (Black) cable first and connect it last.
ib
rv
h
e
S
ro
l
l
y
l
p
a
d
A
CAUTION: Note theolocation of the battery and n
the cable routing and reinstall them in exactly
nu
the same way. When
B reattaching the Positivetio(Red) cables, the doubling of the two cables
a
must be in the —
same positions as before. c
M
u
e
e
l
d
c
ic
i
o
v
r
r
p
eh
e
e
Battery Access V
r
S
r
y
d
e
NOTE:
t The batteries on most ze
d
s
o
i
Aeromasters
are located through
a
r
B
o
m
an access panel in the right-hand
i
—
l
h
i stepwell. Batteries on allutother
t
le
c
U chassis are likely to bealocated
i
n
n
h
o
e
i
U
under the hood. (See Illustrations
t
V
a
r
BA10 and BA15.) Otherwise see r
o
te
the Chassis Service Manual. rp
s
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
Illustration BA10
e
m
t
Stepwell Battery Access i
ili
t
ib
h
U
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t Illustration BA15
e
re
h
ir z
ig Battery Under the Hoodhts
r
o
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
WARNING:
ts
h
rig
34
l
w
d
a
a
e
l
u
1. Make sure the
n
rvignition switch is Off.
y
a
e
b
s
Minto the
2. Plug a memory
saver (with 9-volt battery)
d
re outlet on the dash. (See Illustration
e
e
accessory
t
c
ts
bi
vi
BA20.)
i
h
r
h
e
igDisconnect the Negative (Black)
o
S
r
3.
battery
r
l
l
y BA25.)
l
p
a
cable(s)
first.
(See
Illustration
d
A
n
o
nu
o
i
B
a
NOTE: When removing the Positive
t
c
M
—
(Red) battery cables
e on duel batteries, du
e
l
ctwo Positive cables ro
ic
notice that the
i
v
h may be doubled. p
r
(feed and e
jumper)
e
e
r
S
Illustration BA20
r Vbattery cable away from the
4. Tuck ethe
terminal to
y
d
Plug
a
Memory
Saver
into
the
Accessory Outlet
t accidental contact. (SeezIllustration
d
e
prevent
BA
s
o
i
a
r
B
25.)
o
im
l
h
i
t
e—
t
Battery Removal
l
u
U
a
ic
n
n
h
1. Disconnect battery. (See
the Disconnect Battery
e
U
tio
V
Section.)
a
r
r
e
o
t
2. Remove the Positive battery cable(s).
p
r
as
o
w
3. Remove the battery hold-downs.
m
a
C
i
l
l
y
er and remove the Uti
4. Note the location of the posts
t
b
battery from the vehicle.
as
d
e
m
t
Battery Installation
ili
bi
t
i
h
U in the battery trayin the
1. Install the battery
o
2
r
0
same orientation.
p
aw
l
0
n
2
n
t the battery hold-downs.
2. Secure
io
o
by
i
t
h
c
at
ig the battery cables, Negative last. ted
u
3. rConnect
r
d Illustration BA25 po
i
y
o
b
p
i
r
Disconnect
Negative
(Black) Cable first
r and tuck
NOTE:
Remember
to
fasten
the
hood
h
pcables away from
the battery o
posts
Co or access panel.
e
o
C
r
r
pr
d
te
e
n
s
z
a
ri
tio
o
c
m
u
th
ili
d
t
u
d
U
a
ro
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Disconnect Battery
35
Body Mount Bolts
l
d
a
aw
e
NOTE: TruckvBody and PDV body
l
u
Base
n
y
mount boltsercome in a variety of
a
b
Rail
s depending on the
M
configurations
e
d
r
te
application.
ce
i
s
i
t
Mounting
ib
rv
Overviewgh
Oak
h
e
iroad vibration and the natural changing
o
S
r
Normal
(Wood)
r
l
l
y the chassis
p
a
properties
d
Al of the wood runners between
u
n
Chassisn
and body may reduce the clamping
Bo force on the body tio
a
Frame
mounting bolts.
c
M
—
Rail
u
e
e
l
cto check the alignment of rod
ic
It is therefore, important
i
v
r
body mounting spacers
p
eh and tighten the mountingebolts
e
V
S
after the first 30,r 60, and 90 days of operationrand
y
d
e
every six months
t after that. (See Illustration
d
e BM10.)
s
z
o
i
a
r
B
Alwaysm
tighten the lower nuts because,
o in some
i
—
l
h
applications,
the top nuts have beent welded in place.
i
t
le
u
c
U
a
i
n
h
e
it o
Un
V
a
r
r
te
po
s
Illustration BM10
r
a
o
w
Body
Mounting Bolts
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
Description
Torque ft•lb
ili and Application
bi
t
i
Base
24–31
U rail to crossmember (plated)
oh
2
r
w
Base
rail
to
crossmember
(stainless
steel)
24–31
0
p
la
0
Base rail to crossmember (encapsulated)
24–31
n
2
n
t
Tie rod with angle bar
45–55
io
o
by
i
t
h
t
c45–55
d
U-bolt with angle bar
a
ig
u
e
r
r
d 24–35
it
y
o
Tie rod with J-hook
o
b
p
p
i
r
r
Tie
rod
/
U-bolt
with
out
frame
spacers
24–35
h
p
o
Co
o
5/8 bolt at chassis frame rail
for
body mounting angle re
80–120
C
r
r
pangle
5/8 bolt in body tie-down
80–120
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
36
l
w
d
a
a
e
l
u
NOTE: Truck
rv Body and PDV bumpers an
e
by
that are welded
in place would need toM
s
e and rewelded to replace. e
d
be cut roff
e
t
c
ts Utilimaster has different
bi
virear
i
NOTE:
h
r
h
e the
igbumper configurations to meet
o
S
r
r
l
l various needs of our customers.
y
l
p
a
d
A Although the specific parts
n
o may vary,
nu
o
i
B
a
t
the bumper replacement process will be
c
M
—
e can be removed du
similar. The bumper
e
l
c extensions and then thero
ic
i
from the bumper
Illustration
BU10
v
h
r
p
e
bumper extensions
can be removed from
Rear Bumper e
e
r
S
the chassis
r V depending on the repair
y
d
e
t The shock absorbing bumper
d
needs.
s
ze
o
a
designed
by Utilimaster has rai separate
B
o
mprocess. (See also the SHOCK
i
—
l
h
i ABSORBING Bumper Replacement.)
t
le
ut
c
U
a
i
n
h
e
io
Un
STANDARD Bumper Replacement
t
V
a
r
r
obumper to
te
WARNING: Always support the
p
s
r
keep it from falling.
a
o
w
m
a
C
i
l
l
r
ti
y
e
t
U
b
Removal
as
d
e
1. Support the bumper
to
keep
it
from
falling.
m
t
i
ili
b
t
i
Illustration BU15
2. Remove the eight
h
U 1/213 bolts, washers, and
Standard
Bumperro
Assembly
locknuts holding
the bumper to the bumper
2
0(See Illustrations BU20 or BU30.) law
p
0
channels.
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration BU20
C
n
A
GRIP STRUT Bumper Mount
U
Bumpers
SHIM
CHANNEL
EXTENSION
CHANNEL
IMPACT STRIP
BUMPER
37
l
w
d
a
a
e
l
u
rv should be set low enoughannot to strike the rear structure
y upon impact but close
The bumper
e
b
s
M
enough
shoe in the gap.
d
re to prevent catching someones
e
e
t
c
i
s
t
vi
ib
r
Installationh
h
e
g
i
o a thread adhesive like
S
rand
l
use lock washers
ll r NOTE: If locknuts are notyavailable,
p
a
d and bolts can be used inn place of flat washers.
A Loctite. Flange head onuts
nu
o
i
B
a
t
1. Position the bumper—
on top of the bumper channels.
c
M
u
e
e
l
d be level front to back and side to side.icSet the
2. Align the bumper
c with the rear structure. Itroshould
i
h
bumper approximately
1" below the body.p (See Illustration BU10.) The frame extension
rv bolts may
e
e
have to beVloose to make adjustments.re
S
r
y
d
e
t the bumper in its place. ze
d
3. Support
s
o
i
a
r
B
o
4. im
Secure all fasteners.
—
l
h
i
t
t
le
u
c
Bumper
Channel
and
Extension
Replacement
U
a
i
n
h
e
it o
Removal
Un
V
a
r
r
1. Remove the bumper. (See the Removal
o
te
pBumper
s
instructions under the STANDARD
r
a
o
w
Replacement section.)
m
a
C
i
l
l
er bolts and locknutsUti
2. Remove the six lower 1/213
t
by
s
holding the bumper channels
a to the bumper
d
e
m
t
extensions. (See Illustrations
BU25.)
ili
bi
t
i
3. Remove the sixUupper 1/213 bolts and locknuts
oh
2
r
holding the0bumper
extensions to the chassis.
w
p
la
This will20
free any shims.
n
n
Illustration
BU25
t
io Channel
o
by
i
t
Installation h
Bumper
t
c
d
a
ig
u
e
r
r
d
itlock
yNOTE: If locknuts are not available, use
o
o
b
p
p
i
r
washers
and
a
thread
adhesive
like
Loctite.
Flange
head
nuts
and
bolts
can
be
used
in
r
h
o
Co place of flat washers.
ep
o
C
r
r
p
d time) into the upper holes
er in the chassis
1. Install new 1/2-13 bolts and flatnwashers (no locknuts at e
this
t
s
iz
rail.
io
a
r
t
o
c
im Do NOT tighten at
h
u
l
2. Install shims (as required)
and
bumper
extensions
with
locknuts
and
flat
washers.
t
i
t
u
od
this time.
U
a
r
ed
n
p
2
v
NOTE: Do NOT
re tighten nuts until afterUthe bumper has been attached.
er
00
s
2
d
t Replacement section. re
e
3. Follow the Installation
instructions under the STANDARD Bumper
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
CAUTION: Always use new bolts and two-way Grade 8 locknuts. Do NOT reuse locknuts or
bolts when replacing bumpers.
®
®
38
l
w
d
a
a
e
l
u
Removal
n
rv
a
e
by
s
1. Remove the
bumper. (See the RemovalM
d
re under the STANDARD Bumper
e
e
instructions
t
c
ts
Replacement
section.)
bi
vi
i
h
r
h
e
g
o
2.riRemove all twelve fasteners toSthe bumper
r
l
l extensions.
y
l
p
a
d
A
u
n
o
n
o
i
B
a
NOTE: Each bumper extension will remain t
c
M
attached to the rear
u
e—structure with four BOM
e
l
d
fasteners. ic
ic
o
v
r
h
r
pout
e
e
3. The bumper
plates
may
have
to
be
pried
e
Illustration BU30
r rail.
S
r V the extension and chassis
from between
y
Spring Bumper Mounting
Bolts
d
e
t
d
e
s
z
o
4. The
i
a shims, if present, are reused.
r
B
o
m
ili NOTE: If the bumper uplates
th can not be removed in this manner, remove
e— the BOM
t
l
U fasteners. (See Illustration
a BU35 and then Remove BOM Fasteners
ic section below.)
n
h
e
BOM Fasteners Removal (if U
necessary)
tio
V
a
r door by drilling outerthe buck rivets.
1. Remove the rear kickplate under theorear
t
p
s
r
a
2. Remove the BOM fasteners. (See
section.) This will free the bumper w
o the Fastener Replacement
m
C
i
extensions and shims.
la
l
r
i
t
y
te
U
b
s
a
d
Floor/Chassis
m
teRiser
BOM
i
i
l
Fasteners ti
ib
h
U
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
Chassis
ig
u
e
r
r
d
Frame Rail o
it
y
o
b
p
i
r
Bumper
rp
o
h
p
o
Extension
C
e
o
C
r
r
r
p
d
te
e
n
s
z
Shock
a
ri
tio
o
c
m
Absorbing
Strut
h BU35
u
li
t
i
Illustration
d
t
u Bumper Mount
d
o
Shock Absorbing
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
SHOCK ABSORBING Bumper Replacement
®
39
l
w
d
a
a
e
l
u
n
rv
a
e
by
s
M
d
Installation (when
reBOM Fasteners have NOT been
e removed)
e
t
c
i
s
t If locknuts are not available,
vi use
NOTE:
ib
h
r
h
e
g
ilock washers and a thread adhesive like
ro
l
ll r Loctite. Flange head nutsy Sand bolts can be
p
a
d
A used in place of flat washers.
u
n
it o
Bo
an
M
1. Carefully pry the frame
— extension away from theuc
e
e
l
chassis rail and c
ic
i slide the shim and bumper plate
od
v
r
into place. h
r
p
e
e
e
V
rflat
S
2. Install new
r 1/2-13 locknuts, bolts, and
y
d
e
t into the upper holes. DozeNOT tighten
washers
d
s
o
i
at a
this time.
r
B
o
m
i
—
l
h
i Install new 1/2-13 locknuts,
3.
t bolts, and flat
t
le
u
c
U washers into the loweraholes. Do NOT tighten
i
Illustration BU40
n
hAbsorbing
at this time.
Shock
Bumper Assembly
e
it o
Un
V
a
r the
NOTE: Do NOT tighten nuts untiloafter
er
t
bumper has been attached.
rp
as
o
w
m Bumper Replacement section.
a
C
4. Follow the Installation instructions
under the STANDARD
i
l
l
er been Removed) Uti
t
Installation (when BOM Fasteners have
by
s
a
d
NOTE: If locknutsm
are not available, use lock washers and a thread adhesive like te
i nuts and bolts can be used in place of flat washers.
ilhead
Loctite. Flange
bi
t
i
h
U bolts and flat washers (no locknuts at this time) into the upper oholes
1. Install new 1/2-13
in the chassis
2
r
w
0
p
a
rail.
l
0
n
2
n
y
o
t
i
o
b
2. Place
the
shims
on
the
bolts.
i
t
h
t
c
g
d
a
i
u
e
r
r
3. yMount the bumper extensions where the BOM
d If the BOM fastenerpo
it fasteners were removed.
o
b
p
equipment
is
not
available,
use
new
3/8"
Grade
8
locknuts,
bolts,
and
i
r flat washers. Do NOT
r tighten
o
h
p
o
C at this time.
C
re
ro
r
p
4. Install new 1/2-13 locknuts, bolts,
te at this time.
n and flat washers intoizethed lower holes. Do NOTstighten
o
a tightening
r Bumper Replacement section,
ti
5. Follow the Installation instructionsunder
the STANDARD
o
c
m
i
the 3/8" bolts first.
u
th
il
d
t
u
U
a
rowith aluminum POP rivets.
6. Reinstall the kickplate
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
CAUTION: Always use new bolts and two-way Grade 8 locknuts. Do NOT reuse locknuts or
bolts when replacing bumpers.
SHIM
®
STRUT
EXTENSION
STRUT
IMPACT STRIP
BUMPER
®
®
40
l
w
d
a
a
e
l
u
v the Paint Repair section.n
NOTE: Seeralso
y
a
e
b
s
M
Decal Removal e
d
r
e
e
t
c
1. Usetsa heat gun to soften the adhesive
bi
vi under the decal.
i
h
r
h
e the edge back.
2.rig
With a razor knife, carefully peel
o
S
r
l
l
y manually pulling the decal off.
l
p
a
3.
Continue
to
heat
evenly
while
d
A
u
n
o
n
o
i
B
a
Decal Installation
t
c
M
—
u 24 hours for nonreflective decals or 72 hours
e decals over repaired paint,dwait
e
1. Before reapplying
for
l
c
c
i
i
o
reflective decals.
r
h
rv
p
e
e
e
2. Clean theVsurface with DuPont 2319SrCleaner.
S
r
y
d
e
t the decal into position. ze
d
3. Align
s
o
ir
a
B
o to the edges.
4.imSmooth the decal from the center
—
l
h
i
t
le
ut a proper seal.
5.
c
U Squeegee the edges toaensure
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Decals
41
DoorBulkhead
l
d
a
aw
e
NOTE: This v
service information is
l
u
r in illustrations and an
generic. Details
e
by
s
M
procedures
e may differ from those in eyour
r
ed
t
vehicle.
Use this information as aic
i
s
t where it applies. rv
ib
guideline
h
h
e
g
Striker
o
S
ri
r
l
DoorllReplacement
y
p
a
d
A
u
n
Door Removal
it o
Bo
an
M
1. Use a #11 or 3/16" drill
— bit to drill out the uc
e
e
l
rivets, securingcthe lower door track to the d
ic
i
o
v
r
door.
r
p
eh
e
e
V
S
2. Drill outr the rivets securing the door torthe
y
d
e
rollertassembly.
d
e
s
o
iz
a
r
B DR01
Illustration
3. m
Lift door up and out to remove.
o
i
—
Bulkhead
Door
Latch
(Cargo Side)
l
h
i
t
e
l
DoortInstallation
u
U
a
ic
n
n
h
1. Reverse the removal
e
io
Uprocedure.
t
V
a
r
Door Latch Adjustment
er
o
t
rp
Latch Adjustment (Non-VACS)
as
o
w
m
a
C
i
l
1. Loosen the two screws on the
striker.
(See
l
ti
er
Illustration DR01.)
t
U
by
s
a
d
2. Position the striker to
align with the latch on the
e
m
t
i
bulkhead panel. til
bi
i
U in this position, tighten the
oh
3. Holding the striker
2
r
w
p
screws. 00
la
n
2
n
tand close the door multiple times to ensureby
io
4. Open
o
i
t
h
t
c
Illustration
DR05
proper
a
ig operation. Repeat the process if ted Bulkhead Door Latch
u
r
r
d on VACS Vehicles (Cargo
i
ynecessary.
o Side)
o
b
p
p
i
r
htighter with this adjustment.
pr
o
Co NOTE: You can make the door close
e
o
C
r
r
pr
Latch Adjustment (VACS)
te
ed
n
s
z
o
1. Loosen the two bolts that attach
(See IllustrationaDR05.)
ri
ti the door catch to theobulkhead.
c
im
u the closed position. th
l
2. Slide the bulkhead doordinto
i
t
u
o
U
a
r
ed
3. Align the catch with
the latch on the door. (See
Illustration DR150.) 2
n
p
v
recatch in position, tightenUthe two bolts to 79 ftlb.00
er
4. While holding
the
s
2
d
t
e
re
h
5. Open and
Repeat
the
process
as
necessary.
ir zclose the door multiple times to ensure proper operation.
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
42
l
w
a
a
e
l
u
n
rv
Operation
y
a
e
b
s
M disconnect the safety d
To enter the cargo
re area from outside the vehicle,
e
e
cable on thetslower left-hand side of the dooric(if present) by rotating the it
b
v
h
rthe cable off the peg. (See hi
latch counterclockwise
until you can pull
e
g
i
Illustration
r DR10.) The safety cableSprevents the door from accidentally
ro
l
l
y
l
p
a
opening
while
the
vehicle
is
in
motion.
d
A
u
n
o
n
o
i
B
a
Insert the key in the lock and turn it clockwise. While pressing
t down on
c
M
—
the bottom handle to relieve
tension
on
the
door
before
opening,
turn the
u
e
e
l
d
handle to the right. ic
ic
o
v
r
r
pthe door strap and
eh the outside, pull down on
e
To close the doorVfrom
e
r
S
check to make rsure the door is locked before
driving the vehicle. Place
y
d
e
t in the safety cable latch by
d
erotating the latch
the safety cable
Illustration
DR10
s
z
o
i
a
Safety
Cable Latch (Option)
B
counterclockwise until you can slip ther cable over the peg.
m
—
ho
ili
t
e
t
l
u
WARNING: Do NOT use the rear door pull strap to support yourself
entering or exiting
U
a can break or pull the
ic Use when
n
the rear. The strap
door down upon you.
a grab handle for assisn
h
U in and out of thetioback of the truck. Ve
tance when getting
r
ra
e
o
t
NOTE: Even though on VACS-equipped
vehicles the sbulkhead and rear doors lock
p
r
automatically when they are fully
closed,
you cannotabecome accidentally locked inside
o
m open the bulkhead and sliding doors law
C
i
the cargo area. From inside
the
cargo
area,
you
can
l
ti System for Utilimaster Walk-In Vans y
er Vehicle Access Control
without a key. (See also tthe
U
b
Operation and Service
asManual, P/N 03102103, for more VACS information.)
d
m
te
i
i
l
To exit the cargo area tfrom
i the inside, pull the ring in the lower corner of the door on the drivers
b side (if
imechanism.
h
present) to unlatch theUsafety cable and then pull the door lever to the right to unlatch the door
(See
o
2
r
Illustrations DR15
0 and DR20.)
p
aw
l
0
n
2
n
NOTE:
o on the door
t If the lock sticks, relieve the tension bony the door by pressingtidown
o
i
h
while
t
c
d
a
ig pulling the door lever.
u
e
r
r
t sure the door is locked
d before driving the vehicle.
y the rear cargo door is closed and check tobimake
o
Be sure
o
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
Illustration DR20 Roll-Up Door Release Lever
UIllustration DR15 Safety Cable Release Ring
DoorRear Roll-Upd
43
l
w
d
a
a
e
l
u
n be made by trained service
rv repairs, and adjustments amust
Installation,
e
by personnel using
s
M
proper
tools
and
instructions.
re
e in diameter and 18" long.tedDO NOT USE bent winding bars,
c
Use
two winding bars that are i1/2"
s
tscrewdrivers, or punches forrvspring winding.
bi
i
h
h
e
ig
o
S
r
r
l
l
y
p
a
d
Al
u
n
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
r
p
eh
e
e
V
r
S
r
y
d
e
t
d
e
s
o
iz
a
r
B
o
m
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h
e
it o
Un
V
a
r
r
te
po
s
r
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
byDR25
Illustration
i
t
h
t
c
d on Whiting Roll-Up Door
Location of Serial Number
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h door, specify the serial
o
Co NOTE: When ordering parts for arorear
ep number of the door. C(See
r
Illustration DR25.) The serial p
number can be found on the metal tag attached tor the
te
inside of the door.
ed
n
s
z
o
ri adjustments and propera operation
tofi any part, check relevant
NOTE: After replacement
o
c
im
h
u
l
t
i
of the door.
t
u
od
U
a
r
ed
NOTE: The following
general instructions
and illustrations are2of Whiting doors.
n
p
v
r
e
Doors by otherrmanufacturers
or for a U
particular Whiting door00may differ in details. e
s
2
d
Use these instructions
as a guide where appropriate.
t
e
re
h
ir z
ts
ig
r
o
h
y Always maintain firmigfooting and
WARNING:
Read all instructions before starting repair.
h
t
p
control
of
tools.
u
o
lr
a
l
C
A
Un
WARNING: The counterbalance spring is wound under high tension. This high-tension spring
can cause severe injury or death.
44
l
a
aw
l
u
y
Left-Hand Cable
an Drum must be tight againstbBearing
M
d
e
e
Spring Anchor
Plug
t
c
ts
bi
vi
i
h
r
Spring-Winding
Plug
h
e
ig
o
S
r
r
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
o
Cablei
v
r
h
r
p
e
e
e
Top
r
S
r VDoor
y
Panel
d
Chalk
mark
e
t
e
Spring Anchor Bracket d
s
z
o
i
Left Hand
a
Right Hand r
B
o
(Roadside)
m
Counterbalance
shown
inside
looking
outside
(Curbside)h
ili
t
e—
t
l
u
U
a
ic
n
Illustration
DR30
n
h
U
Counterbalance
tio Mounting DetailsVe
a
r
er
o
t
p on Spring) as
Cable Replacement Procedure (with Tension
r
o
w
m
a
C
Cable Removal
i
l
l
ti
y
eris frayed or damaged,
t
NOTE: If only one cable
U
b
as
d
Utilimaster still recommends
that both cables be replaced
Cable
e
Cable
Anchor
m
t
i Bracket
at the same time.li
it
b
i
h
1. Close the doorUfrom the inside. Release the spring tension
2 by fully inserting a winding bar that is 1/2"
ro
w in
from the cables
0
p
a
0and 18" long into one of the spring-winding lplug
diameter
n
2
n
y
o
t
i
b
holes.
(See
Illustrations
DR30
and
DR40.)
Cotter Pin tio
t
h
ig
ed winding bar duc
ra
Cable Anchor
2.yrRaise the bar enough to allow insertion of aitsecond
o
b enough to let ro
p into the lower hole, and then release theitension
p Pin
r
o
o
C the second bar rest against the top panel.
ep
oh
C
r
r
r
p drum, releasing thed
e
3. Loosen the two setscrews on the
cable
Exterior
View
of Door
t
e
n
s
z
o
i
cable drum from the shaft, and
remove
the
cable
from
the
cable
a
r
ti
Illustration DR35
o
c
drum.
m
u
th
ili Cable Anchor
d
t
u
d
4. Remove the cable from
o the door bottom panelaby removing the
U
r
e
n
p
2
anchor and cotter
pins. (See Illustration DR35.)
rv
U
0
re
e
0
2
d
es
t
e
r
hin place. Raising the doors at this
WARNING:
iz Do NOT raise the door with the winding bar
g
r
t
i
point
can
cause
injury
or
damage
to
equipment.
r
o
h
y
ig
th
p
r
u
o
a
ll
C
n
A
U
ed
v
r
e
s
re
Right-Hand Cable Drum must be tight against Bearing
45
d
e
rv Ceiling
e
s
re
l
a
u
n
Spring Anchor
a
M Bracket
by
w
la
d
e
e
t
c
i
vi
ib
r
Chalk
mark
Locking Pliers
h
e
o
S
against
ceiling
r
l
l
y
l
p
a
d
A
u
n
o
Support Bracket B
it o
an
c
M
u
e—
e
l
d
c
ic
i
o
1/2"
diameter
x
18"
long
or
v
r
r
p
eh
[12.7 mm] diameter x [46 cm] e
e
V
r
S
Winding Bar
r
y
d
e
5"
or [12.7 cm]
t
e for
s
z
od
Spring
i
a
To loosen Spring, wind B
r
growth
m
toward ceiling —
ho
it li
t
le
u
c
U
a
i
n DR40
Illustration
h
o
i
Un
Counterbalance
Winding Details Ve
t
ra
Cable Replacement
outermost
groove toward the inside of the
er
o
t
p
r the
1. Mount the new cable at the baseoof
asdrum.
m6. Maintaining tension on the cable, slide thelaw
C
bottom panel by slipping the cable
anchor pin
i
l
y
through the cable anchor tbracket
er and the eye Uti
cable drum on the counterbalance shaft
b
s
at the end of the cable.a
against the bearing and tighten thedtwo
m
te
setscrews on the drum.
i
i
2. Insert the cotter pin
into
the
cable
anchor
pin
l
i
ib
to secure the cable.
7. Clamp the counterbalance h
shaft with a locking
Ut
2 cable end to the top of the
roceiling, to keep the
w pliers, handle against the
3. Bring the other
0
p
a
l cables tight. (See Illustration
0thread it over the top of the door to
DR40.)
n
door and
2
y
o
t
i tension by rotating the tion
b 8. Release the spring
the inside.
t
h
d
ucplug just far enough to oallow
spring winding
ra
rig
ti e
4. yTemporarily
tape the cable to the outside top
d
removalrof
o the winding bar againstrthe
p panel of the door.
p top of
ib
o
h
o
the door.
C 5. From inside the cargo area, insert therocable
ep
C
r
rand then check
p the
9. Remove
the clamp and tape,
d
e
end into the cable drum slot. Thread
t
e
s
onslot and turn
iz the operation of the door.
cable into the groove nearesttithe
a
r
o NOTE: A properlylim
cuntil all slack is
the cable drum toward you
adjusted door
h
u
t
i
d
t
taken out, making sure the
cable is following u
should open easily and, when
o
Uremain at any
a
r
ed
in its proper groove.
stopped, should
n
p
2
v
given location.
re must be wound from Uthe
00 (See the Spring ser
NOTE: The cable
2
d
Winding
t Procedure section.) re
e
h
z
i
r
ts setscrews
ig
CAUTION:
Make sure the drums are against the counterbalance
shaft bearings, the
r
o
h
y
are
h properly tightened, and the cables have equalptension.
ig
t
r
u
o
a Rotating the counterbalance assembly too far Cmay cause cables to jump off
ll the cable drum.
n
A
U
ts
h
rig
46
l
w
d
a
a
e
l
u
n
rv
y
a
e
b
s
M must be made by trainedd service personnel using
Installation,
repairs, and adjustments
re tools and instructions. ce
proper
ite
s
i
t
b
v
i DO NOT USE bent winding bars,
h Use two winding bars that are
r 1/2" in diameter by 18" hlong.
ir g screwdrivers, or punchesSefor spring winding.
ro
l
l
y
l
p
a
d
A
u
n
Chalk mark
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
rV
y
d
e
Wound chalk mark
t
d
e
s
z
o
i
a
B
or
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
Illustration
DR45
r
aTrack of Winding
o
w
Mark Spring
with Chalk to Keep
m
a
C
i
l
l
ti removing the first bar. Repeat for 10-1/2
y
er
Spring Winding Procedure
t
U
b
as
turns. Turns are counted by using d
the chalk
1. Close the door and,m
on the inside, clamp the
e
t
marks, which show up as stripes
i as the spring
counterbalance shaft
ili with the handle of the
b
t
i
is wound. (See IllustrationhDR45.)
locking pliers U
against the ceiling to keep the
2(See Illustration DR40.)
rotension, tighten both
wAfter adjusting the spring
cables tight.
6.
0
p
a
l setscrews on the spring-winding
plug and
n
20 mark the full length of the
2. Run at chalk
n
y
o
i
o
b
remove
the
locking
pliers
from
the
i
t
h
counterbalance
spring. (See Illustration
t
cshaft.
d
a
ig
counterbalance
u
e
r
r
DR45.)
d
it
y
o
o
b
p
p
7.
Check
the
operation
of
the
door
by
opening
i
r
r
3. Insert a winding bar that is 1/2" in diameter
o
and closing
Co and 18" long into one of the spring-winding
ep the door.
oh
C
r
r
r
p and
d
plug holes. (See Illustrations DR30
e
NOTE:
A
properly
counterbalanced
door
t
e
n
s
z
DR40.)
when stopped,aremain at any given
ri should,
tio
o
c
location.
If the door
imleaves the floor by
4. Loosen the setscrews onuthe spring-winding
h
l
t
i
itself, the spring tis wound too tightly, and a
u
plug.
od
U should be released. If ethed
a
r
few quarter turns
n
p
2
rv
5. Wind the springrby
e lifting the bar. While U
door has a 0tendency to drop when stopped,
e
0
holding the first
2 quarter turns should beesadded.
a few more
d bar, place a second bar in the
t
e
r
next hole zand lift in the same manner after
h
ir
s
t
ig
r
o
h
y
th
ptoo far may cause cables rtoigjump off the
u
CAUTION: Rotating the counterbalance assembly
o
a cable drum.
ll
C
n
A
U
WARNING: The counterbalance spring is wound under high tension. This high-tension spring
can cause severe injury or death. Only qualified technicians should adjust this spring.
47
Intermediate Door Panel Replacement
l
w
d
a
a
e
l
u
nthe panel to be replaced y
rvclosed, clamp the track below
a
1. With the door
e
b
sthe door from rising.
M
e
to prevent
d
r
te
ce
i
s
i
t
2. Using
a 1/4" drill bit, drill off the rivets
v in the center hinges on theibpanel
h
r
h
e
g
DR50.)
ito be removed. (See Illustration
o
S
r
r
l
l
y
p
a
d
Al
CAUTION: Do NOT o
drill through the outside panel.
n Punch
nu
out the rivets and,Bin at least one of the hinges,
it o insert a
a
punch into one—
of the rivet holes to stabilize
c the door panel
M
e the remaining rivets anddubolts.
while detaching
e
l
c
ic
i
o
v
r
r
eh and socket, remove botheproller brackets and rollers at
e
3. Using a wrench
V
r Illustration DR55.)
S
r or at the top of the panel.d(See
both joints
y
e
t
d
e
s
o
4. Drill
iz to the bottom of the panel with a
a off the end hinge rivets attached
r
B
o
m
1/4" drill bit.
i
—
l
h
i
t
DR50
t
le Illustration
u
5.
Lift
the
door
panels
(above
the panel to be replaced) into the
c
U
Center Hinge
a
i
n pliers clamped on the
n them with a locking
h
horizontal track and secure
o
e
i
U
t
V
horizontal track.
a
r
r
te
6. Remove the punch and lift out the old
popanel.
s
r
a
o
w
m
a
C
i
l
l
ti
er
Intermediate Panel Installation
t
U
by
s
d
1. Line up the new panel a
and drill all of the hinge holes on the bottom
e
m
t
of the new panel. ili
bi
t
i
Udoor section clamped so that it will not fall, tip the
2. With the upper
oh
2
r
w
0 you to insert the bolts.
panel toward
p
la
0
n
2
n
3. Installt the hinges over the bolts and tighten the nuts.
io
o
by
i
t
h
d the hinge holes uc
at
ig a 1/4" drill bit, drill holes into the panelteusing
4. Using
r
r
d
i
yas a guide and install Magna-Lok fasteners.
o
o
b
p
p
i
r
r
hinto position.
o
Co5. Swing the new panel upright and clamp
ep
o
C
r
r
r
p
d
e
6. Lower the door from the horizontal
tracks
and
drill
all
the
holes
in
t
e
n
s
iz
the top of the new panel. tio
a
r
Illustration
o
c
im Roller DR55
h
u
l
Joint
Bracket
t
7. Insert the bolts and install
the
hinges
over
the
bolts.
Tighten
the
nuts.
i
d
t
u
o
U
a by opening and
rand check the door operation
ed
8. Remove the clamps
n
p
2
v
U
closing the door.re
er
00
s
2
t stopped, should remainreat any
ed adjusted door should open easily and, when
NOTE: Azproperly
h
i
r
ts
given location.
(See Spring Winding Procedure section.)rig
o
h
h repair is necessary, see the Paint Repair section. py
ig
t
9. If paint
r
u
o
a
ll
C
n
A
U
Intermediate Panel Removal
48
l
w
d
a
a
e
l
u
Top Panel Removal v
n
r
y
a
e
b
1. With the s
door closed, clamp the track below
the
top
M
d
reprevent the door from raising.
e
e
panel to
t
c
ts
bi
vi
i
h
r
h
ig CAUTION: Do NOT drillSethrough the
o
r
r
l
l
outside panel. Punch
out the rivets and,
yhinges,
l
p
a
d
in
at
least
one
of
the
insert
a
A
n
nu
punch into one ofothe rivet holes to stabi- io
B
a
lize the door panel while detaching the ct
M
—
remaining e
rivets and bolts.
u
e
l
d
c
ic
i
o
v
r
h
r
pthe center
e
e
2. Using a 1/4"
drill
bit,
drill
out
the
rivets
in
e
ron the end
S
ronVthe top panel and the rivets
hinges
y
d
e
t at the joint in the lower half
d
eof the top panel.
hinges
s
z
o
i
a
r
B
oDR55.)
m(See Illustrations DR50 and
i
—
l
h
i3. Punch out the rivets and,uint at least one of the hinges,
t
leIllustration DR60
c
U insert a punch in one ofathe rivet holes to stabilize
i
n the
n
h Top Roller Bracket
o
e
i
U
door panel while detaching the remainingt rivets and
V
a
r
bolts.
r
o
te
p
s
4. Using a wrench and socket, remove
a
or the roller
w
brackets and rollers at the topCof the panel. (See im
a
l
l
Illustration DR60.)
ti
y
er
t
U
b
5. Remove the punch and
aslift out the old panel.
d
e
m
t
Top Panel Installation
ili
bi
t
i
h
U panel and drill all of the hinge holes
1. Line up the 2
new
o
r
0 of the new panel.
on the bottom
p
aw
l
0
n
2
n
t panel toward you to insert the bolts through
2. Tip the
io
o
by
i
t
h
t
c
the
d
a
ig outside of the panel.
u
e
r
r
t
d
ithe
y
o
3. Install the hinges over the bolts and tighten
nuts.
o
b
p
p
i
r
r
o
Co 4. Using a 1/4" drill bit, drill holes intorthe
ep
ohpanel using the
C
r
r
p
hinge holes as a guide and install Magna-Lok
d
e
t
e
n
fasteners.
s
iz
it o
a
r
c on the bottom of theho
NOTE: The roller brackets
u
lim
t
i
d
t
top panel and on the
uplay
d
o top of the bottom panel
U
a
r
e
an important partpin maintaining proper door
n
2
rv
0 Illustration DR65
alignment within
re the track. The rollersUon these
e
0
2 Help Align Door in Track
d have three or four spacer washers
Washers
brackets must
es
t
e
r
h
(depending
iz on the alignment) to maintain the
g
r
ts
i
r
o
h
correct
distance in the track. (See Illustration DR65.)
y
h
ig
t
p
r
u the new panel upright and clamp into position. o
5. a
Swing
ll
C
n
A
U
Top Panel Replacement
49
6. Drill all the holes in the new panel for the top
roller bracket. ed
l
w
a
a
l
u
rvand install the hinges over thean
7. Insert the bolts
e
by
s
M
bolts. Tighten
d up
re the nuts.
Move troller
e
e
c
i
s
i
8. Remove
t the clamps and check thervdoor
to move
ib panel in
h
operation
by
opening
and
closing
the
door.
h
e
g
i
S
ro
l
ll r NOTE: A properly adjusted
y
p
door
should
a
d
A open easily and, when stopped,
nMove roller down
o
it should
nu
o
i
B
a
t to move panel out
remain at any given location. (See Spring
c
M
—
u
e section.)
Winding Procedure
e
l
d
c
ic
i
o
v
r
9. Also check the
r
eh seal on the outside top ofepthe
e
roll-up door.
V
r
S
r
y
d
e
t The top panel can be adjusted
d
NOTE:
e by
s
Illustrationo DR70
izbolt and
a
loosening
the top roller bracket
r
B Adjustments
Top Roller Bracket
odown to adjust
m
i
moving
the
top
roller
up
or
—
l
h
i the top panel in or out. u(See
t Illustration
t
le
c
U
a
i
n
DR70.)
h
e
it o
Un
aRepair section. r V
10. If paint repair is necessary, see the Paint
r
te
po
s
r
a
o
w
m
a
C
i
Top Panel Adjustment
l
l
ti
er
t
U
by
1. Close the door.
s
a
d
e
2. Loosen the nuts slightly
on
the
top
roller
bracket.
(See
Illustration
DR70.)
m
t
ili
bi
t
i
3. Position the top
Uroller brackets so that the top panel is nearly vertical and seals bothohalong the top and at
the sides. 2
0
pr
aw
l
0
n bracket down
NOTE:2Moving the roller bracket up moves theypanel in; moving the roller
n
o
t
i
o
b
i
t
moves
the panel out.
h
t
c
d
a
ig
u
e
r
r
d before it latches. po
it cause the door to jam
yNOTE: Adjusting the panel too tightlybmay
o
p
i
r
pr
o
Co4. Tighten the nuts with a wrench. roh
e
C
r
r
p
te
ed
n
s
z
o
a
ri
ti
o
c
m
i
u
th
il
d
t
u
U
a
ro
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
50
l
w
d
a
a
e
l
u
Bottom Panel Removalv
n
r
y
a
e
b
s
1. Push open
the door until the bottom of the
M
e
d
e
e
door israbout 16" [40 cm] from the header
at
t
c
s of the door opening. vi
ttop
the
bi
i
h
r
h
etracks, on
g
o
S
2.ri Place a clamp in the horizontal
r
l
l each side, below the bottomy rollers.
l
p
a
d
A
u
n
o
n
o
i
B
a
3. Place a clamp on one of the cables, near the
t
c
M
eye of the cable. e—
u
e
l
ic
ic with one hand, releaserthe
od
4. Grasping thehclamp
v
r
p
e
e
cable from
the
bottom
of
the
door
by
pulling
e
r and
S
r Vpin out of the cable anchord pin
the cotter
y
e
t the anchor pin. (See Illustration
e
IllustrationdDR80
removing
s
z
o Bracket
i
a
Bottom
Roller
r
B
DR35.)
o
m
ili CAUTION: Do NOTudrill
th through the outside panel. Punch out the
e—rivets and, in at least one of
t
l
U
the hinges, insert aa punch in one of the rivet holes to stabilize
ic the door panel while detaching
n
n
h
the remaining rivets
and bolts.
e
U
tio
V
a
r Installation
r
Bottom Panel
e
o
t
5. Allow the spring to wind the cableponto the
r
1.
asRemove a bottom roller bracket from the old
drum until the clamp stops it by o
contacting the
w
m panel.
a
C
i
l
drum.
l
ti 2. Insert the roller into the bottom brackety of the
er
t
U
b
6. Repeat with the opposite
new panel.
as cable.
d
te in the track.
7. Drill out the centerlim
hinge rivets attached to the
i
3.
Position
the
new
panel
and
roller
i
ib
bottom panel. (See
h
Ut Illustration DR50.)
2 and socket, remove both
ro
w
8. Using a wrench
0
p
a
l
0 located at the bottom of the
roller brackets
n
2
n
y
o
t
i
bottom
panel
and
remove
the
rollers.
(See
o
b
i
t
h
t
c
d
Illustration
DR80.)
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
9. Using a wrench and socket, remove both
i
r
r
o
Co roller brackets and rollers at the jointroorh top
ep
C
r
of the bottom panel. (See Illustration
r
p
d
e
t
e
n
DR65.)
s
iz
it o
a
r
o
10. Using a 1/4" drill bit, drill out
c the end hinge
h
u
lim
t
i
rivets attached to the bottom
panel.
d
t
u
d
o
U
a
r
e
11. Remove the panelpfrom the tracks and push n
2
rv
U
0
rethe door slightly toward the
e
the remainder of
0
2
d
es
front of theetruck.
t
r
h
iz
ts
ir g
12. Place o
a rclamp in the track to prevent the door
h
y
hrolling back down.
from
ig
t
p
r
u
Illustration DR85
o
a
ll
C
Normal Latch andAStriker Position
n
U
(Adjust to This Position)
Bottom Panel Replacement
51
4. Install the other bottom roller in the track and align with the
bottom roller bracket.
al
ed
w
a
l
u
n bolts.
rv to the door with nuts and
5. Attach the assembly
a
e
by
s
M
6. Using the
re hinges as a template and a #11
e or 3/16" drill bit, drill ted
c
rivettsholes in the new panel.
i
i
b
v
i
h
r
Make sure the panels ealign for a close fit at the h
g
iNOTE:
S
r
ro
l
l joint.
y
l
p
a
d
A 7. Rivet the hinges into place.
n
nu
it o
Bo
a
8. Replace the rollers —
at the joints, as well as any spacer washers
M
e (See Illustration DR65.)duc
e
l
on the roller shafts.
c
ic
i
o
v
r
hroller brackets on the toppof the bottom panel
NOTE: The
r
e
e
e
V
and on the bottom of the top panel play
r an important part in
S
r proper door alignment
y
d
e
maintaining
within
the
track.
The
t
d
e
s
o
rollers
a on these brackets mustrizhave approximately five
B
mspacer washers (dependinghoon the alignment) to maintain
i
—
l
i the correct distance in the
t track.
t
le
u
c
U
a
i
n to the outside h
9. Reconnect each cablenby drawing it by theoclamp
Illustration DR90
e
i
U
t
V
of the bottom door panel.
Square Latch Plate with Fan
a
er
orcable eye and the cable
t
10. Insert the cable anchor pin throughpthe
r
as
anchor bracket. (See IllustrationoDR35.)
w
m
C
la
11. Secure the cable anchor pin rwith the cotter pin. ili
te
Utby
by
12. Remove the clamps andscheck the door operation
a
d
opening and closingm
the door.
e
t
ili adjusted door should open easily
bi
NOTE: A properly
t
i
U it should remain at any given
and, when stopped,
oh
2
r
w
location.00
(See the Spring Winding Procedure
p
la
n
2
section.)
n
t
io
o
by
i
t
h
t
c
g repair is necessary, see the Paint Repair
13. Ifipaint
dsection.
a
u
e
r
r
d
it
y Lock Adjustment
o
Two Point
o
b
p
p
i
r
r
o
Co1. From inside the truck, close the doorrtightly.
ep
oh
C
r
r
pprimary latch position d
e
2. The fan-type latch should be in the
t
e
n
s
iz
(see Illustration DR85), withiothe latch plate rod resting
a
r
t
o
on the top of the fan of the clatch assembly. If necessary,
im
h
u
l
t
i
reposition the latch platedso that the latch plate fits
t
u snugly
o
U
a
r
ed
against the fan. p
n
2
v
U with the
re plate is level and square
er
00
3. Ensure that the latch
s
2
d
t
fan. (See Illustration
DR90.)
e
re
h
ir z
g
ts
NOTE:o If the door is closed with excessive force, the ri
h
y
hwill lock in the secondary position (see
ig
t
latch
p
u
Illustrationl rDR95
o
Illustration
DR95) as a safety precaution.
a
l
C
Secondary LatchAand Striker Position
n
U
52
4. After both latches
l to this procedure, check thatwlatching/unlatching is
d are checked/adjusted according
a
e
la
smooth and that
v the door seals at the bottom.u
n
r
y
a
e
b
Roller Change s
M
e
d
r
e
e
t
c
1. Open
the
door.
ts
bi
vi
i
h
r
e two nuts that secure theohroller cover. (See Illustrations DR60,
2. igUsing a wrench and socket, remove
S
r
r
l
l DR65, and DR80.) y
l
p
a
d
A 3. Remove the roller fromothe track.
u
n
it o
B
an
c
M
4. Install a new roller
in the track.
u
e—
e
l
ic
ic cover on the hinge and tighten
od the nuts.
5. Replace the h
roller
v
r
r
p
e
e
e
r
Checking RollerVPlay
S
r
y
d
e
t that the door has some butzenot excessive side play (1/4" maximum) andodis centered in opening.
1. Check
s
i so that the door does not bind in the track.B Five spacer washers
a should be some slight play
r
There
m
ho joint roller and the second-from-bottom
ili should be at the second-from-top
t
e—joint roller on each side.
t
l
u
U 2. Add or subtract spacerawashers on roller shafts,
ic proper play. Equal numbers of
if necessary, to achieve
n
n
h
e centered.
washers should beUused on each side to ensure
tio that the door remains
V
a
r
er
o
t
p
r
as
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
53
Pull Strap Replacement
l
d
a
1. Open the door enough
e to allow for comfort while
u
v
r clamp the track to prevent theandoor from
working, then
e
M
opening e
orsclosing.
r
e
2. Drilltsout the two rivets holding the pull
ic strap to the
v
h
r(See Illustration
bottom
g panel of the roll-up door.
Se
riDR100.)
l
Al3.
y
Attach the end of the newdstrap to the bottom panel ofn
the roll-up door with rivets
Bo or sheet-metal screws. tio
c
4. Remove the clamp
and test the strap while opening
u and
e—
l
d
c
closing the door.
i
o
d
te
i
ib
h
o
pr
by
w
la
l
a
u
an
M
ce
i
r
h
rv
p
e
e
Door Seal Replacement
V
re
S
r
Illustration
DR100
y
d
e
Brush Seals Replacement
t
d Strap
Pull
s
ze
o
i
a
r
B
1. m
Open the roll-up door.
o
i
—
l
h
i Drill out the rivets that holdutthe brush-seal aluminum
e
2.
t
cl
U extrusion in place usinga#11 or 3/16" drill bit.n(See
i
h
e
io
Un
Illustration DR105.)
t
V
a
r
r
3. Uncrimp both ends of the seal extrusion.
te
po
s
r
a
4. Remove the brush seals from theoextrusion.
w
m
a
C
i
l
l
5. Cut the new brushes to the proper
length
with
bolt
cutters.
ti
er
t
U
by
6. Reattach the extrusion using
aluminum fasteners or stainlesss
a
d
steel sheet-metal screws.
e
m
t
ilicheck the seals.
bi
t
i
7. Close the door and
U
oh
2
Vinyl Seals Replacement
r
w
0
p
la
0
n
2
1. Raise the
roll-up door to the full Open position andyclamp
Remove the n
t below the bottom panel to prevent the door
io
b from
rivets holding
the track
io
t
h
t
c
g
d
the seal strip
moving.
u
ra
ri
te
d
to the o
door
i
y
o
b Illustration
p Uncrimp both ends of the seal extrusion.i(See
frame
r
2.
rp to
o
h
p
o
remove the
C DR110.)
Cbrush
re
ro
seals
r
p
d
e
3. Use a locking pliers to extract the
old
seal.
t
e
s
on
izto
i
a
r
t
4. Slide the new seal into the extrusion
and
crimp
the
ends
o
c
im
h
u
l
secure the seal.
t
i
d
t
u
o
Illustration DR105
U
a
r
ed
5. Remove the clamp,pclose the door, and check
the seal.
n
2
Brush
Seals on Roll-Up Door
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
54
l
wUncrimp both ends
d
a
a
e
l
u
of the Bracket to
This seal is held in place
rv by both an undercut designanof the panel
y
remove
the old Seal
e
b
and seal and by fasteners
placed through the vinyl seal into the
s
M
d
bottom door panel.
re
e
e
t
c
ts the roll-up door part of therway
bi
vi (with enough
1. Open
i
h
eand place a clamp in the oh
igclearance to work comfortably)
S
r
r
l
l track to prevent the door from
opening or closing.
y
l
p
a
d
A
u
n
2. Unscrew and discard the
it o
BoPhillips-head fasteners holding
an
c
the vinyl seal to the—
bottom door panel. (See Illustrations
M
u
e
e
l
DR115 and DR120.)
d
c
ic
i
o
v
r
hold seal.
r
p
3. Remove the
e
e
e
r
S
r Vnew seal, angle edge first,dand
4. Installethe
rotate it into
y
t
d
e
position.
s
o
ir z
a
B
o stainless-steel screws.
mSecure with nine #8 (or larger)
5.
i
—
l
h
i
e
t
DR110
lIllustration
utthe door, and check the seal.
c
U 6. Remove the clamp, close
a
i
Top
Seal
on
Roll-up
Door
n
h
e
it o
Un
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
Illustration DR115 p
r
d
e
Vinyl Seal on Bottom of Rear Roll-Up
Door
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
Illustration DR120
ts
i
r
o
h
y Cross-Section of Bottom Panel
h
g with Vinyl Seal
i
t
p
r
au
ll
Co
n
A
U
Bottom Vinyl Seal Replacement
55
DoorSide Sliding
d
e
rv
e
s
re
l
Al
ts
h
g
Stripping
riWeather
er
t
as
m
ili
Seal
t
U
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
by
w
la
d Track Channel
te
i
ib
h
o
pr
Rollers
ce
i
rv
e
S
l
a
u
an
M
dy
o
B
Fixed Window
—
le
c
i
Roll-up
Window
n
h
o
e
ti
V
a
Door
r
er Frame
o
t
rp
as
o
w
m
a
C
i
l
l
Exterior
ti
er
t
Seal
U
by
s
a
d
e
m
t
i Regulator
it li
b
Bracket
i
h
U
Interior
2
ro
w
0
p
Seal
a
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
Seal
u
e
r
r
d
it
y
oChannel
o
b
p
p
i
r
Exterior
Handle
r
h
o
Co
Exterior Door
ep
o
C
r
r
Panel
r
p
d
e
t
e
n
s
iz
Regulator
io
a
r
t
o
c
im
h
u
l
t
i
Catchd
t
u Window Crank
o
U
a
r
ed
n
p
2
v
re Door Guide Extrusion U Interior DoorPanel 00
er
s
2
dInterior Handle
Shim
t
e
re
Guide Retainer
h
AccesssPlate
ir z
t
ig
r
o
h
Plastic Guide
y
ig
th
p
r
u
Illustration DR125
o
a
ll
C Window
Side Sliding Door with Roll-Up
n
A
U
56
ed
z
ri
o
th
u
a
n
U
l
l
A
ts
h
rig
ed
v
r
e
s
re
er
t
as
m
ili
t
U
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
ed
z
i
r
ho
t
u
a
Un
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
ti e
ib
h
o
pr
by
w
la
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
an
M
n
io
t
ra
er
o
t
p
r
as
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration DR126
C
n
A
Side Sliding Door with Upper Sliding and Lower Fixed Windows
U
57
Side Sliding Door Handle Replacement
l
w
d
a
a
e
l
u
nthe interior
rv
a
1. Remove theefour two-way 7/16" locknuts on
by
s
M
of the door
d
re mechanism. Discard the cnuts
e because the
e
t
locking
feature
has
been
destroyed.
(See
Illustration
i
s
t
vi
ib
h
r
DR130.)
h
e
g
i
S the exterior handle, pull ro
l
ll r Grabbing the interior handleyand
2.
p
a
d
A apart the mechanism. The
u
interior handle, spacer, andnthe
it o
Booff. (See Illustrations DR135
an
exterior handle all come
c
M
and DR140.) e—
u
e
l
d
c
ic
i
o
Handle Installation
v
r
r
pthe door.
eh
e
e
1. Align the V
exterior handle in the cutout on
r
SDR130
Illustration
r
y
d
e
Unscrew
tthe dot on the bushing withzthe
d Handle
2. Align
e 3/16" square hole
s
o
i
a the lock knob) with therarrow stamped in the lock
(above
B
o
m
i
body.
—
l
h
i
t
e
t
u
cl
U 3. Insert four new carriageabolts into the handlenfrom the
i
h
exterior.
e
io
Un
t
V
a
r
r
4. Set the spacer in place.
te
po
s
r
5. Align the square shafts on the exterior
handle with the a
o
w
a
square openings on the interiorChandle and push themlim
l
ti
er
together.
t
U
by
s
a locknuts.
d
6. Install four new two-way
e
m
t
iliwith the four holes on the exterior of
bi
7. Align the four bolts
t
i
U to 8 ftlb.
the door. Tighten
oh
2
r
w
0
p DR135
la
0
Illustration
n
2
n
Remove
t
io Inner Handle
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
Illustration
DR140
o
a
ll
C
RemoveAOuter Handle
n
U
Handle Removal
58
l
w
d
a
a
e
l
u
1. Loosen the two
rv bolts that attach the door an
y
e
b
catch to the
body. (See Illustration DR145.)
s
M
d
re cab door into the Closed position.
e
e
2. Slidesthe
t
c
t
bi
vi
i
h
r
3. g
the catch with the latch onethe door.
h
i Align
o
S
r
(See
Illustration
DR150.)
r
l
l
y
l
p
a
d
A 4. While holding the catchoin position, tighten the
n
nu
o
i
B
a
t
two bolts to 79 ftlb.
c
M
—
u
e
e
l
5. Open and closecthe door multiple times to d
ic
i
o
v
r
ensure proper
operation.
Repeat
the
process
h
r
p
e
e
e
if necessary.
r
S
rV
y
d
e
tDoor Replacement
d
e
Side Sliding
s
o
ir z
a
B
Door Removal
Illustration DR145
o
m
i
—
l
h
i NOTE: Although it is not
e Catch
t
lLoosen
ut required,
c
U removing the door handle
a
i
n first (see theion
h
e
U
Sliding Door Handle Assembly section)t
V
r
makes removing the door easier. ra
o
te
p
s
r to brace
1. From the interior, use a 7/16" wrench
a
o
w
m
the two-way locknuts in the bottom
of the
a
C
i
l
l
door. From the exterior, unscrew
y
er the four Uti
t
Catch
b
panhead bolts with a Phillips
Plate
as screwdriver. (See
d
e
m
t
i
li
i
b
t
i
2. Remove the lower
h
U door guide. (See
o
1/8"
2
r
w
0
p
a
l
0exterior, locate the two-way locknut
3. From the
n
2
n
y
o
t
i
o
b
under
the
top
seal
and
brace
the
nut
with
a
1/2"
i
t
h
c
at
ig (See Illustration DR165 and ted
wrench.
u
r
r
d
Latcho
i
y DR170.) From the interior, use a 1/2" socket
o
b
p
i
r
Tongue
rp
o
wrench to loosen the top two bolts andh
p
o
C remove.
e Illustration DR150 C
o
r
r
r
p
d
Align Latch and Catch
e
t
n
NOTE: Discard bolts and two-way
s
ze
o
i
i
a
r
t
locknuts. New bolts andctwo-way
locknuts
o
h
u
lim
are required.
t
i
d
t
u
d
o back into the door pocket.
U
a
r
e
4. Push the roller assembly
(See Illustration DR175.)
n
p
2
rv
U
e
0
e
0
5. Lift the door uprand out. (See Illustration DR180.)
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Side Sliding Door Catch Adjustment
59
Door Installation
d
l
a
e Illustrations DR155 through
NOTE: Refer to
u
v
n the
r
DR180 (inereverse
order) for the installation
a
M
door. es
by
w
la
d
r
e
e
t
c
i
s
1. Set the
t door in the door opening. rvi
ib
h
h
e
g
2.riSlide the roller assembly into place.
S
ro
l
l
y
l
p
a
d
A 3. From the exterior, lift theodoor.
n
nu
o
i
B
a
t
4. From the interior, align the front hole on the door with
c
M
—
the front hole on the
e top of the roller assembly.du
e
l
c
ic
i
o
v
r
5. From the interior,
quickly
insert
a
new
bolt.
r
p
eh
e
e
V
S
6. From the
r exterior, brace the front ofdther door and
y
e
push tbackwards as the interior person
d
e aligns the back
s
Illustration DR155o Remove Bottom Screws
z
i
a on the door with the back rhole on the top of the
hole
B
obolt.
m
roller assembly. Insert a new
i
—
l
h
i
t
t
le
u
c
U 7. From the exterior, lift the
black rubber seal on the top
a
i
n the bolts. ion
h
of the door frame toUexpose
e
t
V
a locknuts.
r
r
8. Attach the washers and the new two-way
o
te
p
s
r
NOTE: Do NOT reuse the two-way
locknuts and a
o
w
a
C
bolts when replacing the sliding
door. New boltslim
l
r
ti
and two-way locknuts are
erequired.
t
U
by
s
d
9. From the interior, use aa1/2" socket wrench to tighten
e
m
t
the bolts.
ili
bi
t
i
U place the new panhead bolts into
10. From the exterior,
oh
2
r
w
the lower door
0 guide at the bottom, using the existing la
p
0
n
holes. 2
t
io Remove Lower Door Guidetion
by Illustration DR160
t
h
11. From
c
g the interior, place the washers and the new
d twoi
u
e
ra
r
t
way
locknuts
onto
the
bolts
and
brace
with
a
7/16"
d
i
y
o
o
p wrench.
ib
r
rp
o
h
p
o
C 12. From the exterior, tighten the bolts with
e
o
C
r
pr a screwdriver. d r
te
e
n (See Side
13. Replace the door handle if necessary.
s
z
o
a
ti and adjustment.)ori
Sliding Door Handle for installation
c
m
i
u
th
il
d
t
u
U
a
ro
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll Remove Locknut
C
Illustration DR165
n
A
U
60
l
w
d
a
a
e
l
u
Panel Removal
n
rv
y
a
e
b
s handle. (See the Side Sliding
1. Removeethe
Door
M
d
e
e
HandlerAssembly section.)
t
c
s
bi
vi(See the
i
ht the door from the vehicle.
r
2. g
Remove
h
i Side Sliding Door section.) Se
o
r
r
l
l
y
l
p
a
d
A 3. Place the door on a flat osurface exterior side up. n
u
it o
B
an
4. Remove the window.
(See the Side Door with c
M
u
e—
e
l
Sliding Window
section.)
d
c
ic
i
o
v
r
hrivets using a #11 or 3/16" drill
r
5. Remove the
p bit
e
e
e
V sure to remove all of the rivets).
r
S
and drill
r (be
y
d
e
t the seal and the extrusion
d
efrom the back
6. Remove
s
z
o
i
a
Illustration
DR170
Remove Bolts
r for reuse. (See
B
edge of door and set them aside
o
m
ili Illustration DR205.) uth
e—
t
l
U 7. Remove the exterior door
a metal.
ic
n
n
h
e
U
tio
V
Panel Installation
a
r
r
e
o
t
1. With the exterior door metal positioned
p on a flat
r
as
surface, attach the seal and extrusion,
using the
o
w
m
a
C
i
l
original holes.
l
ti
y
er
t
U
b
2. Attach the door metal with
3/16"
as
d
MONOBOLTS. m
e
t
ili (See the Side Door with
bi
t
i
3. Reinstall the window.
h
U section.)
Sliding Window
o
2
r
0
p
aw
l
0
4. Reinstall
the
door.
(See
the
Side
Sliding
Door
n
2
n
t
section.)
io
o
by
i
t
h
t
Illustration DR175
c Push Back Roller Assembly
d
a
ig the handle. (See the Side Sliding Door
u
e
r
5. rAttach
d
y Handle Assembly section for door handlebit
o
o
p
p
i
r
r
o
Co installation and adjustment.)
ep
oh
C
r
r
r
p
d
e
Side Sliding Door Lower Guide Replacement
t
e
n
s
iz
it o
a
Guide Removal
r
o
c
h
u
lim
t
i
1. Open the door.
d
t
u
d
o
U
a
r
e
2. Use a #11 or 3/16"pdrill bit to drill out and n
2
rv
U
0
reretaining rivet. (See Illustration
remove the small
e
0
2
DR185.) ed
es
t
r
h
z
iplastic
g
r
ts
3. Slide the
lower
guide
toward
the
rear
of
i
r
o
h
y
h and into the door pocket until it stops.
vehicle
ig
t
p
r
u
o
a(See Illustrations DR190 and DR205.)
ll
C
n
A
U
Illustration DR180 Remove Door
Side Sliding Door Exterior Panel Replacement
61
4. Close the door.
l
w
d
a
a
e
5. Remove the nylon
guide
from
the
underside
of
l
u
n
rvrear of the door pocket. Pullathe
vehicle, at the
e
by
s
M
lower nylon
e guide down and out of theedoor
d
r
e
t
pocket.
(See Illustrations DR195 and
DR
c
i
s
t
vi
ib
200.)
h
r
h
e
g
S
ri
Guidel Installation
ro
l
y
l
p
a
d
A 1. Feed the replacement nylon
o guide into the door ion
nu
B
a
pocket and aluminum retainer extrusion in the
t
c
M
—
reverse procedure
u
eof Step 5 above.
e
l
d
c
ic
i
o
v
r
2. Open the door.
r
p
eh
e
Illustration DR185
e
V
r edge of
S
3. Pull thernylon guide forward to the front
Remove Retaining Rivet
y
d
e
the retainer
t extrusion.
d
s
ze
o
i
a
r
B
4. m
Replace the removed retaining
orivet with a new
i
—
l
h
i rivet.
t
t
le
u
c
U
a
i
n
Side Sliding Door Adjustment
h
e
it o
Un
V
Door Inspection
a
r
r
te
1. Use an air hose or vacuum along the
podoor track
s
r
a
o
and guide to clear out any debris.
w
m
a
C
i
Illustration DR190
l
l
ti
2. Note the door action duringeropening and
Lower Guide
y
t
U
b
s
closing.
a
d
e
m
t
a. If the door moves
i
li in or out as it engages the
i
b
t
i
catch. (SeeUthe Adjusting Side Sliding Door
oh
Catch section.)
2
r
w
0
p
la
0
b. If the
top of the door is out of line with the
n
2
n
t adjust the upper door guide. (See by
io
o
bottom,
i
t
h
t
c
d
a
igthe Upper Door Guide Adjustment Section
u
e
r
r
d
it
y and Illustration DR205.)
o
o
b
p
p
i
r
r
o
Co c. If the door is loose or catches atrthe
ep
ohbottom,
C
r
adjust the lower door guide. (See
r
p the
d
Illustration DR195
e
t
e
n Section and
Lower Door Guide Adjustment
Guide Beneath Truck
s
o
iz
i
a
r
t
o
c
im
h
u
l
t
i
3. Check the door action and
d adjust until it is smooth.
t not rise during closing.d
u The rear of the door should
o
U
a
r
The door front should not rise while opening.n
p
2
ve
r
U
e
0
r (In and Out)
e
Upper Door Guide Adjustment
0
s
2
d
re
1. Loosen theze
ht (See Illustration DR205.)
ir five nuts holding the upper door track to the doorigjamb.
tsthe bottom
r
o
h
2. Adjust
the
track
to
move
the
door
to
the
inside
or
outside,
depending
on
the
alignment
with
y
ig
thdoor track.
p
ofuthe
r
o
a
ll
C
n
A
U
62
l
w
a
a
e
l
u
4. Check the door
rv action and adjust until it isan
y
e
b
smooth. s
M
d
re Adjustment
e
e
Lower Door Guide
t
c
i
i
ts
b
v
i
h
r
1. g
the six 1/4" screws along
h
e the bottom of
i Loosen
o
S
r
the
side
door.
(See
Illustration
DR210.)
r
l
l
y
l
p
a
d
A 2. Adjust the bottom dooroguide all the way up (into n
nu
o
i
B
a
the plastic door track). (See Illustration
t
c
M
—
DR205.)
u
e
e
l
d
c
ic
i
o
v
r
3. If the door scrapes
or
binds,
push
the
guide
down
h
r
p
e
e
slightly into
the
track.
e
r
S
rV
y
d
e
4. Cycle
t the door open and then closed.
d DR200
e
s
z
o
Illustration
i
a
r of the side
B from Wheel Well
5. mTighten the screws along theobottom
View
i
—
l
h
i door.
t
le
ut
c
U
a
i
n
CAUTION:h Be careful not to chip the paint!
e
io
Un
t
V
a
r
er
o
t
p
r
as
Upper
Door
o
w
m
a
C
Track
i
l
l
ti
y
er Roller
t
U
b
Assembly
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
n
s
ze
Pan
o
i
i
Illustration DR210
a
r
t
Head
o
c
Loosen iScrews
Screw
h
u
lm
t
i
d
t
u
d
o Nylon Door
U
a
r
e
Track
n
Bottom
p
2
rv
U
0
Door re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration DR205
C
n
A
Upper Door Cross-Section
U
3. Tighten the five nuts
d to 79 ftlb.
63
ts
h
ig
r
l
Al
d
e
rv
e
s
re
ce
i
rv
e
S
y
d
Bo
e—
l
ic
Illustration
DN10
h
e
Duck-bill Drain
V
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
by
w
la
Gently
d insert
ti epointed tool
drain
ib topthrough
h
(from inside
o
cargo area)
pr
Or squeeze bottom
“lip” edges to release
accumulation (from
underneath vehicle)
ce
i
rv
e
S
l
a
u
an
M
er
Clean the Duck-bill drains
t
dy
ed
s
z
in
the
rear
cargo
floor
corners
o
i
r
B
Drains a
o
m
i
—
l
h
i Drain Valves Overview ut
Duck-bill
t
le
c
U
a
i
n to escape from theh cargo area from each corner of the
n drain valves allowiowater
The rubber Duck-bill or Kazoo
e to siphon into the cargo area in a
U
tout without allowing water
rear structure. They are designed to let the water
V
a
r
Negative pressure condition.
er
o
t
rp
as
Drain Cleaning
o
w
m
a
C
i
l
l
Clean the rubber duck-bill drain valves
in the rear cargo floor
ti corner periodically to ensure that the drain yis not
erto drain
t
U
blocked by debris or dirt and is able
properly.
(See
Illustration DN10.)
b
as
d
· From the interior ofim
the vehicle, use a small pointed tool, such as a pen or small screwdriver,
te to gently
i
l
i the drain.
poke down through
ib
h
Ut
· Or from underneath
the vehicle, squeeze the wide section
2
rolips and release
w on the bottom to openpthe
0
a
l
any accumulation
that did not drain
0
n
2
n
y
normally.
o
t
i
o
b
i
t
h
t
c
d
a
ig
Drain Removal
u
e
r
r
d
yFrom underneath the vehicle, drill out the bit
o
o
p
p
1.
i
r
r
o
Co two POP rivets. (See Illustration roh
ep
C
r
DN15.)
r
p
d
e
t
e
n
s
2. Remove drain valve assembly.io
iz
a
r
t
o
c
im
Drain Installation
h
u
l
t
i
t
u
odassembly.
U
a
1. Position the drain valve
r
ed
n
p
2
v
U
2. POP-rivet it intore
place.
er
00
s
2
d
t
e
re
NOTE: See
also information about
h
z
i
r the drain in the Positive
ts
maintaining
ig
r
o
h
y
h System section.
Pressure
ig
t
p
r
u
o
Illustration
DN15
a
ll
C
Duck-bill Drain Installation
n
A
U
®
64
l
w
a
a
e
l
u
Echovision Tests rv
n
y
a
e
b
s
M
NOTE:eThis test requires a driver in the
d
r and pedestrian behind the
e
e
vehicle
vehicle.
t
c
i
i
ts
b
v
i
h
r
1. g
driver starts the vehicle, puts
h
e the vehicle in
i The
o
S
r
reverse
and
observes
the
start-up
audible
alert
r
l
l
y
l
p
a
and
the
green
Ready
light.
d
A
n
o
nu
o
i
B
a
The pedestrian observes the external audible
t
c
M
—
alarm.
u
e
e
l
d
c
ic
i
o
Illustration
EV10
v
r
2. With a shipping
box
(or
equivalent)
held
h
r
p
e
Test Signal in Stepe2
perpendicular
to
a
sensor
axis
(see
Illustration
e
r
S
r Vthe pedestrian should moved from
EV10),
the
y
e
t range (approximatelyz10e feet) to the minimum range (approximatelyo3dfeet) while the driver
maximum
s
i will start as a low-pitched interrupted signal
a
r
B that increases in pitch,
observes
the
audible
warning,
which
o
m
i
—
l
h
i as the notes of a musicaluscale,
t and then changes to a continuous high-pitched
e signal.
t
l
U 3. Repeat the test for botha sensors.
ic
n
n
h
e
U
tio
V
(For 1996 Through 1998 Units Only)
a
r
r
e
o
t
4. The pedestrian presses a finger to p
each sensor module transducer
face while the driver observes that the
s
r
a
red light goes on (after three seconds)
and
the
green
light
goes
o
w
m
a
C
i
l
off. (See Illustration EV15.)
l
ti
y
er
t
U
b
NOTE: Components for
1998
and
earlier
units
do
not
work
as
d
with 1999 and later
components.
(See Illustration EV20.)
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
Illustration
r EV15
p
d
e
Test
Signal
in Step 3
t
e
n
s
z
o
i
a
r
ti
o
c
m
u
th
ili
d
t
u
d
U
a
ro
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Echovision Back-Upd Alarm
65
Echovision Troubleshooting
l
d
w
a an alternate method of troubleshooting
e connectors are accessible,
NOTE: If the cable
is
la
u
v
n
r
to sequentially
a for the modules in question
e substitute known good modules
by without
s
M
dismounting
the
installed
modules.
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Illustration EV20 Echovision
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Removal
n
rv
y
a
e
b
s
Msurface, cut the
1. Using aerazor knife, at an 90° angle to the
d
raround the outside of the end-cap
e
e
sealant
casting.
Also
cut
t
c
s
tvertical
vi rail. Cut as close to the ibi
the
seam at the cap and rub
h
r
h
e BR10.)
igcap as possible. (See Illustration
o
S
r
r
l
l
y
l
p
a
d
A
u
n
o are especially dangerous.
WARNING: Razor knives
n
o
i
B
a
Always try to cut at an 90° angle to the surface
t and do
M
—
not cut towards
yourself. Be careful not tocpress so
u
e
e
l
hard that it breaks the blade.
d
c
ic
i
o
v
r
h
r
p
e
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e
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r Vthe two rivets holding thedendr cap with a #11 or
2. Remove
y
e
t drill bit. (See Illustration BR15.)
d
e
3/16"
s
o
ir z
a
B
o bar or large screwdriver
3.limRemove the end cap with ahpry
—
BR10
i from inside the vehicle byutpushing it out. (See Illustration
e Illustration
t
l
Cutting
Sealant
U BR20.)
a
ic
n
n
h
e
U
tio
V
a
r
er
o
t
p
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as
o
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Illustration BR20
r
p
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Prying Out End Cap
e
t
e
n
s
iz
it o
a
r
Illustration
BR15
o
c
im Rivet
h
u
l
Drilling
t
i
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End Cap Replacement
d
67
4. Remove any remaining sealant from the side
wall and rub rail.ed(See Illustration BR30.)
l
w
a
a
l
u
n
rv
5. Inspect bareealuminum
surfaces for corrosion.
a
by
s
M
(See Illustration
BR25.)
d
re
e
e
t
c
i
s
i Step 7.
6a. If not corrosion is visible, proceedvto
ib
h
r
h
e
g
6b.riIf corrosion is present on painted
S surfaces
ro
l
l surrounding the end cap, refer
y
l
p
to
the
Paint
a
d painted surface
A Repair section and repairothe
n
nu
o
i
B
a
before installing the new prepainted end cap. ct
M
—
u
e
e
l
d
6c. If corrosion is present
c on unpainted surfaces,
ic
i
o
v
r
h area with 220-grit p
sand the unpainted
r
ewipe
e
sandpaper,
the surface clean withrae
V
S
y
cleantrag,
er and apply a small amountedof sealant
d
(P/N
o
iz
as 12605981) to the treatedrarea.
B
o BR35 and
m
i
7.
Apply
sealant
(see
Illustrations
—
l
h
i BR40) around the precoated
t replacement
t
le Remove Remaining Sealant
Illustration BR30
u
c
U
a
i
n
end cap (P/N 06924153).
h
e
it o
Un
V
a the
8. Install the replacement end cap by sliding
r
r
o
te
tongue of the cap into the rub rail. p
(See
s
r
a
Illustration BR45.)
o
w
m
a
C
i
l
l
9. Tap the end cap into positionr with a rubber
ti
e
t
U
by
mallet.
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
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0
p
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0
n
2
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o
t
i
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by
i
t
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t
Illustrationc BR35 Apply Sealant
d
a
ig
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r
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it
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o
o
b
p
p
i
r
r
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o
Co
ep
o
C
r
r
r
p
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e
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s
iz
io
a
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o
c
im
h
u
l
t
i
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er
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d
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ir z
ts
ig
r
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Illustration BR25
y
h Inspect Bare Surfaces
ig
t
p
r
u
o
Illustration
BR40
Apply
l Sealant
a
l
C
n
A
U
68
10. From inside the vehicle,
using the previous
l
d
a
e
mounting holes
u
v in the sidewall as guides, drillntwo
r
17/64" or F-bit
e holes through the end cap.a
w
la
y
b
s
e end cap with two aluminume M
d
11. Securerthe
e
t
c
(P/N 11400027).
MONOBOLTS
ts
bi
vi
i
h
r
h
e
igSeal with P/N 12605981 (orS12605820)
12.
around
o
r
r
l
l the exterior of the end cap, yincluding where the
l
p
a
d
A end cap meets the rub rail.
o (See Illustrations BR ion
nu
B
a
t
50 and BR55.)
c
M
—
u
e
e
l
d
NOTE: Cut a csmall tip off of the
ic
i
o
v
r
h to first seal the narrow p
sealant nozzle
r
e
e
e
seams. Make
a
second
larger
cut
to
V
r
S
y
seal tthe
d
er larger seams.
d
e
s
o
iz Paint Repair
13. Ifapaint repair is necessary, seerthe
B
o
msection.
i
—
l
h
i
t
le
ut
c
U
a
i
Illustration BR45
n
h Insert
New End Cap
e
it o
Un
V
a
r
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o
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p
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m
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i
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U
e
0
r
e
0
Illustration
BR55
s
Illustration
BR50
2Apply Touch-up Paint
d
e
t
e
r
Secure zWith Fasteners and Sealant
h
i
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r
ts
i
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C
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A
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®
69
Fan (Auxiliary)
l
w
d
a
a
e
l
u
n
rv
a
e
1. Disconnect
the
battery
Negative
(Black)
cable.
by
s
M
d
re screwdriver, remove three
e screws
e
2. Withsa Phillips
t
c
i
i
t the fan to the header. (SeervIllustration
holding
ib
h
h
e
g
iFA10.)
S
ro
l
ll r
y
p
a
to fan.
d
A 3. Disconnect the wire harness
u
n
o
n
o
i
B
a
Installation
t
c
M
—
u
eprocedure.
e
1. Reverse the above
l
d
c
ic
i
o
v
r
r
p
eh
e
e
V
r
S
r
y
d
e
t
d
e
s
o
Illustration
FA10
iz
a
r
B
Auxiliary
Fan
o
m
—
h
it li
t
le
u
c
U
a
i
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h
e
it o
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V
a
r
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po
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r
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o
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m
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by
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oh
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C
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Removal
70
l
w
a
a
e
l
u
v access to the fuel sending unitn
Some vehicles have ran
y
alife
e
b
through the cargosfloor in case of failure during the
M
d
of the vehicle. rIteis a smooth aluminum plate secured
e
e
t
c
s Phillips-head screws. (SeevIllustration
i
with four totsix
bi
i
h
r
FS10.)igRemoving this plate should give
h
e you full
o
S
r
r
access
l
l to the fuel sending unit for repair
y or
l
p
a
d
replacement.
A
n
o
nu
o
i
B
a
t
NOTE: Utilimaster does not warrant the
c
M
—
e drive train, or other du
fuel sending unit,
e
l
c parts. (See the chassis ro
ic
i
chassis supplied
v
h service information.) p
r
e
manufacturer's
e
e
r
S
rV
y
d
e
t
d
e
s
o
ir z
a
B FS10
Illustration
o
m
i
—
Fuel
Sending
Unit Access
l
h
i
t
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t
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u
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a
ic
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e
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tio
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Fuel Sending Unit Access
d
71
Grab Handle Replacement
l
w
d
a
a
e
l
u
All grab handles are removed
and
replaced
in
the
same
manner.
n
rv
a
e
by
Grab Handle Removal
s
M
re
e stainless-steel
ed
1. While
holding the handle, remove theicfour
t
i
s
t
Phillips-head
fasteners from the handle.
ib
h
rv
h
e
g
i
S hand. (See Illustrations ro
2.
l
ll r Handle should release into your
y
p
a
A GH10 and GH20.) od
n
nu
o
i
B
a
Grab Handle Installation
t
c
M
—
u
e
1. While holding thelenew handle in place, use four
stainlessc attach it to the door. rod
ic
i
steel fasteners
to
v
r
p
eh
e
e
V
r
S
2. Torque rto 46 ftlb.
y
d
e
t
d
e
s
o
iz
a CAUTION: Use stainless-steel
r
B
o fasteners for all
m grab handles.
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h
e
it o
Un
V
a
r
r
te
po
s
r
a
Illustration GH10
o
w
m
C
i
Grab
Handle at Cab Entrancela
l
ti
er
t
U
by
s
a
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e
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Illustration
a
ll GH20
C
n
Grab Handle A
at Roll-Up Door Entrance
U
72
Heater (Only) System
d
l
l
A
ts
h
rig
ve
r
e
s
re
l
a
u
n
a
M
d
ti e
ib
h
ro
p
Transition Duct
n
o
it
c
u
od
r
p
re
ce
i
rv
e
S
by
w
la
Defrost Duct
y
d
Bo
e—
l
ic
h
Ve
Ele
ctr
ic
Co
ntr
ol
ce
i
rv
e
S
l
a
u
an
M
y
er
t
d
ed
s
z
o
i
a Shut-Off Valve
r
B
(ELECTRONIC)
m
ho
ili
t
e—
t
l
u
U
a
ic
n
n
h
e
U
tio
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a
r
er Fresh Air Inlet
o
t
p
r
Shut-Off Valve
as
o
w
(Manual)
m
a
C
i
l
l
Controller
ti
y
er
Wire Harness
(ELECTRONIC)
t
U
b
as
d
Heater Coil
e
m
t
Plenumi Air Inlet
ili
t
ib
h
U
2
ro
w
0
p
a
l
0
n
2
n
y
Controller
o
t
i
o
b
Heater
Hose
i
t
h
(Manual Cable)
t
c
d
Spacer
a
ig
u
e
r
r
d
it
y
o
Bulkhead
o
b
p
p
i
r
r
h
p Tube Fitting
o
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o
C
r
r
r
p
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n
s Blower Inlet Duct
iz
it o
a
r
o
HeatercPlenum
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
Resistor
n
p
2
Louver U
rv
0
re
e
0
Vent Hose
2 Blower
d
es
t
Blower
e
r
h
iz
Wheel Housing
g
Motor
r
ts
i
r
o
h
y
h
ig
t
Floor Duct
p
r
u
o
a
ll
C
Illustration HE-5
n
A
U
Heating System (Heat Only)
Ma
nu
al
Co
He
ntr
at
ol
On
ly
Ma
nu
al
Co
ntr
ol
73
System Controls Overview
d
l
w
a with cable (manual) and electronic
This section describes heating
controls. The
e systems of Utilimaster vans
la
u
v
n
r
control module assembly
panel, to the right of
a HE15) is located on the instrument
e (Illustrations HE5 through
by
s
M
the steering column.
The
outlet
registers
can
be
adjusted
to
direct
air.
e
d
r
te
ce
i
s
i
t
ib
h
rv
h
e
g
i blower motor is on and dashSlever (2) is set to dash, ro
When rthe
l
l
you lcan direct the flow of air whereyyou want by rotating two p
Heater Only
a
d
A
Cable Control
nto
circular vents on the dash. When
o the heater control lever isiset
nu
o
B
a
t
defrost (4), most of the airflow is directed through the defrost
c
M
—
1
u
ducts near the window, and
e only a small amount of airdcomes
e
l
ic
through the air louvers.icAs the floor control lever (3)
is moved
o
v
r
r
p through
to the right or left, varying
eh amounts of air will beedirected
e
V
r
S
the floor ducts. r
2
y
d
e
t
d
e
s more air to the defrost orizto the floor ducts, close the
To direct even
o
a
3
r
B
louversm
by rotating them on their pivots
approximately 90 degrees.
o
i
il Control Switch uth
4
e—
t
l
(1) Blower
c
U
a
i
n
n
h
0Off, 1Low, 2Medium,U
3High
5
e
it o
V
ra higher the voltageer
The blower motor is a variable-speed motor. The
o
applied to the motor, the faster the speed.rWith
p the heater control
sint
a
the Off position, no voltage is applied toothe Low blower relay, the
w
Illustration HE10
a
Cthe blower motor. ilim
l
relay is off, and no voltage is appliedr to
Cable (Heat Only) Control Module
t
y
e
t
U
b
s
As the blower switch is moved to the Medium Low and Medium
apart of the blower motor resistors, allowing more voltage to be applied
d to the
e
positions, the switch bypasses
m
t
i
li
blower motor, which willtiincrease
its speed. When the blower motor switch is on High, batteryibvoltage is
U motor. The blower motor runs at maximum speed.
applied directly to the blower
oh
2
r
w
0 is located on the evaporator case (on thelainside of vehicle) and behind
p the right-hand floor
The resistor assembly
0
n
2
n
duct. (See Illustration
HE5 and HE30.)
t
io
o
by
i
t
h
t
c
d
(2) Off/Dash
a
ig
u
e
r
r
d
it
y control lever directs the airflow to the airblouvers.
o
o
The dash
p
p
i
r
r
o
h
o
COff/Floor
ep
o
(3)
C
r
r
r
p the floor.
d
e
The floor control lever directs the airflow
to
t
e
n
s
o
iz
i
a
r
t
(4) Off/Defrost
o
c
im
h
u
l
t
i
The defroster control lever directs
t
u outlets.
od the airflow to the defroster
U
a
r
ed
n
(5) Cold/Hot (TemperaturepControl)
2
v
U
0
re
er
For a warmer airflow,dslide the temperature control toward the right (Red).20
For a cooler airflow, slide the
s
t
e
re
temperature control
h
ir z toward the left (Blue).
ts heater core
ig
r
o
h
The temperature
controls
the
water
valve
located
in
the
engine
compartment.
The
water
flow
to
the
h with the setting of control lever. The water valve pisylocated in the engine compartment
ig in the
t
is proportional
r
u
o
a inlet hose.
ll
heater coolant
C
n
A
U
CABLE (Manual) Control Operation
3
2
1 0
OFF
DASH
OFF
FLOOR
OFF
COLD
74
HOT
l
w Heat Only
d
a
a
e
l
u
When the blower motor
n (16 or 17),
rv is on and control is set toadash
y Electronic Control
e
b
you can direct thesflow of air where you want by rotating two
M
circular vents on
11ed
re the dash. When the heaterccontrol
e is set to
it
smost of the airflow is directedvithrough the defrost
defrost (20),
t
b
i
hthe window, and only a smalleamount
r
ducts near
of air comes
h
g
i
o
S
r
through
the
air
louvers.
As
the
floor
control
is
rotated
(13),
varying
r
l
l
12
y the louvers and the floor p
l
a
amounts
of
air
will
be
directed
through
d
A
u
n
n
ducts.
it o
Bo
a
17
c
M 18
—
16
19
To direct even more air to
the
defrost
or
to
the
floor
ducts,
close
u
e
e
l them on their pivots approximately
d
20
c
c
i
the dash louvers by rotating
90
i
o
v
r
h
r
degrees.
p
13
e
e
e
r
S
r V Switch
(11) Blower Control
y
d
e
d
st Low, Medium, Highize
o
Off, Low,aMedium
r
B
o
m
Illustration HE15
i
—
l
h
The iblower motor is a variable-speed
t motor. The higher the
ELECTRONIC
t
le (Heat Only) Control Module
u
voltage
applied
to
the
motor,
the
faster
the speed. With the heater
c
U
a
i
n no voltage is applied
h
control head in the Off position,
on to the Low
e
i
U
t
V
blower relay, the relay is off, and no voltage is applied
to the blower motor.
a
r
r
o voltage is applied totethe blower relay and voltage is applied to
When in any other mode, except Off and High,
p
r
as switch is on Low, voltage is applied w
the blower switch and the blower motororesistors. When the blower
C the blower relay toilthe
imblower motor. The blower motor runs at lowla
through the blower motor resistors rand
t
y
e
speed.
t
U
b
asthrough positions Medium Low and Medium, the switch bypassesepart
d of the
As the blower switch is moved
m
t
blower motor resistors, allowing
ili more voltage to be applied to the blower motor, which will increase
bi its speed.
t
i
h blower motor
U switch is on High, voltage is applied directly to the blower motor.oThe
When the blower motor
2
r
runs at maximum speed.
0
p
aw
l
0
n
2
n
The resistor assembly
is located behind the right-hand floor
o
t
o
by duct. (See IllustrationtiHE5.)
i
h
t
c
d
(12) Cold/Hot
a
ig (Temperature Control)
u
e
r
r
itcolder airflow, rotate itotod the left.
y airflow, rotate the knob to the right; for
o
For warmer
b
p
p
i
r
r
h attached to the waterepvalve located in the engineo
Co temperature control operates an electricroservo
The
C
r
r
p core is proportional with
compartment. The water flow to the heater
the
setting
of
control
knob.
d
e The water
t
e
n
valve is located in the engine compartment
s
io in the heater coolantrizinlet hose.
a
t
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
ELECTRONIC Control Operation
75
(13) Function Selector (ELECTRONIC)
l
d
w
a each for dash door, floor door,
The function selector actuates
e electric servomotorsone
la defrost door, and the
u
v
n
r
y
outside/recirculation
upon the evaporator
e door. In the Defrost position,athe compressor operation is bdependent
s
M
thermostat settings.
e
d
r
e
e
itis in the Recirculate Air position. It
s selector in the Off position,
icthe outside/recirculation door
With the function
t
b
v
r
is closedgtohoutside air, and no air passesethrough
the system. The blower
hi motor is Off.
i
S
ro
l
ll r
y
p
a
d
A
n outside, and outside air is discharged through
o
nu
In the Panel position the outside/recirculation
door is open toiothe
B
a
t
the panel registers, except for
a small amount of floor bleed.
c
M
—
u
e
e
l
d
(17) Panel/Floor
c
ic
i
o
v
r
r through the
p door is open to outside air. Air is discharged
eh the outside/recirculation
In the Panel/Floor position
e
e
V
S
heater outlet floor
r ducts and panel registers.d r
y
e
t
d
e
(18) Floor s
o
iz
a
r
B
o
m position the outside/recirculation
In the lFloor
door is open to outside air. Air is discharged
through the heater
i
—
h
i
t
e
t
outlet floor ducts, and a small amount
u of bleed is directed to the windshield. icl
U
a
n
h
(19) Defrost/Floor
e
it o
Un
V defroster hose nozzles and heater
a both the windshield
r
In the Defrost/Floor position air is discharged through
r
te
outlet floor ducts in approximately equal amounts.
po
s
r
a
o
w
(20) Defrost
m
a
C
i
l
l
ti
er through the windshield
In the Defrost position the air is discharged
defroster hose nozzles. There is alsobaysmall
t
U
s
amount of floor bleed.
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
(16) Panel
76
l
w
d
a
a
e
l
u
Control Head Removalv
n
r
y
a
e
b
s
1. Remove and
retain the four screws holding
the
control
module
M
d
re
e
e
to the dash.
t
c
ts
bi
vi
i
h
2. Remove
the retaining ring plate.er
h
ig
o
S
r
r
l
l3. Remove and save the retaining
y rings that hold the cables pin
l
a
d
A place. (See IllustrationoHE20.)
n
nu
o
i
B
a
tmodule and
4. Disconnect the cables
from the back of the control
c
M
—
u
e dash.
e
remove it from the
l
d
c
ic
i
o
v
r
h
Control Head Installation
r HE20
p
Illustration
e
e
e
V
r the control module
Connect S
Heater Cables
1. Pull therends of the control cables through
y
d
e
t
d
port.
e
s
o
ir z
a
B rings.
2.imAttach the color-coded cables
o to the control module and secure with the retaining
—
l
h
i3. Install the retaining ring plate.
t
le
ut
c
U
a
i
n
4. Reattach the module
ehscrews and strip the threads.
io not to overtightenVthe
Unto the dash. Be careful
t
ra
er
ELECTRONIC Control Module Replacement
o
t
p
r
as
Control Head Removal
o
w
m
a
C
i
l
l
1. Remove and retain the fourrscrews holding the control
ti module to the dash.
y
e
t
U
b
2. Disconnect the wire harness
as and remove the module from the dash.
d
e
m
t
Control Head Installation li
i
bi
t
i
h
U through the control module port.
1. Pull the wire harness
o
2
r
0 wire harness to the control module. law
p
2. Attached0the
n
2
o strip the threads. ion
t the module to the dash. Be careful notbtoyovertighten the screwstiand
3. Reattach
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
CABLE (Manual) Control Module Replacement
77
Blower Motor Replacement
l Disconnect
w
d
a
electrical
Blower Removal
a
e
l
u
n
rv
connector
a
1. Disconnectethe Negative (Black) battery cable.
by
s
M
d
rethe electrical connections from
ethe
2. Remove
e
t
c
i
s
t motor. (See Illustration HE25.)
blower
vi
ib
h
r
h
e
g
3.riRemove the blower motor vent
Stube.
ro
l
l
y
l
p
a
d
A 4. Remove the attaching screws.
n
o
nu
o
i
B
a
Disconnect
5. Remove the blower—
motor assembly from the ct
M
vent tube
u
e
e
housing.
l
d
c
ic
i
o
v
r
h wheel retaining nut. p
r
6. Remove theeblower
e
e
V
r
S
NOTE:r Nut threads are standard dright-hand
y
e
t
d
e
threads.
s
o
iz
a
Illustration
HE25
r
B
o the blower
7. im
Remove the blower wheel from
Disconnect
Blower Motor
—
l
h
i motor.
t
t
le
u
c
U
a
2.
Remove
the
resistor
cover plate. (See
i
n
n
h
8. Remove the blower wheel
stop (clip) from o
the
Illustrations
e HE5, HE30, and AC10.)
U
ti
V
motor shaft.
a
r
3. Remove
er the electrical connections from the
o
t
Blower Installation
s assembly.
rp
aresistor
o
w
1. Install the blower wheel stop on
the
new
motor.
m Remove the resistor assembly.
a
C
i
4.
l
l
r
ti
2. Install the blower wheel. te
U
Resistor
Installation
by
s
d
3. Install the retaining nutaand torque it to 2327
1. Position the replacement resistor.te
m
i
inlb [2.603.05 Nm].
ili
b
t
i
2. Attach with screws and torque
h to 1315 inlb
U assembly in the housing.
4. Position the 2
blower
o
[1.471.69
Nm].
r
w
0
p
a
l
0
5. Attach with
and torque them to 1315
n
2 screws
n
y 3. Attach the electricalioconnections.
t
inlb [1.471.69
Nm].
o
b
i
t
h
t
c cover plate.
d 4. Install the resistor
a
ig the electrical connector.
u
6. Attach
e
r
r
dNegative (Black) batterypcable.
it
y
o
5. Connect the
o
b
p
i
r
r
7.
Reattach
the
blower
motor
vent
tube.
h
o
Co
ep
o
C
r
r
8. Connect the Negative (Black) battery
cable
and
r
p
d
e
check the blower motor for proper
operation.
t
e
n
s
iz
io
a
r
t
Resistor Replacement
o
c
im
h
u
l
t
i
t
Resistor Removal
u
od
U
a
r
ed
n
p
2
v
1. Disconnect the Negative
(Black) battery cable.
U
re
er
00
s
2
d
t Illustration HE-30
e
re
h
ir z
ig Heating System Resistor hts
r
o
y
h
t
p
rigsame order.
u
CAUTION: Make note of the locations of the colored
wires and reinstall in lthe
o
a
l
C
n
A
U
78
l
w
d
a
a
e
l
u
Overview
n
rv
y
a
e
b
s
Under extreme temperature
fluctuations the defrost
duct
M
d
re may crack/break around thecefasteners. In
e
mounting flanges
t
s cracks are superficial however,
tthe
most cases
bi
vi an upgrade
i
h
r
h
e failure occur
procedure
ig has been created should a dramatic
o
S
r
r
l
overlltime.
y
p
a
d
A
n
o the defrost ducts and installing
nu
The following describes replacing
o
i
B
a
t
metal strips on the bottom —
and top of the defrost duct mounting
c
M
u
e
e
flange.
l
d
c
ic
i
o
v
r
hfollowing instructions represent
r
NOTE: The
p
e
e
e
V
the RH (passenger
side) of the vehicle.
r In
S
r
y
d
e
order
t to make this repair on thezeLH (drivers
d
s
o
side)
ir the dash
a defrost duct, first remove
B
o
massembly.
i
—
l
h
i
t
le
utfasteners holding the defrost
1.
c
U Remove the Phillips head
a
i
n the fasteners. (See
h
duct in place and discard
onIllustration
e
i
U
Illustration HE40
t
V
HE40.)
a
r
r
Remove Fasteners
e
o
t
p
r
as
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
Co Illustration HE45 Mark Length roh
ep Illustration HE50 CCuto Shims
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Illustration HE55 Clamp Assembly
Defrost Duct Upgrade
79
d
e
rv
e
s
re
ts 4
h
rig
ce
i
rv
e
S
l
a
u
n
a
M
d
te
i
ib
h
15
o
pr
by
w
la
1/2
1
l
y
a
d
u
Illustration HE60 n
Bo
Hole Locations tio
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h duct by sliding the outboard
2. Remove theedefrost
r
p side
e
e
V
back until you can pull it off of the transition
r duct.
S
r
y
d
e
t the length of the defrostzduct
d
e flange. (See
3. Measure
s
o
i
a
r
Illustration HE45.)
B
o
m
i
—
l
h
i Cut shims (P/Ns 6924053
t and 06924138) to the
e
4.
t
u
cl
U determined length. (SeeaIllustration HE50.)n
i
n
h
o
e
i
U
t
V
5. Place the .100 x 1.0 shim (P/N 06924053)
a below the
r
r
defrost duct flange and the .063 x .75oshim (P/N
e
p the shims flush ast
06924138) on top of the flange. Align
r
o
w
with side and rear edges. (SeeCIllustration HE55.) im
a
l
l
ti
er
6. Clamp the assembly together.
t
U
by
s
afrom the rear edge at 4" from
d
7. Mark three holes 1/2"
e
Illustration
HE65
m
t
inboard edge, 1"tfrom
ili outboard edge, and 15" from
bi
Drill Holes
i
outboard edge.U(See Illustration HE60.)
oh
2
r
w
05/32" holes through all three pieces as marked.
p
8. Drill three
la
0
n
2
(See Illustration
HE65.)
n
t
io
o
by
i
t
h
c
d onto
9. Place
at
ig the defrost duct back in the vehicle bytsliding
u
e
r
r
d
i the
ythe transition duct and aligning it parallel with
o
o
b
p
p
i
r
r
windshield.
h
o
Co
ep
o
C
r
r
10. Assemble the shims with the defrost
r
p duct as they were d
e
t
e
drilled.
n
s
iz
io
a
r
t
o
c into place inside the
m
CAUTION: Do NOT clamp
i
h
u
l
t
i
vehicle. Do NOT drill
holes in the cowl metal or
t
u
od
U
the selfdrilling rfasteners
will not hold. a
ed
n
p
2
v
U
re using the 8 x 3/4" selfdrilling
er
00
s
11. Attach in three
places,
2
d
t
e
re
screws (P/N
11300251).
(See Illustration HE70.)
h
ir z
ts
Illustration HE70
ig
r
o
h
y
Install Screws
h
ig
t
p
r
u
o
a
ll
C
n
A
U
l
Al
80
l
a
aw
l
u
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b
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r
h
e
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o
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r&ORVHG
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l
y
p
a
d
u
n
it o
Bo
an
c on the Purple wire to the mode switch toM
— flows from the control module
In the Off position the current
the
u
e
e
l
d
c
control module ground.
de-energized, and all mode doors are driven
i closed.
ic The blower motor powerrrelay
o theismode
v
h
The motors are driven
to
position
for
30
seconds
after
is
selected,
and
then
both
motor
inputs
go high
r
p
e
e
e
(+12V to ground).
r
S
rV
y
d
e
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e
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81
Floor Position
d
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a on the Orange wire tolathe mode switch to the
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v
n
r The system power relay isaenergized.
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is driven open, and the
e
by the
s
M
panel door is driven
closed.
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motors
are
driven
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position
for
30
seconds
after
mode is selected, and
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then both motor
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position the current flows rfrom the control module on the Pink wire to the
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r
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the control module
t ground. The blower zmotor
e power relay is energized. The floor andoddefrost outlet doors are
s
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for 30 seconds after the mode is selected, and then both motor
i
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control module ground. tThe
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Al
82
l
w
d
a
a
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l
u
1. Disconnect the
nmodule. (See Illustration HE70.)
rv wire harness from the control
y
a
e
b
s
M the resistance from Pind1 (Black wire) of the control
2. Using aeDVOM (Digital Voltmeter), measure
r
e
e Off position.
module
s connector to Pin 2 (Purplevwire)
ic with the control switchbinitthe
t
i for an open circuit in the Black or
hless than 2 ohms, go to the next
r step. If more than 2 ohms,hcheck
e
ir gIfPurple
ro
wire. If wires are OK,Sreplace the control module switch.
l
l
y
l
p
a
d
A 3. Using a DVOM, measure
n wire) of the control module connector tonuPin
o the resistance from Pin 1io(Black
B
a
3 (Light Green wire) with the control switch in the tPanel position.
c
M
—
uthan 2 ohms, check for an open circuit in thee Black or
le go to the next step. If more
If less than 2 ohms,
d
c
c
i
i
o
v
r
Light Greenhwire. If wires are OK, replace the control module switch.
r
p
e
e
e
V
r from Pin 1 (Black wire) of the control module
S connector to Pin
4. Using ar DVOM,
measure the resistance
y
d
e
t wire) with the control zswitch
4 (Yellow
d
e in the Floor/Panel position.
s
o
ir
a
B circuit in the Black or
onext step. If more than 2 ohms, check for an—open
mIf less than 2 ohms, go to the
i
l
h
i Yellow wire. If wires areutOK, replace the control module switch. le
t
U 5. Using a DVOM, measure
a the resistance fromn Pin 1 (Black wire) ofhthe
ic control module connector to Pin
n
U the control switch intiothe Floor position. Ve
5 (Orange wire) with
ra
ercheck for an open circuit in the Black or
o
If less than 2 ohms, go to the next p
step. If more than 2 ohms,
t
r the control module
asswitch.
Yellow wire. If wires are OK, replace
o
w
m
a
C
i
l
l
r resistance from Pint1i (Black wire) of the control module connectory to Pin
6. Using a DVOM, measure the
e
t
b
6 (Pink wire) with the control
s switch in the U
a
d
Floor/Defrost position.
e
m
tYellow/Black
Black
i
i
l
ti go to the next step. If
ib
h
U
more than 2 ohms, check for an open circuit in
2
ro Yellow/White
wPurple
the Black0or Pink wire. If wires are OK,
p
a
l
0
n
replace2the control module switch.
Blue
y
Blue/Black n
o
t
i
b
io
t
h
t
c
7. Using
a
DVOM,
measure
the
resistance
from
g
d
i
u
Dk. Green
e
Blue/White
ra
rPin
1 (Black wire) of the control module it
d
y
o
p connector to Pin 7 (White wire) with theib
ro
rp
o
h
Lt. Green p
o
Green/Black
C control switch in the Defrost position.
e
o
C
r
r
r
p
d
If more than 2 ohms, check fornan open circuit
te Green/White
e
Yellow
s
z
in the Black or White wire.tiIfowires are OK,
a
ri
o
c
m
replace the control module
switch.
Brown/Black
u
th Orange
ili
d
t
u
d
U
a
ro
e
Brown/White
Pink
n
p
2
rv
U
0
re
e
0
d
White t 2
Green
es
e
r
h
iz
s
g
r
tGray
i
r
o
h
yRed
h
ig
t
p
r
u
o
a
ll
Illustration HE-70
C
n
A
Control Module Connector
U
ELECTRONIC Control Module Switch Test
83
Connectors
d
e
rv
e
s
re
l
a
u
n
a
M
by
w
la
d
e
e
t
c
i
vi
Red/White
ib
Blue
r
Yellow/Red
h
e
Blacko
S
r
l
l
y
l
p
a
d
A
n
nu
Locked
it o
Bo
a
Black/Red
Terminal —
c
M
u
Orange/Red
e
(No Wire)
e
l
d
c
ic
i
o
Temperature Control
v
r
r
p
eh Brown
e
e
V
S
Blower Switch r
r
y
d
e
t
d
e
s
o
iz
a
Blue
r
Orange/White Dk. Blue/WhiteB
o
m
i
Gray
l
h
i
t
e—
Black
t
l
u
U
a
ic
n
n
h
e
io
U
t
V
a
r
r
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o
t
Orange
Red
p
Orange/Red s
r
a
o
w
m
a
C
i
l
l
Dk. Blue/White r
ti Blower: High Speed
y
e
t
U
b
s
Fan Power
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
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p
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Black
laLt. Blue
0
n
2
n
t
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o
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t
c
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ig
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r
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it
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b
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o
Co
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o
Red/Black
C
r
r
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p
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t
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s
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t
Body
Interface
o
c
im
h
u
l
t
i
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U
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n
p
2
v
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re
er
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ts
ig
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C
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ts
h
rig
84
l
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ts
h
rig
ed
v
r
e
s
re
er
t
as
m
ili
t
U
l
a
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M
Blue/Black
Green/Black
ce
i
rv
e
S
y
d
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e—Green/White
l
ic
h
Ve
d
ti e
ib
h
o
pr
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it o
c Yellow/White
u
od
Blue/White
r
p
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Servo Harness
d
ztoe Main Harness
i
r
ho
t
u
a
Un
Yellow/Black
by
w
la
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d
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e—
l
ic
h
Ve
ce
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rv
e
S
l
a
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an
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ra
er
o
t
p
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o
Green/Black
w
m
a
C
i
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ti
y
er
Defrost Motor
t
U
b
as
d
e
m
t
ili
bi
t
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h
U
o
2
r
0
p
aw
l
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t
io
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t
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ig
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e
r
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it
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o
Yellow/White o
b
p
p
i
r
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h
o
Co
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oYellow/Black
C
r
r
r
p Floor Motor
d
e
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s
iz
it o
a
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c
h
u
lim
t
i
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t
u
d
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U
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r
e
n
p
2
rv
U
0
re
e
0
Blue/White 2
s
d
e
t
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r
Blue/Black
h
iz
g
r
ts
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h
Vent
Motor
y
h
ig
t
p
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a
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C
n
A
U
85
d
e
rv
e
es
rBlue/White
ts
Yellow/White
h
rig
Green/White
ce
i
rv
e
S
l
a
u
n
a
M
Brown/White
d
te
i
ib
h
o
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w
la
l
y
a
d
n
o
nu
o
i
B
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Yellow/Black
c
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Brown/Black
e
e
Blue/Black
l
d
c
ic
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v
r
Green/Black
r
p
eh
e
e
V
S Yellow/Black
r Control Harness d r
Black
y
e
t
d
e
to Servo Harness
s
o
iz
a
r
B
Yellow/White
Purple
o
m
i
—
l
h
i
t
t
le
u
Blue
Blue/Black
c
U
a
i
n
Pink
n
h
e
io
Blue U
White
t
Dk. Green V
Blue/White
a
r
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te
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poBlack
Lt. Green
s
Green/Black
r
a
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m
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Green/White
ti Yellow
er
t
U
by
s
a
d
Orange
Brown/Black
Orange
Lt. Green
e
m
t
ili Yellow
biBrown/White
t
i
Pink
UControl Harness
oh
2
r
w
0 to Control Switch
p
la White
0
Green
n
2
n
y
o
t
i
o
b
i
t
h
t
Gray
c
d
Red
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Red
a
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it
y
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l
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Green
t
u
od
U
a
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ed
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p
2
v
Harness
U
e
rControl
er
00
s
to
Main
Harness
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
l
Al
86
HVAC (Heating, Ventilation,
and Air-Conditioning)
l System
d
l
l
A
ts
h
rig
ve
r
e
s
re
Ma
nu
al
Co
ntr
y
d
Bo
e—
l
ic
h
Ve
er
t
as
m
ili
t
U
a
u
an
Shut-Off Valve
M(Manual)
e
ic
v
r
e
S
ol
ed
z
i
r
ho
t
u
a
Un
Spacers
d
ti e
ib
h
o
pr
n
it o
c
u
od
r
p
Transition Duct
re
Ele
ct
Co
by
w
la
Shut-Off Valve
(ELECTRONIC)
ntr
ol
ce
i
rv
e
S
l
a
u
an
M
y
d
Bo
e— Defrost Duct
l
ic
h
Ve
n
io Vent Tube
t
a
Plenum
r
er
Blower Assembly
o
Controller
t
p
(ELECTRONIC)
r
as
o
w
m Expansion Valve
a
C
i
l
l
ti
y
er
t
U
b
Receiver/Drier d
as
m
te
i
i
l
i
ib
h
Ut
2
ro
w
0
p
a
Controller (Manual Cable)
l
0
n
2
n
y
o
t
Fresh Air Inlet
i
o
b
Resistor
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
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o
Co
ep
oh
C
r
r
r
p
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e
t
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s
iz
io
a
r
Floor tDuct
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
Plenum Air Inlet
2
d
es
t
e
r
h
iz
g
r
ts
i
Evaporator
Assembly
r
o
h
y
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ig
t
p
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u
o
a
Illustration AC10
ll
C
n
A
Heating and Air-Conditioning System (HVAC)
U
Ele
ct
Co
ntr
ol
Ma
nu
al
Co
ntr
ol
87
Principles
l
w
d
a
a
e
l
u
n a licensed automotive air-conditioning
rv Utilimaster recommends that
WARNING:
specialist
a
e
by
s
work on
the vehicle's air-conditioning
(HVAC) system.
M
d
re
e
e
t
c
i
s
t
vi
ib
h
r
h
e
g
iNOTE: Details about your vehicle
o information provided here.
S may vary from the general
r
l
ll r
y
p
a
d
General
A Information
n
o
nu
o
i
B
a
t
This section overviews the basic principles and service procedures
that apply to air-conditioning systems.
c
M
—
u
Automotive air conditioning
of the air in the passenger compartment. Refrigeration
e is the cooling or refrigeration
e
l
d latent heat of vaporization, and refrigeranticflow.
c practical use of heat transfer,
is accomplished by making
i
o
r
h
rv
p
e
e
Heat Transfer
V
re
S
r
y
d
e
If two substances
t of different temperaturezeare placed near each other, the heat in the warmer
d substance will
s
o
i
always travel
to
the
colder
substance
until
both
are
of
equal
temperature.
For
example,
a cake of ice in an
a
r
B
o
m not communicate its coldness
iceboxlidoes
to the bottle of milk standing nearby. Rather,
— the heat in the warm
i
th The amount of heat that transfers from onelesubstance
milktautomatically
flows into theuice.
to another is
c
U
a
i
expressed by the British Thermal
nBTU is the amount ofhheat required to raise the
n Unit or BTU. One
o
ethe temperature of one pound of
i
U
temperature of one pound of water 1° F [0.55° C].
t For example, to raise
V
a
rmust be added for 1° F [0.55° C] rise in
r C], one BTU of heat
liquid water from 32° F to 212° F [0° C to 100°
e
o
t
temperature or a total of 180 BTUs of heat.
lower the temperature of one pound of
rp Conversely, in orderastoheat
liquid water from 212° F to 32° F [100°oC to 0° C], 180 BTUs of
must be removed from the water. w
m
C
i
la
l
r
i
t
y
te
U
b
s
a
d
m
te
i
i
l
i
ib
h
Ut
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
Illustration
AC15
a
ll
C
n
Operation Principles
A
U
88
l
w
d
a
a
e
l
u
v
When a liquid boils r(changes
to a gas) it absorbs heatnwithout raising the temperature of the resulting gas. When
ytemperature of the resulting
a off heat without lowering the
e
b
the gas condensess(changes back to a liquid), it gives
M
dover a flame. With each BTU of
liquid. For example,
at 32° F [0° C] in a container
re place one pound of water
e
e
t
c
i C]. Thus, after it has absorbed
iits temperature rises 1° F [0.55°
heat that the
tswater absorbs from the flame,
b
v
i
h
r
180 BTUs
of heat, the water reaches a e
temperature of 212° F [100° C].
Even though the flame continues to
oh F [100° C]. The water, however, startsl
S of the water remains atr212°
righeat to the water, the temperature
givelits
ythe gaseous state. It continuesp to boil until the water has passed off into thea
l
toAboil or change from the liquid to
d
n
nu
atmosphere as vapor. If this vapor
it also would show a temperatureaof
it o
Bo were checked with a thermometer,
212° F [100° C]. In other—
words, there was a rise of only
c 180° F [100° C] (from 32° F to 212° F [0°MC to
u
e
l
100° C]) in the water and
d the flame applied many more than 180iBTUs
ce of heat.
c vapor temperature evenrthough
i
o
In this case, the heathis absorbed by the liquid in the process of boiling and disappears in the vapor.
rv If the vapor
p
e
e
were brought into
Vcontact with cool air, the hidden
re heat would flow into the cooler air as theSvapor condensed
back to water.erScientists refer to this natural
law
y Water has a latent
d as the latent (hidden) heat of vaporization.
t
d
e
heat of vaporization
of 970 BTUs and aizboiling point of 212° F [100° C]. This meansothat one pound of water
s
a
B C]. Conversely, the
at 212°mF [100° C] will absorb 970 BTUs
or of heat in changing to vapor at 212° F—[100°
i
l
h
vapor
i will give off 970 BTUs ofuheat
t in condensing back to water at 212° F [100°
e C]. This tremendous heat
t
l
U which occurs when a liquid
transfer,
boils or a vapor condenses, forms the basic
ic principle of all conventional
n
na to be a refrigerant,
h
refrigeration systems. For U
a liquid
it
must
also
have
a
low
e boiling point. That is, the
io
t
V
temperature at which it boils must be lower than
Refrigerant 134a is the liquid most
a the substance to be cooled.
r
r
e
o
commonly used in automotive air-conditioning systems because in
it boils at -5.7° C [-21.7°
pwell below passengeracompartment
st an open container
r
F]. Here is a liquid that boils or vaporizes
temperatures
and, in vaporizing,
o
w
m
a
absorbs tremendous amounts of heat without
getting any warmer
itself.
C
i
l
l
ti
y
er
t
Refrigerant Flow
U
b
as
d
The boiling temperature ofm
refrigerant increases when the pressure exerted on it increases, and theteboiling
temperature decreases when
ili the pressure decreases. In the air-conditioning system, liquid refrigerant
bi is stored
t
i
h by the expansion
U pressure. When the liquid refrigerant is released into the evaporator
in the receiver under high
o
2
r
valve, the resulting
0 decrease in pressure lowers its temperaturelatowits boiling point. As thep refrigerant flows
0
through the evaporator
coils, warm passenger compartment air, or outside air, passesnover the outside surface of
2
n
t
the coils. As
it boils, the colder refrigerant absorbs heat from
o
by the air and thus coolstiothe passenger compartment.
i
h
t
g the air is absorbed by the boiling refrigerant,
d which is convertedutoc a gas. The refrigerationracycle
The heat
ifrom
e
r
it remains to be done:od
o
is nowyunder way. To complete the cycle, the following
b
p
p
i
r
r
o
Co1. Dispose of the heat in the gas. roh
ep
C
r
r
d
2. Convert the gas back to liquid for p
reuse.
e
t
e
n
s
iz
it opoint in the refrigerant cycle.
a
r
3. Return the liquid to the starting
o
c
h
u
lim
t
i
The compressor draws the gasdout of the evaporator and
forces
it
under
high
pressure
and temperature into the
t
o the outside air stream atauthe front of the vehicle. The
U
condenser, which is locatedrin
temperature
of the gas ed
n
p
2
rv
entering the condenserrisehigher than that of the outside
U air. As the heat transfers
0 from the hot gas to the ecooler
0
s where
air, the refrigerant condenses
back to a liquid. The liquid under high pressure
2 now returns to the reservoir
d
e
t
e
r
it is stored for reuse.
h
iz
g
r
ts
i
r
o
h
Heat can be h
transferred from a comparatively cooler passenger compartment
to the hot outside
y
g air because of
i
t
p
r
the difference
between
the
refrigerant
pressure
in
the
evaporator
and
the
pressure
in
the
condenser.
At the
u
o
l
a
l
C reduces the boiling point
evaporator,
the expansion valve reduces the pressure and thereby
A below the
Un
Latent Heat of Vaporization
89
temperature of the passenger compartment. Thus, heat transfers from the passenger compartment to the boiling
l
d the compressor raises the acondensation
refrigerant. In the condenser,
point above theaw
temperature of the
e
l
u
v
outside air. The heat,rtherefore, transfers from the condensing
refrigerant to the outside
n
y air. The expansion
a
e
b
valve and the compressor
simply
create
pressure
conditions
that
permit
the
laws
of
thermodynamics to provide
s
M
e
d
r effects.
the desired cooling
e
e
it
s
ic
t
b
v
The function
regulate the flowi of refrigerant into the evaporator and is
h of the expansion valve is toeautomatically
r
h
g
i
the dividing
point in the system between
high- and low-pressure refrigerant.
o
S
r
r
l
y
ll
p
a
d
A
System Components
n
o
nu
o
i
B
a
t
Compressor
c
M
—
u
e
e
l
The compressor is a pump
da drive belt. It draws in low-pressure refrigerant
c powered by the engine rvia
ic gas and
i
o
v
exhausts it as high-pressure
gas.
Your
vehicle
has
one
of
two
types
of
compressors:
piston
or
rotary.
r
p
eh
e
e
V
r
S
Condenser
r
y
d
e
t
d compressed
The air-conditioning
condenser is located
s
zein front of the radiator. The condenser receives
o
i
a
r
B through the condenser,
(therefore
heated) refrigerant gas from
flows
o the compressor. As the hot refrigerant gas—
m
i
l
h
it is cooled
i by air passing over theutfins. The cooled, compressed refrigerant gaslecondenses to liquid refrigerant,
t
which
U then flows into the receiver/drier.
a
ic
n
n
h
e
io
U
Control Module
t
V
a
rdash. The control module
This driver-operated device is mounted on the
er sets the cab temperature, blower
o
t
speed, and distribution of airflow for driver
rpconvenience. (See also
as the System Controls section .)
o
w
m
a
C
i
Evaporator Assembly
l
l
er to the right side ofUtheti dash and extends into the engine compartment.
t
by The
The evaporator assembly is mounted
s
a
d vehicle
resistor, thermostat, outside/recirculation
door, heater core, and evaporator core are serviced fromethe
m
t
i instrument
interior. When servicing iany
li of the above components, it is not necessary to loosen or removeithe
b
t
panel. The drain hose and
U right-angle expansion valve are serviced from the engine compartment.
oh
2
r
w
Evaporator Core 0
p
la
0
n
2
yrefrigerant flows into the
The evaporator
o expansion valve and ion
t core used is a fin and tube core where liquid
i
b
t
h
t
vaporizes g
as it passes through the core. When the cooling
cthe liquid refrigerant flows
d system is in operation,
a
i
u
e
r
r
from the
it evaporator where it isodallowed to evaporate at apreduced
y condenser unit through a flexible hose tobthe
o
p
pressure,
to
cool
the
evaporator.
Air
is
blown
through
the
evaporator
fins
and
is
thus
cooled
by
the
evaporator.
i
r
r
h
o
Co
ep
o
Expansion Valve
C
r
r
p
d to cooling requirements.
erThe restrictive
t
The expansion valve releases refrigerantninto the evaporator according
e
io the refrigerant flowrizto the evaporator, results inasreduced evaporator
effect of the expansion valve, while limiting
t
o
c of a valve and a temperature-sensing
m and bulb. The valve
pressure. The expansion valve consists
capillarylitube
h
u
t
i
t outlet tube of the
u
is connected to the inlet tube o
ofdthe evaporator, and the sensing
bulb is clamped toUthe
a
r
ed
n
evaporator.
p
2
v
U
re
00 of the diaphragm. Theser
The expansion valvedis opened and closed by opposing pressures on either2side
t contains refrigerant. Asrethe
e bulb that is clamped to the evaporator outlet tube usually
temperature-sensing
h
z
i
r temperature rises, the refrigerant expands and exerts
ts to open
igpressure against the diaphragm
evaporator outlet
r
o
h
yincreased cooling. As theievaporator
h and admit more refrigerant into the evaporator for
g
the valve farther
outlet
t
p
r
u
o
a
ll
C
n
A
U
90
temperature falls, the pressure
Inlet pressure on the
l
w opposite side of the
d against the diaphragm isadecreased.
a
e
diaphragm then startsvclosing the valve. The valve tends
u to seek a position to controll the refrigerant flow to
n
r
maintain near-maximum
a
e cooling from the evaporator.
by
s
M
d
re
The temperature-sensing
bulb, clamped to theesuction (outlet) tube on the evaporator,
measures the temperature
e
t
c
i
s
i
of the refrigerant
the temperature variation
t in the suction tube and transmits
b to the expansion valve. This
v
i
h
r
temperature
variation
regulates
the
refrigerant
flow
to
the
evaporator
core.
When the bulb senses a high
h
e
ig
o
S
r
r
temperature,
the valve opens and allows
to flow into the evaporator core. When the bulb senses a l
l
y refrigerant
l
p
d
low
temperature,
the
valve
starts
closing
to
reduce
the
refrigerant
A
ua
n flow to the evaporator core.
io
Bo
an
t
c
M
—
u
e
e
l
Some vehicles are equipped
dcompressor similar to service valves. Theseicvalves do
c with manual valves atrthe
i
o
not have service ports
and
are
used
only
to
isolate
the
compressor.
h
rv
p
e
e
V
re
Receiver/Drier Unit
S
r
y
d
e
t
dreceiver and
e refrigerant under pressure in a combination
The air-conditioning
system stores the liquid
s
z
o
i
a
dehydrator. (See Illustration AC15.)rThe pressure in the receiver normally variesBfrom about 552 to 2068
o
m
kPa (80
ili to 300 PSI), dependinguonththe surrounding air temperature and compressor
e— speed. The drier serves
t
l
the
Upurpose of removing any traces
a of moisture thatnmay have accumulatedhiinc the system. Even one drop of
n
moisture will cause an air-cooling unit to malfunction.
e
U
tio
V
a
Service Valves
r
er
o
t
pservice valve in the high-pressure
s
These valves are similar to a tire valve. The
line (from compressor to
r
a
o
condenser) allows access to the high-pressure
side of the system
m for attaching a service hose and pressure law
C
i
l
r
gauge. The service valve in the low-pressure
line (from evaporator
to compressor) allows access to theylowti
e
t
U
b
pressure side of the system for attaching
a service hose and pressure gauge.
as
d
Suction Receiver/Drier
m
te
i
i
l
ti between the condenser and the evaporator that removes water
iband acts as a
The receiver/drier is aUcanister
h
storage reservoir for2liquid refrigerant.
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
Illustration AC20
ig
t
p
r
u
o
Make
Hose
Connections
a
ll
C
n
A
U
Manual Valves
91
System Controls Overview
l
d
w
aare peculiar to the A/C andlaheater system of
This section deals with the
e controls and components that
u
v
n
y
Utilimaster vans with
ercable (manual) and electronicacontrols.
s
M
b
d
The air conditioner
system (stacked coil
re used on the Utilimaster walk-in
e vans is an integral air-conditioner/heater
e
t
c
i
s
i
design) and tis composed of an A/C-heater vassembly
mounted on the right
of the cowl panel and an air
b side
i
h
r
distribution
plenum
and
ductwork
located
behind
the
instrument
panel.
The
control
module assembly
h
e
g
i
o
S
r
(Illustrations
AC25 and AC30) is located on the instrument panel,
r to the right of the steering column. The l
l
y
l
p
outlet
A registers can be adjusted to ddirect air.
ua
n
o
o
i
B
an
t
CABLE (Manual) Control Operation
c
M
u
e—
e
l
(1) Blower Control Switch
d
c
ic
i
o
v
r
h Off and High, voltage pis applied to the Low blower relay and voltageris applied to the
When in any mode e
except
e through
e the blower switch is on Low, voltage isSapplied
V
blower switch and
the blower motor resistors. rWhen
r
the blower motor
te resistors to the blower zmotor.
ed The blower motor runs at low speed.ody
s
a more air to the defrost orrito the floor ducts, close the dash louvers by Brotating them on their
To direct
even
o
im
pivotsilapproximately
90 degrees. th
e—
t
l
u
U
a
ic Heater and A/C
0Off, 1Low, 2Medium, 3High
n
n
h
Cable Control
o
e
i
U
t
V
The blower motor is a variable-speed motor. The
the
r
ra higher
voltage applied to the motor, the faster the speed.
With the
o
6
1e
t
p
r
heater and HVAC control head in the Off position,
no voltage is as
o is off, and no voltagem
w
applied to the Low blower relay, the relay
a
C
i
l
l
ti
is applied to the blower motor. er
t
U
by 7
s
d
As the blower switch is movedato the Medium Low and Medium
e
8
m
t
i part of the blower motor
positions, the switch bypasses
i
l
i
b
tvoltage to be applied to the blower
i
resistors, allowing more
h
9
U
o
motor, which will increase
its speed. When the blower motor w
2
r
0 voltage is applied directly to the la
p
switch is on High,0battery
10
n
2
n
blower motor.t The blower motor runs at maximum speed. y
io
o
b
i
t
h
t
c
d
a
ig assembly is located on the top of the evaporator
The resistor
u
e
r
r
d Illustration AC25 po
it
ythe inside of the vehicle.
case on
o
b
p
i
r Module CABLE (Manual)
r A/C
o Switch
h
pControl
o
(2)
CA/C
e
o
C
r
r
r
p
Switch inbutton light onA/C compressor on. Switch out d
te
e
n
s
z
button light offA/C compressor off.io
a
ri
t
o
c
m
i
Or (depending on model) switchuto the rightA/C compressor
compressor on.
th off. Switch to the leftA/C
il
d
t
u
U
a
ro
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
3
2
1 0
FLOOR
DASH
RECIRC
COLD
92
HI/LO
FRESH
HOT
l
w
d
a
a
e
l
u
Air comes out defroster
ducts in Floor position
n position). Air comes out floor
rv ducts in Defrost position (right
y
a
e
b
(left position). s
M
e
d
r To enable the floor/defrostcefunction the dash/Hi-Lo lever
NOTE:
te must be in the Hi-Lo
i
s
i
t
b
v
position.
i
h
r
h
e
g
i
S
(8) Dash/Hi-Lo
ro
l
lr
y
l
p
a
d
A comes out dash louvers in theo Dash position (left position).nLever in Hi-Lo position (right position) enables
u
Air
n
o
i
B
a
the floor/defrost function.
t
c
M
—
u
e
(9) Recirc/Fresh
e
l
d
c
ic
i
o
v
r
h position), air is drawn from
In Recirc position (left
r air is drawn
p the cab area and recirculated. In Fresh position,
e
e
e
in from the outside.
r
S
rV
y
d
e
(10) Cold/Hott
d
e
s
z
o
i
a
r (cold, left; hot, right).
B
Controls
oair
mthe temperature of the outlet
i
—
l
h
i
t
le
ut
ELECTRONIC
Control Operation
c
U
a
i
n
h
(11) Blower Control Switch
e
io
Un
t
V
a
Heat and A/C
r
r
Off, Low, Medium Low, Medium, High
e
Electronic Control
o
t
p The higher the voltage
r
The blower motor is a variable-speed motor.
as
o
w
11
m
applied to the motor, the faster the speed.
With the heater control
a
C
i
l
l
i relay,
head in the Off position, no voltage
y
eris applied to the LowUtblower
t
b
the relay is off, and no voltage iss applied to the blower motor.
a
d
e
12
m
t
When in any mode exceptliOff and High, voltage is applied to the
i
i
b
t
i
blower relay, and voltage
is applied to the blower switch and the
h
U When
16
17
o
blower motor resistors.
the blower switch is on Low, voltage
is
2
r
w
15
18
0
p
a
applied through 0the blower motor resistors and the blower relay
l to the 14
19
n
2
n
y
blower motor.
The blower motor runs at low speed.
o
t
20
i
o
b
i
t
h
13
t
c
d Low and
a
ig switch is moved through positions Medium
As the blower
u
e
r
r
d
it resistors,
y the switch bypasses part of the blower bmotor
o
Medium,
o
p
p
i
r
r
o more voltage to be applied to the blower
allowing
h motor, which will ep
o
C
o
C
increase its speed. When the blower motorrswitch is on High, voltager
Illustration
r AC30
p
eELECTRONIC
is applied directly to the blower motor.nThe blower motor runs ated
Control Module
A/C
t
s
z
o
maximum speed.
i
a
r
ti
o
c
m
The resistor assembly is locatedubehind the right-hand floor
th duct. (See Illustration HE5,
ili AC10, and
d
t
u
AC30.)
d
U
a
ro
e
n
p
2
rv
(12) Cold/Hot (Temperature
U
0
re Control)
e
0
2
d operates the water valve located in the engine compartment.
etos the
The temperature control
The water flow
t
e
r
h
iz
heater core is proportional
to the setting of the control knob.
g
r
ts
i
r
o
h
ywater valve located in the iengine
h control operates an electric servo attached to the
g
The temperature
t
p
r
u
o
compartment.
in the heater coolantlinlet
l hose.
a The water valve is located in the engine compartment
C
n
A
U
(7) Floor/Defrost
93
(13) Function Selector (ELECTRONIC)
l
d
w
a each for dash door, floor door,
The function selector actuates
e electric servomotorsone
la defrost door, and the
u
v
n
r
outside/recirculating
the compressor operation
dependent upon the
a
e door. In the A/C and Defrost positions,
by is core;
s
M
evaporator thermostat
settings.
The
thermostat
senses
the
temperature
of
the
evaporator
the cutout
e
d
r
e
e
temperature s
is 32 F ±2° F [0° ±1.1° C] (clutch
t temperature is 42° F ±2° F [5.5°
c is disengaged), and the cutin
i
i
t
b
v
±1.1° C] (clutch
i
h is engaged).
r
ig
e
h
S the outside/recirculation
r function selector in the Off position,
Withlthe
ro door is in the Recirculate Air position. It l
y
l
p
is closed
d through the system. The blower motor is off.
A to outside air, and no air passes
ua
n
o
o
i
B
an
(14) Max A/C
t
M
e—outside/recirculation doordisucin the Recirculated Air position. All of thecair
e
In the Max A /C position the
l
c louvers, except for a small
i operates
ipanel
o amount of floor bleed. The A/C compressor
discharges through the
v
r
h
r
e setting.
in this function control
ep
V
r
Se
r
(15) A/C
te
dy
ed
s
z
o
i door is open to the outside, and outsideBair is discharged through
In the A /Caposition the outside/recirculation
r
o
the panel
limlouvers with a small amount
i
th of floor bleed. The A/C compressor operates
e— at this function control
t
l
u
setting.
U
a
ic
n
n
h
(16) Panel
e
io
U
t
V
a
r is open to the outside,
In the Panel position the outside/recirculation door
er and outside air is discharged through
o
t
the panel louvers, except for a small amount
rpof floor bleed. as
o
w
m
(17) Panel/Floor
a
C
i
l
l
ti
er
In the Panel/Floor position the outside/recirculation
doorUis open to outside air. Air is discharged through
t
bythe
s
heater outlet floor ducts and panel
a louvers.
d
e
m
t
(18) Floor
ili
bi
t
i
Uoutside/recirculation door is open to outside air. Air is discharged through
In the Floor position2the
oh the heater
r
w
0 a small amount of bleed is directed to thelawindshield.
outlet floor ducts,0and
p
n
2
n
(19) Defrost/Floor
t
io
o
by
i
t
h
t
c hose nozzles and heater
d the windshield defroster
a
ig
In the Defrost/Floor
position air is discharged througheboth
u
r
r
d
y ducts in approximately equal amounts.bit
o
outletpfloor
o
p
i
r
r
h
o
(20)
CoDefrost
ep
o
C
r
r
r is also a small
In the Defrost position the air is dischargedpthrough the windshield d
defroster hose nozzles. There
e
t
e
n
s the air.
amount of floor bleed. The A/C compressor
iz setting to help dehumidify
io operates in this control
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
94
l
w
d
a
a
e
l
u
v refrigerant in automotive air-conditioner
The most commonlyrused
systems has been Refrigerant-134a.
n
y
a
e
Refrigerant 134a sis nonexplosive, nonflammable, and heavier than air. Althoughbit is classified as a safe
Mto protect the parts involvedd and the person who is working
refrigerant, certain
re precautions must be observed
e
ite
ic
on the unit.ts
b
v
i
h
r
h
e
ir g
S
ro
l
l
y
l
p
a
d
A
u
n automotive air-conditioning specialist
o recommends that a licensed
WARNING: Utilimaster
n
o
i
B
a
work on the vehicle's air-conditioning (HVAC)
t system.
c
M
—
u
e A/C refrigerant and lubricant
Avoid breathing
vapor or mist!
e
l
d
c system discharge occurs,
ic
i
o
v
r
If accidental
ventilate
work
area
BEFORE
resuming
service.
h health and safety information
r lubricant
p may be obtained from refrigerant and
e
Additional
e
e
r
S
manufacturers.
rV
y
d
e
t
Always
wear safety gogglesewhen servicing any part of the refrigerant
s
odsystem.
a Certain precautions mustribez observed to protect the parts involved Band
the person who is
o
m
—
it li working on the unit.uth
le
c
U
a
i
To remove R-134a from the A/C system,
n use service equipment
h certified to meet the
requirements of
e
UnSAE J2210 (R-134atiorecycling equipment).
V and temperatures, evaporates so
a atmospheric pressures
r
Liquid Refrigerant 134a, at normal
r
o to freeze anything ittecontacts. For this reason, be very
quickly that it has the tendency
p
s in contact with the skin and especially
careful to prevent any liquidr refrigerant from coming
a
o
w
the eyes.
m
a
C
i
l
l
ti types of oil. It is therefore recommendedy that
Refrigerant-134a. is readily
er absorbed by most
t
U
b
a bottle of sterile mineral
oil and a quantity of weak boric acid solution be kept nearby
s
a
d
when servicing the air-conditioning system.
m
te
i
i
l
Should anytliquid
i refrigerant get into the eyes, immediately use a few dropsibof mineral oil
to wash them
out, then wash the eyes clean with a weak boric acid solution.
U
oh Seek a
doctors
aid immediately, even though irritation w
may have stopped.
2
r
0
p
la
The20
refrigerant in the system is always under pressure.
Because thensystem is tightly sealed,
n
y
heat
to build up excessively.
t applied to any part would cause this bpressure
io
o
i
t
h
t
dweld, use a blow torch,ucsolder, steam clean, bake
a
ig To avoid a dangerous explosion, never
e
r
r
d immediate area of anypopart of
it of heat on or inothe
y body finishes, or use an excessivebamount
p
the air-cooling system or refrigerant
supply
tank
while
they
are
i
r closed to the atmosphere,
r
o
h
p
o
whether
filled
with
refrigerant
or
not.
C
e
o
C
r
pr so rapidly that thed resulting
The liquid refrigerant evaporates
refrigerant gas rwill displace
te the oxygen,
the air surrounding the area
where it is released.e The refrigerant will displace
n
s
z
so always work in well-ventilated
areas to prevent
a
ri suffocation.
tio
o
c
m
The discharge of refrigerant
gas near openth
flame can produce a verylipoisonous gas. This
u
i generated when a
d
t
gas will also attack
all bright metal surfaces.
This poisonous gas is
u
d
o
ainhaling the fumes from Uthe leak detector.
e
flame-type leakr detector is used. Avoid
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Refrigerant Precautions
95
l
w
d
a
a
e
l
u
nincinerate refrigerant containers.
rv
Never intentionally
drop, puncture, or
a
e
by
s
M
d
Never
above 125° F [52° C].
re store or heat refrigerant containers
e
e
t
c
i
s
tIf it is necessary to carry a container
of refrigerant in a vehicle,
do not carry it in the
vi
ib
h
r
passenger
compartment.
h
e
g
i
Sscrew cap to protect the valve
ro and safety plug of the Refrigerant- l
ll r Always replace the metal
y
p
a
134a container from d
damage when not in use.
A
u
n
o
io
B
an
t
c
M
—
u
e
e
l
d NOT use refrigerant canned for pressure-operated
CAUTION: cUse only Refrigerant-134a. Do
ic cause a
i
o
v
r
accessories
(such
as
boat
air
horns).
This
type
is
not
pure
Refrigerant-134a
and
will
r
p
eh
e
malfunction.
e
V
r
S
r refrigerant and R-134a refrigerant
y
R-12
must never be mixed, even in the smallest
of amounts.
d
e
t
d
e other. If the refrigerants are mixed, compressor
They are incompatible with zeach
failure is
s
o
i
a likely to occur.
r
B
m
ho and components in the A/C system.le—
it li Use only specified lubricants
t
If lubricants other than
u
U
those specified areaused, compressor failure is likely to occur.icAll fittings and O-ring seals
n to provide a leakproof
h seal and aid assembly and
should be coatednwith clean mineral o
oil
e
i
U
t
disassembly.
V
a
r
r
e
Do NOT introduce compressed o
or refrigerant component,
tcontainer
p air to any refrigerant
s
because contamination will occur.
r
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
WARNING: Never heat a refrigerant container with an open flame. If the container must be
warmed, place the bottom of the container in a pail of warm water.
96
l
w
d
a
a
e
l
u
(See also Refrigerantrv
Precautions section.)
n
y
a
e
b
s
M
dthe work area is wellre
e
e
WARNING:
Before opening thecrefrigerant
system, make sure
t
i be done on or near
s
i
Welding or steam-cleaning
operations shouldbnot
tventilated.
vother
i
h
r
refrigeration
system
lines
or
air-conditioning
parts
on
the vehicle.
h
e
ir g
o
S
r
l
l
y
l
p
a
d
A
nof dents or kinks to prevent loss of systemnu
Maintaining Chemical Stabilityo
o
CAUTION: All metal
tubing lines should be free
i
B
acrosscapacity due to line restriction. Do NOT letctthe connection become kinked, crushed, or
M
—
threaded. (See
le Illustration AC20.) du
ce
c
i
i
o
Never bend
r of less than four times the diameter rofv the hose.
h flexible hose lines to a pradius
e
e
Do NOT
allow flexible hose linesre
to come within a distance of 2.5" [6.5 mm]Sof the exhaust
V
manifold.
y
d
er
t
d
e
s
z
o with new lines if
flexible hose lines iregularly for leaks or brittleness and replace
a Inspect
r
B
deterioration
or
leaking
is
found.
o
m
ili When disconnectinguany
th fitting in the refrigerant system, the system
e— must be discharged of all
t
l
c gauge readings. Open
U
a proceed very cautiously,
refrigerant. However,
regardless of ithe
n
n
h
fittings very slowly,
keeping your face
and
hands
away
so
that
can occur. If
ioloosened, allow it toVebleednooffinjury
U
t
pressure is noticed when a fitting is
very slowly.
a
r
er in an attempt to remove moisture.
o
Alcohol should never be used in the refrigeration system
t
p could occur. as
Damage to system components
r
o
w
m cap immediately to prevent the entrance
a
If any refrigerant line is C
opened to the atmosphere,
i
l
l
r
i internal compressor wear or pluggedylines
of moisture and dirt. eMoisture
and dirt can tcause
t
U
b
in the condenser and
s evaporator core, expansion (orifice) tubes, or compressor inletd screens.
a
Remove sealing
imcaps from subassemblies just before making connections for final
ite assembly.
Use a small ial mount of clean mineral oil on all tube and hose joints. Use newbO-ring
seals
t
i
dipped in U
mineral oil when assembling joints. The oil will aid in assembly and
help
provide
h a burr or a
o
a leakproof
joint. O-ring seals and seats must be in perfect condition because
2
r
piece 0
of dirt can cause a refrigerant leak.
p
aw
l
0
n
2
Itt is important to use the proper wrenches when
seal fittings. n
io ontheO-ring
o
by making connections
t
h
(See Illustration AC20.) The use of improper wrenches may damage
connection. Theti
c
g
d
fitting should always be backed
up with a wrench to u
prevent distortion of
ra
ri opposing
te connecting
d
i
y
connecting lines or components. When
the flexible
hose connections, it iso
o coupling to which it isrp
p important that the crimped fitting and
ib flare nut, as well asprthe
o
h
attached, be held at the same time
using two different wrenches
to prevent turningo the fitting
C
e
o
C
r
r
and damaging the seat. Tighten
p tubing connectionsdto the specified torque. er
t
e
n
s
z
o
i
a
r
ti
o
c
m
u
th
ili
d
t
u
d
U
a
ro
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Lines and Fittings Precautions
97
The life and efficient operation of the air-conditioning system depends upon the chemical stability of the
d foreign materials, such as dirtalor moisture, contaminate theawrefrigeration system, they
refrigeration system. When
e
l
u
change the stability ofrv
the refrigerant and polyalkalinenglycol (PAG) refrigerant oilyor ester refrigerant oil. They
a
e
b internal corrosion and
also affect the pressure/temperature
relationship,M
reduce efficiency, and could cause
s
e
d
abnormal wear rof moving parts. The followingegeneral practices should be followed
to ensure chemical stability
te
c
i
i
in the system:
ts
b
v
h
ir g
l
Al
r
Se
i
h
o
pr
l
y
a
d
n
o it becomes necessary toiodisconnect
nu
CAUTION: Whenever
a hose connection, wipe away any
B
a
t the possibility of dirt entering the system.
dirt or oil at or near the connection to eliminate
c
Mto
— connection should be capped,
Both sides ofethe
plugged, or taped as soon as possible
u
e
l
d Remember that all air contains moisture.
prevent thecentrance of dirt and moisture.
ic Air that
i
o
v
r
enters any
part
of
the
refrigeration
system
will
carry
moisture
with
it,
and
the
exposed
r
p
ehwill collect the moisture equickly.
e
surfaces
V
r
S
r tools clean and dry. Thisd includes
y
Keep
the manifold gauge set and all replacement
parts.
e
t
d
e
s
z
o
tube through
a When adding polyalkalineriglycol (PAG) refrigerant oil, the container/transfer
B
which
the
oil
will
flow
should
be
exceptionally
clean
and
dry.
Refrigerant
oil
must be as
o
m
—
h
it li moisture-free as possible.
t
le
u
c
U
a
i
When it is necessary to open an air-conditioning
system to the atmosphere, have
n time as possible
n ready so that as little
h
o
everything needed
will be required to perform the
e
i
U
t
V any longer than necessary.
operation. Do NOT leave the air-conditioning
system open
a
r
r
o has been opened,
te it should properly evacuated before
Anytime the air-conditioning system
p
s
r
recharging.
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
98
l
w
d
a
a
e
l
u
NOTE: Details
provided here.
n from the general information
rv about your vehicle mayavary
y
e
b
s
M
e
d
r
e that a licensed automotive
te air-conditioning specialist
WARNING:
Utilimaster recommends
c
i
s
i
t
b
v
(HVAC) system. i
h work on the vehicle's air-conditioning
r
h
e
ir g
o
S
r
l
l (Refrigerant System) y
l
p
a
Overview
d
A
u
n
it o the system's high- and low-pressure readings.
Diagnosis of the refrigerant system
Bo must be done by analyzing
an
c
M
— to the chart shown in Illustration
Compare the pressure readings
AC40 to determine if the system pressures
u
e
e
l
d system tests must be satisfied to obtain
are normal. The conditional
c requirements for the refrigerant
ic accurate
i
o
v
r
pressure readings. eh
r
p
e
e
r the pressure readings will not be accurate and
S could indicate
If the conditional
r Vrequirements are not satisfied,
y
d
e
t system is not functioning properly.
e If the conditional requirements cannotodbe satisfied, the pressure
that a normal
s
z
i
a
readings will not be accurate but can be
B in the system.
or used to determine what is causing the problem
m
i
—
l
h
i Use of Manual Valves ut
t
Proper
le
c
U
a
i
n
hthe back seated position, the lowManually operated valves arenused in some vehicleoapplications.
When in
e
i
U
t
pressure valve is open between the suction sideaof the compressor andV
the evaporator. The high-pressure valve
r
r
is open between the discharge side of the compressor
and the condenser.
o
te This is the normal operating position.
p
s
In the front seated position, the low-pressure
side of the compressor from the
or valve cuts offmtheaofsuction
evaporator. The high-pressure valve C
cuts off the discharge side
the
compressor
from the condenser. law
i
l
ti
y
er
t
Attaching the Manifold Gauge Set
U
b
as to the refrigerant system when performing any of the various tests.
d If
e
Test equipment must be connected
m
t
i
ili
charge-station type of equipment
is used, follow the instructions of the manufacturer. To attachiba manifold gauge
t
h
U gauge port valves, proceed as follows:
set to the service access
o
2
r
0manifold gauges set valves fully clockwiselatowclose the high- and low-pressure
p
1. Turn both
hoses at the
0
n
2
n
y
gauge.
service (Schrader)
o access gauge port valves
t Remove the caps from the high- and low-pressure
i
o
b
i
t
h
t
ingthe high- and low-pressure lines.
c
d
a
i
u
e
r
r
d
it hoses with adaptersocontaining
oto the
2.y Connect the high- and low-pressure refrigerant
depressing pins
b
p
p
i
r
r
h access gauge port valves.
o
Co respective high- and low-pressure service
ep
o
C
r
r
r
3. Connect the hoses attached to the p
manifold center fitting todrefrigerant supply tank and vacuum
pump
e
t
e
n
valves.
s
iz
io
a
r
t
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Diagnosis and Testing
99
Checking for Leaks
l
d
w
a gauge set valves at the maximum
1. Attach the manifold
clockwise
e gauge set. Leave both manifold
la
u
v
n
r
position. Both
6080 PSI [414551ykPa] 75° F [23.9° C] with
a
e gauges should show approximately
b
s
M
the engine
not
running.
e
d
r
e
e
it closed, open the refrigerant tank
s little or no pressure is indicated,
ic leave the vacuum pump valve
2. If very
t
b
v
i to the counterclockwise position.
r
(suction)
manifold gauge set valve
h
e
gh and turn the low-pressure
ir valve,
ro
l This opens the system to tankSpressure.
l
y
p
a
d
nfilter plug, and the shaft seal for leaks, usingnu
Check all connections, the
o compressor head gasket,ioil
o
B
a
either the Rotunda Electronic Leak Detector 055-00014
t or equivalent.
c
M
—
u oil from the shaft seal area to reducee
le
NOTE: Use compressed
air to blow off excessive
d
c
ic
i
o
v
r
the possibility
of
an
erroneous
detection
of
refrigerant
retained
in
the
refrigerant
oil.
r
p
eh
e
e
V
r
S
Electronic Leakr Detector
y
d
e
t
d or equivalent) is
e
s
The battery-operated
Electronic Refrigerant
o
iz Leak Detector (Rotunda Model No. 055-00014
a
r
Bcan be detected by the
an electronic
o a much smaller type of refrigerant leak than
m instrument that will locate
i
—
l
h
i leak detector. Followuthe
flame-type
t directions with the leak detector to ensureleabsolute accuracy. When the
t
U
instrument
is set to the On position,
itself and is ready
a it automatically calibrates
ic for detecting. The countern
n
h
ticking/beeping signal will speed
e to the refrigerant leak.
U up as the flexibletioprobe head comes closer
V
a
r
Expansion Valve Test
er
o
t
rp system, the expansion
as valve and capillary tube assembly will w
In the properly operating standard refrigerant
o
C maximum refrigerant
imsystem efficiency. Corrosion of the polished metal
maintain the refrigerant flow required for
la
l
r
i
t
y
e valve stem in the expansion
surfaces of the internal valve seat tor
can cause erratic compressor suction
and
U invalve
b same
s
discharge pressures. This would
be
seen
as
a
sudden
increase
the
discharge
(high)
pressure
and,
at
the
a
d
e
m
time, the suction (low) pressure
will
suddenly
decrease.
The
reverse
might
also
happena
sudden
decrease
in
t
i
i
l
i
b
discharge (high) pressuret combined with a sudden increase in the suction (low) pressure. Refrigerant
system
i
U of sludge or moisture may also cause a similar compressor suctionohand
contamination in the2form
dischargepressure reaction.00The blocking action of sludge in the valve seat
awwill cause an increase pinrthe compressor
l
2 and a reduction of the suction pressure.yWhen the sludge clears othen valve seat opening, the n
discharge pressure
t
b
io
ti
h
t
c
g
d
u
ra
ri
te
d
i
y
o
o
p
ib
r
rp
o
h
p
o
C
o
C
re
r
pr
te
ed
n
s
z
o
a
ri
ti
o
c
m
i
u
th
il
d
t
u
U
a
ro
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
Fig 3
h
ir z
ts
ig
r
o
h
Illustration
AC25
y Assembly
h
ig
t
p
Expansion
Valve
and
Capillary
Tube
r
u
o
a
ll
C
n
A
U
Al3.
100
discharge pressure will suddenly
reduce, and the suction lpressure will suddenly increase.
w Moisture, on the other
d
a
a
e
l higher compressor
hand, may cause the valve
u the valve is stuck closed, the
v to stick in any position. When
n
r
y
discharge pressureeand temperature will soon thawathe frozen area and release the
b refrigerant, causing a sudden
s
M
drop in compressor
discharge
pressure
and
increase
in
suction
pressure.
When
e
d the valve is stuck open, the
r
e
e
increase in evaporator
(suction) pressure and
it of the frozen area, and the
ictemperature aids in the thawing
ts
ib
expansionhvalve begins to function again.rv
h
e
ig
o
S
r
r
To test
l
l the expansion valve:
y
l
p
a
d
A 1. Start the engine and runoat fast idle (approximately 1500
n RPM) in Max A/C mode and blower speed
nu on
o
i
B
a
t
High for approximately 10 minutes.
c
M
—
u
e
e
l
d temperature-sensing bulb. (See Illustration
2. Remove the insulation
from the expansion valve
c
ic AC25.)
i
o
v
r
Remove thehclamp and expose the bulb to
p the high engine compartment temperatures.erThe expansion
e
e
valve should
open
with
a
resulting
drop
in
V
r compressor discharge pressure and an increase
S in
r
y
compressor
te suction pressure. zed
d
s
o ice or spray with
i bulb into a container of salted, melting, chipped
a
3. Immerse
the temperature-sensing
r
B
m refrigerant. The expansion
— in compressor discharge
ho valve should close with a resulting increase
ili liquid
t
e
t
l
u
pressure.
U pressure and a reduction
a in compressor suction
ic
n
n
h
The compressor pressuresU
observed in Steps 2 and
e deliberate. If at any time during
io 3 should be smoothVand
t
a
the pressure change period you should see a hesitation
followed by a rjump in the pressure-gauge readings, the
r
o
tevalve stem may also be interfering with
system may be contaminated and require cleaning.
Corrosion
of the
p
s
r
a
proper valve operation.
o
w
m
a
C
i
l
l
r does not increase when
If the compressor discharge pressure
ti performing Step 3, the expansion valve willy have
e
t
U
b
to be replaced.
as
d
m
te
i
i
l
i
ib
h
Ut
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
101
Measuring Temperature
l
d
w
a
This guide was developed
systems. The information
e to assist in evaluating air-conditioning
la given is the result of
u
v
n
r
extensive testing inelaboratory conditions. Actual results
a may vary by as much as
by±4° F [±2.2° C] due to
s
M
variances in installation
technique
or
chassis
manufacturer.
e
d
r
e
e
it performance. Warmer air can
scontent of the ambient air plays
ican important role in air-conditioner
The moisture
t
b
v
i
h moisture than cooler air. Inerthe cooling process, air oftenhreaches
contain more
saturation temperature, at
g
i
o
S
r
whichl point no additional cooling can occur without a corresponding
r drop in moisture content. As relative l
y
l
p
a
humidity
a greater percentage of the systems refrigeration capacity is needed
d
A of the air to be cooled increases,
u
n
o
to extract the moisture, and lessBis available for actual cooling.
io
an
t
c
M
—
In the process of removing
of air
emoisture, it is important thatduice not be allowed to form and block the flow
e
l
c
ic
through the cooling (evaporator)
coil. The system iso
equipped with a thermostat that will turn off the
i
v
r
r discharge air
compressor clutch when
pto a temperature at which ice could form. The
eh the evaporator coil drops
e
e
V
temperature willr be approximately 37° F [2.8°rC] when the thermostat cycles the system off.S
e
tthe
dytemperature as the
edthe air entering the evaporator coil be the same
When testing
system it is important that
s
z
o
a
rithe air-conditioner control to the NORMAL
B A/C position (not
ambientmair surrounding the coach. Set
o
i
—
l
h
MaxtiA/C).
t
le
u
c
U
a
i
n
UnR -134a T E M P E RtiAoT U R E P R E S S U RVeEhC H A R T
a
TEM P F
P S IG *
TrE M P F
P S IGe*r
TEM P F
P S IG *
o
t
p
16
15.69
60
57.47
110
C
146.50
r
as
o
18
17.04
65
64.10
112
O
151.30 aw
m
C
i
l
l
i
20
18.43r
70
71.19
114
N
156.10
t
y
te
U 78.75
b
22
E
19.87
75
116
D
161.10
s
a
d
24
V
80
86.80
118
E
im21.35
ite166.10
26
A til 22.88
85
95.40
120
N b 171.30
i
UP
28
24.47
90
104.40
122
Sh
176.60
o
2
r
w
30
91
124
0 O 26.10
p E 182.00
a106.30
l
0
32 2
R
27.79
92
126 n
R
187.50
n
y 108.20
o
t
i
b
34
A
29.52
93
110.20
128
193.10 tio
t
h
c130
d
ig36
u
T
31.32
94 te
112.10
R
198.90ra
r
d
i
y
o
38
O
33.17
95
114.10
135
A
210.70
o
b
p
p
i
r
r
h100
o
40
R
35.07
124.30 ep
140
N
229.40
Co
o
C
r
r
42
37.03
128.50
145
G r 245.80
p 102
d
e 263.00
e
n
44
39.05
104
132.90
150
Et
s
z
o
i
a
r137.30
45
40.08ti
106
155
281.00
o
c
m
i
h
u
l
50
45.48
108
141.90
160
300.00
t
i
d
t
u
55
165
320.00
U
a
ro51.27
ed
n
p
2
v
340.80 r
U
0 170
reInch G auge
e
0
*Pounds per Square
s
2
d
t
e
re
h
ir z
Illustration AC40
ts
igCharts
r
o
Air-Conditioner Pressure Performance
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
102
l
w
d
a
a
e
l
u
Dash outlet temperature
nthe high-pressure (discharge)y and low-pressure (suction)
rv and pressures developed on
a
e
b
side of the compressor
s indicate whether or not the
M system is operating properly.
e
d
rthe system, attach the manifoldcegauge set with both gauge valves
1. To test
te at the maximum clockwise, or
i
s
i
t
b
v
closed,
to attach the refrigerant
i tank.
h position. It will not be necessary
r
h
e
g
i
S the engine running at 1500roRPM, all controls set for maximum cooling,l
l2.r Check the system pressuresywith
l
at least 5 feet from any wall. pUse a large fan in front of the condenser toua
d
A and the front of the vehicle
on conditions for 510 minutes in order foran
simulate vehicle motion.
Bo Operate the system undertithese
pressures to stabilize.
c
M
u
e—
e
l
d depend on the temperature of the surrounding
c indicated on the gauges
ic air and
3. The actual pressures
will
i
o
v
r
hHigher air temperatures along
r
the humidity.
At idle
p with high humidity will give higher systemepressures.
e
e
V
r
S
speed and
a surrounding air temperature of 100110° F [37.743.3° C], the high pressure may go as
y
er300 PSI [2069 kPa] or more.
hightas
conditioner
under
d
ed If it becomes necessary to operate the air
s
z
o
i
these
a conditions, keep the highr pressure down with a fan directed at the condenser
B and radiator.
o
m
i4.li Measure the ambient (outside)
th air temperature with a thermometer heldlein—front of the condenser.
t
u
U Referring to the Temperature
Pressure Chart (see Illustration AC40),
ic compare the suction and
nathe values shown. ion
h
discharge pressuresUto
e
t
V
a
NOTE: Relative humidity of the airraffects air-conditioner
er performance. As humidity
o
t
p
increases, air-conditioning performance
decreases. s
r
a
o
w
m
a
5. If the pressures are within or near
the specified limits,
but the cooling performance is poor, the problem
C
i
l
l
ti
may be related to the heater
unit is a stacked coil design yin
ercontrol valve. The Uevaporator/heater
t
b of
s passes through both the evaporator and heater coils. The smallestdamount
which the conditionedaair
hot engine coolantiin
mthe heater coil will affect A/C performance. Both the inlet and outletiteheater lines at
l
the unit should be
ti cool if the heater control valve is functioning properly. Adjust or replace
ib a leaking
h
U
cable-operated valve or proceed to the Voltage Test (Temperature Control).
2
ro
w
0
p
a
6. If the discharge
are not within the specified limits, see the
l
0 (High Side) or suction (Low Side) pressures
n
2
n
y
possible
causes chart below.
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
High
Side
Pre
ssure
r
r
o
Co
Too Low
Too High
ep
oh
C
r
r
r
p
• Low refrigerant charge
• Collaps
ed hos e on high s ide
d
e
t
e
• Expans ion valve s tuck clos edn
• Clogged
receiver/drier
s
iz
io
a
• Ice on evaporator due to tdefective
thermos tat
r
cing ice in expans ion valveho
• M ois ture in s ys tem caus
u
lim
t
i
• Inoperative or defective
compres s or
•
Overcharge
d
t
u • Defective condensUer fan
d
o
a
r
e
n
p
2
• Clogged condens
fins
rv
U
0 sertuck
re
e
0
• Expans ion valve
open
2 in s ys tem
d
es
• Contaminants
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Too Low
Too High
Low Side Pressure
Measuring Pressure
103
Receiver/Drier Test
l
d
1. Operate the air conditioner
for about 5 minutes.
e
ua
w
la
n
rv
y
a
e
2. Slowly move
your
hand
across
the
length
of
the unit from one end to thebother. There should be no
s
M
d
noticeable
re difference in temperature. ce
e
t
i
s
t spots are felt, it indicates that
vithe unit is restricting the refrigerant
3. If cold
ib flow, and the receiver/drier must
h
r
h
e
g
ibe replaced.
S
ro
l
ll r
y
p
a
d
Magnetic
A Clutch Test
n
o
nu
o
i
B
a
t in as it should, the battery should be checked
1. If the magnetic clutch on the compressor does not pull
for
c
M
—
u
operation voltagel(10
e volts minimum).
d
ce
c
i
i
o
v coil.
r disconnect the electrical connector at therclutch
2. If the operating
h voltage is within specifications,
p
e
e
V voltage to the coil feed wire.
re If the clutch engages, the clutch is OK, and
S the electrical
3. Apply battery
r
y
d
e
t is elsewhere in the system.
problem
d
e If the clutch does not engage, replace the clutch.
s
z
o
i
a
r
B
Excessim
Moisture
o
—
l
h
i the characteristics of an airuconditioner
t
t
le air passing through the cooled
One
of
is that it will remove moisture from
c
U
a
i
nthe evaporator core, and
n condenses, runs off
evaporator core. This moisture
h is drained from the evaporator
o
e
i
U
t
case. Because the A/C system is a draw-through
(blower downstream
V of the evaporator core), the
a design
r
r
primary cause of condensation dripping or blowing
into
the
passenger
compartment
is air being drawn through
e
o
t
p
s air-leak paths, thereby inhibiting
the drain tube, housing seals, holes or cracks
r in the housing, or other
aconditions
o
condensation drainage. In some instances,
due
to
environmental
(leaves or other foreign material aw
m
C
i
lis
l
r
i
plugging the drain) and sometimes mechanical
conditions (damaged
or kinked drain tube), the condensation
t
y
e
tevaporator
U of these conditions exist, condensation maybdrip
prevented from draining from the
case. If either
s
a
d
from the blower housing or be blown from the instrument panel registers.
e
m
t
li
bi
Performing the followingtiinspection and corrections can best eliminate the cause of insufficientievaporator
case
h
drainage or leaks. 2 U
ro
w
0
p
a
l Replace any missingngrommets, plugs, or
0 vehicle for missing grommets, plugs, or seals.
1. Inspect 2
the
n
y
seals. t
io
o
b
i
t
h
c the evaporator case-tod
at
ig for correct sealing of the evaporatortcase-to-plenum
u
2. Inspect
gasket. Tighten
e
r
r
dand the cowl panel. po
i the evaporator case
ydash retaining nuts to correct a seal leak between
o
b
p
i
r
pr
o
Co3. Inspect for possible air leaks aroundrthe
ohrefrigerant lines at thereevaporator
case. Seal anyCleaks around
r or
p Insulating Tape YZ-1,dCaulking Cord D6AZ-19560-A,
the refrigerant lines with Motorcraft
e
t
e
n
equivalent.
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
104
l
w
d
a
a
e
l
u
Overview
n
rv
y
a
e
b
The temperature s
is controlled by adjusting the center
knob
on
the
control
head.
M
d
re
e
e
t
c
With the control
set
to
the
Max
Cold
position,
the
output
of
the
dash
potentiometer
will be more than 11 volts.
i
s
i
t
b
v
i
h is fed to Pin 9 of the servoemotor.
r The motor is then driven
This voltage
to the Max Cold position. As the dash
h
g
i
o
S the voltage is decreased,r and the servo is driven to match the voltagel
control
r is turned to the Max Hot position,
l Pin
y
l
p the output of the dash potentiometer willabe
set
at
9
(Red/Black
wire)
of
the
servo.
At the Max Hot position
d
A
u
n
less than 0.75 volts.
it o
Bo
an
c
M
Blower Motor Power e—
u
e
l
d
c supplied from the blowerrmotor
ic
i
o
Blower motor power
is
power
relay.
v
h
r
p
e
e
e
r power to the coil on Pin 88 (Blue wire) Sof the relay. A Gray
Blower motor power
r V relay supplies ignitiondswitch
yin any position except
e
wire from Pin
t 85 of the relay to Pin 20 ofzthe
d
e controller is grounded through the controller
s
o
i the blower motor.
Off, closing
a the relay contacts and energizing
r
B
m
ho
ili Control
Blower
t
e—
t
l
u
U
a
icto the motor, the faster the speed.
n
The blower motor is a variable-speed
motor. The higher
the voltage applied
n
h
e
U
tio
V
When the heater and HVAC Control Head is rinathe Off position, no voltage
is applied to the Low blower relay.
r
e
o
The relay is Off, and no voltage is applied to the blower motor. t
p
r
as
o
When in any other mode except Off, voltage
is applied to them
Low blower relay, and voltage is applied to thew
C
la
li
blower switch and the blower motorr resistors.
i
t
y
e
U the blower relay and blower motor resistors
b to the
st voltage is applied though
When the blower switch is in a
Low,
d
blower motor. The blowerim
motor runs at low speed.
te
i
l
i
ib part of the
As the blower switch is
h
Utmoved though positions Medium Low and Medium, the switch bypasses
blower motor resistors,
the blower motor. This will
2 allowing more voltage to be applied to w
roincrease its speed.
0
p
a
0motor switch is in High, voltage is applied tol the coil of the High blower
When the blower
n relay. The High n
2
y
o
t
i
b
blower relay
t voltage is applied tio
h is energized, removing the blower motordresistors from the circuit. cBattery
g
a
i the blower motor though the High blowerterelay contacts. The blower
directlyrto
u motor runs at maximumorspeed.
d
i
y
p
ib
ro
rp
A/C
Clutch Control
o
h
p
o
C
e in defogging the windshield.
o and in defrost mode toraid
C
r
The A/C clutch is energized in Max A/C, A/C,
r
p
d
teflows to the
e
n
The A/C clutch is supplied power to the
coil
on
Pin
85
of
the
relay
(Blue
wire).
Current
then
s
z
i
io
a allowing current to
rcloses
deicing switch on the Black/Whitectwire. The de-icing switch
above 35° F [1.7°m
C],
o
u the relay and allowing
flow to the control module, grounding
th the contacts to close. tCurrent
ili flows to the relay on
d
u
Pin 30 through the closed contacts
U switch mounted on theed
ro out Pin 87a on thenaGreen wire to the high-pressure
p
2
receiver/drier. From theehigh-pressure switch the U
current flows to the low-pressure
rv
0 switch located on theeinlet
r
0
fitting of the evaporator. Then, via the Green wire, current flows to the A/C
2 clutch.
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Voltage Tests (Temperature Control)
105
ELECTRONIC Control Module Switch Test
l
w
d
a
a
e
1. Disconnect wire
harness
from
the
Control
Module.
(See
Illustration
AC45.)
l
u
n
rv
a
e
by wire) of the control
2. Using a DVOM
(Digital
Voltmeter),
measure
the resistance from Pin 1 (Black
s
M
e
dOff position.
modulerconnector
to Pin 2 (Purple wire)
e with the control switch in the
e
t
c
i
s
t than 2 ohms, go to the nextrstep.
vi If more than 2 ohms, check
ib for an open circuit in the Black or
If less
h
h
e
g
iPurple wire. If wires are OK, Sreplace the control module switch.
ro
l
ll r
y
p
a
wire)
of
the
control
module
connector
to
Pin
A 3. Using a DVOM, measureodthe resistance from Pin 1 (Black
u
n
3 (Blue wire) with the B
control switch in the Max A/C
it oposition.
an
c
M
u
e—go to the next step. If more
than 2 ohms, check for an open circuit in theeBlack or
l
d module switch.
c are OK, replace the control
ic
i
o
Blue wire. If wires
v
r
r
p Pin 1 (Black wire) of the control moduleeconnector
eh measure the resistanceefrom
4. Using a DVOM,
to Pin
V
r
S
r
4 (Dark
te Green wire) with the control
dy
edswitch in the A/C position.
s
z
o
i step. If more than 2 ohms, check for an open
If a
less than 2 ohms, go to the next
r
B circuit in the Black or
o
m
i
h OK, replace the control module switch.le—
il Dark Green wire. If wiresutare
t
U 5. Using a DVOM, measure
a the resistance fromnPin 1 (Black wire) ofhthe
ic control module connector to Pin
n
5 (Light Green wire)Uwith the control switch
ioin the Panel position.Ve
t
raIf more
If less than 2 ohms, go to the next step.
er
o
Yellow/Black
Black
t
p in the
s
than 2 ohms, check for an open circuit
r
a
o are OK,
w
Black or Light Green wire. IfC
wires
m
a
Yellow/White
i
Purple
l
l
replace the control module switch.
ti
y
er
t
U
b
s
Blue
Blue/Black
6. Using a DVOM, measure
a the resistance from
d
e
m
Pin 1 (Black wire) of
the
control
module
t
li
Dk. Green
bi Blue/White
connector to Pin t6i (Yellow wire) with the
i
Uin the Floor/Panel position.
control switch
oh Green/Black
2
r
Lt.
Green
w
02 ohms, go to the next step. If more la
p
0
If less than
n
2
n
than 2t ohms, check for an open circuit in the
io
o
by Yellow
Green/White
i
t
h
t
c
Black
d
a
ig or Yellow wire. If wires are OK, replace
u
e
r
r
d
it
ythe control module switch.
o
Brown/Black
Orange
o
b
p
p
i
r
r
hfrom
o
Co7. Using a DVOM, measure the resistance
ep
o
Brown/White
C
Pink
r
r
Pin 1 (Black wire) of the control module
r
p
d
e
connector to Pin 7 (Orange wire)
with
the
t
e
n
s Green
iz White
io
control switch in the Floor position.
a
r
t
o
c
im
l
If less than 2 ohms, go d
touthe next step. If more th
Gray
i
Red
t
u
o
U
than 2 ohms, check for
r an open circuit in thena
ed
p
2
v
Illustration
Black or Orangeewire. If wires are OK, U
0 Module AC45
r
er
0
Control
Connector
replace the control
module
switch.
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
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o
a
ll
C
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A
U
106
8. Using a DVOM,dmeasure the resistance from Pinl 1 (Black wire) of the controlwmodule connector to Pin
e the control switch in the Floor/Defrost
la
8 (Pink wire) v
with
position.
ua
an
r
y
e2 ohms, go to the next step. If more than 2 ohms, check forban open circuit in the Black or
If less than
s
M
re If wires are OK, replace thee control module switch. ed
Pink wire.
it
ic
ts
bof the control module connector to Pin
v from Pin 1 (Black wire)
i
9. Using
a DVOM, measure the resistance
h
r
h
e
rig9 (White wire) with the controlS switch in the Defrost position.
ro
l
l
A
y
al
p
d for an open circuit in the Black
If more than 2 ohms, check
n or White wire. If wires are OK, replacenuthe
o
o
control module switch.B
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107
ELECTRONIC Control Module Tests
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Mode Switch rv Rec Motor
Defrost Motorn
Panel Motor
Floor Motor
A/C Clutch
y
a
e
b
Off
Closed
Closed
Closed
Closed
Off
s
M
d
Max A/C re
Open
Closed
Open
Closed
On
e
e
t
c
A/C ts
Closed
Closed
Open
Closed
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i
viClosed
ib Closed
h
r
Panel
Closed
Open
Off
h
e
g
i
Floor/Panel
Closed
Closed
Open o
Open
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S
r
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l
l Floor
Closed y
Closed
Closed
Open
Off
l
p
a
d
A Floor/Defrost
u
n
Closed
Open
Closed
Open
Off
o
n
o
i
B
a
Defrost
Closed
Open
Closed
On
t Closed
c
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r module on the Purple wire to the modeSswitch to the
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In the Off position
e
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dyare driven closed.
epower relay is de-energized, and all mode door
control module
s
z
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rv current flows from the control
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M relay is energized. Thedmotors
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are driven to position for
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panel door is driven
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NOTE: This
Utilimaster
rvvehicle was designed usinganEnglish (S.A.E.) measurements.
y
e
b must be used, but
providessmetric conversion equivalents as a courtesy if metric tools
Mvalues given in this manual.
e
d
Utilimaster
does
not
warrant
metric
r
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S
Torquer Specifications
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A
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o
nu
Description
N•m io
Ft•Lb
B
a
Expansion Valve to Evaporator
Core
21–27 ct
15–20
M
—
u
e
Liquid Line to Expansion
Valve
14–20
10–15
e
l
d
c
ic
Liquid Line to Receiver/Drier
Suction Line to
41–47
30–35
i
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v
r
h
r
Evaporator Core
p
e
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e
r 34
S
Suction Line
25
r Vto Compressor
y
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22
18
t to Compressor
d
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s
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Compressor
Fitting
Tube-O
41
30
i
a
B
Compressor
to Manifold Hold Down
26
or Clamp 35
m
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l
h
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t
t
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T-Bolt
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e
it o7.3–8.5
Un
V (44 In•Lb)
Pressure Switches
a 5
r
r
Control Head Illumination Bulbs
o Trade Number 53te
p
Plenum to Cowl 1/4" Studs
27
20
r
as
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Plenum to Cowl 3/8" Studs
43
32
m
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Evaporator to Cowl
27
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io
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Line FittingshTorque
i
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NOTE:riUse
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Copper
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A
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Torque, Voltage, and Charge Specifications
111
Blower Voltage Chart
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r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
l
Al
112
Connectors
l
l
A
ts
h
rig
ed
v
r
e
s
re
ce
i
rv
e
S
y
d
o
B
Red
e— Black
l
ic
h
Ve
l
a
u
n
a
M
Dk. Blue/White
n
it o
c
u
od
r
p
re
d
ti e
ib
h
o
pr
Black
by
w
la
Lt. Blue
ce
i
rv
e
S
Dk. Green
l
a
u
an
M
y
er Gray
t
d
ed Red/Black
s
z
o
i
a
r
B
o
m
—
Green th
ili
e
t
l
u
Dk. Blue/White
U
a
ic
n
Main Harness
n
h
e
Body Interface
to ControlUHarness
tio
V
a
r
er
o
t
Yellow rp
asBlue Dk. Blue/White
o
w
m
a
C
i
l
l
ti
y
Black
er
t
U
b
Green/White
as
d
e
m
t
ili
bi
t
i
h
U
o
Orange
2
r
0 Brown
Blue
p
aw
l
0
n
2
Orange/White
n
t
io
o
by
i
t
h
t
Blower Resistor
cSpeed
d
Blower: High
a
ig
u
e
r
r
d
it
y
o
Red
o
b
p
p
i
r
r
o
Gray
Co
ep
oh
Dk. Green
C
r
r
r
p
d
e
t
n
s
ze
o
i
i
a
r
t
Red/White
o
c
h
u
lim
t
i
d
t
Black/White u
Red
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
Dk. Blue/White
2
d
Dk. Blue/White
es
t
e
r
h
iz
g
r
ts
i
A/C
Clutch
Relay
r
Blower Power h
o
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
113
Blue
Yellow/Red
d
ve
r
e
s
re
l
a
u
n
a
M
Red/White
Black
by
w
la
d
e
e
t
c
Black/Red
i
i
b
v
i
h
Orange/Red
er
o
S
Temperature
Control
r
l
l
y
l
p
Brown
a
d
A
n
o
nu
o
i
B
a
Blower Switch
t
c
M
—
u
e
e
l
d
cGreen/White
ic
i
o
v
r
h
r
p
e
e
e
V
Blue/White
r
S
r
Brown/White
y
d
e
Yellow/White
t
d
e
s
o
iz
a
r
B
o
m
i
—
l
h
i
t
t
le
u
Yellow/Black
c
U
a
i
n
h
Blue/Black
e
UnBrown/Black tio
V
Green/Black
a
r
r
te
po
s
Control Harness
r
a
w
to Servo Harness Co
m
a
i
l
l
ti
y
er
t
U
b
s
Pink a
d
White
Blue
e
m
t
i
ili
b
t
i
Purple
Black
U
Black
oh Yellow/Black
2
r
w
Dk. Green 0
p
la
0
n
2
Yellow/White
Purple
n
y
o
t
Lt.
Green
Orange
i
o
b
i
t
h
Yellow
t
c
d
Blue
ig
Blue/Blackra
u
e
r
d
it
y
o
Control Harness
o
b
p
p
i
r
r
Dk.
Green
Blue/White
to Control Switch
h
p
o
Co
e
o
C
r
r
rGreen/Black
p
Lt. Green
d
e
t
e
s
on
iz
i
a
r
t
Black
oYellow
c
Red
im Green/White
h
u
l
t
i
t
u
d
od
U
a
r
Brown/Black e
Orange
n
p
2
v
U
re
er
00
s
Brown/White
Pink
2
d
t
e
re
h
Green
ir z
Gray
ts
Whiterig
Green
o
h
y
h Control Harness
ig
t
p
r
u
o
l Gray
a
l
C Red
to Main Harness
n
A
U
Locked
Terminal
(No Wire)
ts
h
rig
114
ed
v
r
e
s
re
l
a
u
n
a
M
by
w
la
d
e
e
t
c
ts
bi
vi
i
h
r
h
e
ig
Blue/Black
o
S
r
r
l
l
Green/White
Brown/Black y
l
p
a
d
A
u
n
Brown/White
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
Brown/White
e
e
e
rGreen/Black
S
r V Yellow/White
y
d
e
t
d
e
s
o
Blue/White
ir z
a
B
o
m
i
—
l
h
Control
i
t Harness
t
le
u
c
U
to aMain Harness
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
Blue/Black i
Brown/Black
Blue/White
ili
t
ib
Brown/White
h
U
2
w Vent Motor pro
0
a
Rec Motor
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
n Yellow/Black ize
s
Green/Black
o
Green/White
i
a
r
t
Yellow/White
o
c
h
u
lim
t
i
d
t
u
Defrost Motor
d
oFloor Motor
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
115
Hood
l
w
d
a
a
e
l
u
n
rv
y
a
e
bstraps,
s
M
WARNING:
Hood
should
be
opened
by
releasing
the
hold-down
lifting the hood, and
dbefore working
re the prop rod. Be sureceprop rod is properly engaged
engaging
on the vehicle.
e
t
i
s
i
t
ib
h
rv
h
e
g
i
S
ro
l
ll r
y
p
a
d
A
u
n
Hinge
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
r
p
Sponge Tape
eh
e
e
V
r
S
r
y
d
e
Hinge
t
d
e
s
z
o
i
a
RIM
r
B
Fenderim
o
Gas Spring
—
l
h
i
t
e
t
u
cl
Aluminum
U
a
i
n
Center
h
e
io
Section
Un
t
V
a
r
r
te
po
s
r
a
o
w
m
Upper la
C
Grille
i
l
Support
(Stone
ti
er
Bracket
Guard)
t
U
by
s
a
d
e
m
t
ili
bi
t
i
Bumper
h
U
Hazmat
2
Placard
ro
w
0
p
a
l
0
n
2
Reflector
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
RIM Fender
o
b
p
p
i
r
r
Side Marker
Turn
h
p
o
Headlight
Hood
Co
Light
e
o
Light
C
r
r
Support
r
p
d
e
t
e
n
s
o
iz
i
a
r
t
Hood
o
c
Hood
Prop
im
u
Hold Downth
l
i
Stop
t
(Jeep) Strap
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d Prop Catch
t
e
re
h
ir z
g
ts
Illustration HO10 ri
o
h
h
RIM Hood Assemblypy
ig
t
r
u
o
a
ll
C
n
A
U
116
l
w
d
a
a
e
l
u
n
rv
y
a
e
b
s
M
e
CAUTION:
Some trucks have aneautomatic locking gas strut. d
Do NOT close the hood without
r
e
t
c
first
depressing
the
orange
button
on
the
passenger
side
gas
strut
to disengage the safety
i
s
i do so could result in damage
t
b
v
locking
mechanism.
Failure
to
to
the
hood.
i
h
r
h
e
ir g
S
ro
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
c
M
u
e—
e
l
d
ic
o
Strut Support ic
v
r
r
Bracket eh
p
e
e
r
S
Bulb Seal
rV
y
d
e
t
d
e
s
o
ir z
a
Gas
B Spring
Grab
o
m
i
—
Handle
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
Bracket
ili
bi Guide
t
i
h
Hazmat
U
o
Backer
Placard 2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig Rod
u
Prop
e
r
r
d Latch
it
y
o
o
b
p
p
i
r
r
h
p Reflector
o Guide
Bumper
Co
e
o
Headlight
C
r
r
Side
r
p
Grommet
Marker
d
e
Bumper
Turn
Light
t
e
n
Light
s
iz
Prop Catch tio
a
r
o
c
h
u
lim
t
i
d
t
u HO11
d
o
U
a
Illustration
r
e
n
p
2
Fiberglass
rv
U Hood Assembly
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
117
RIM Hood Adjustment
CAUTION: Loosen fasteners only
l
wadjustment.
d
a
enough to allow
a
e
l
u
Removing the nut completely or
n
rv
y
a
1. To align theeRIM fender to the quarter panel,
repetitive b
adjustment will damage the
s
M
two-waydlocknuts and require
loosen the
re two nuts attaching the hoodcesupport
e of both the nut and the
replacement
t
strutts
to the hood brace. (See Illustration
i
i
bolt.
ib
h
rv
HO15.)
h
e
g
i
S support
ro
l
ll r Loosen the nut attaching theyhood
2.
p
a
d
A strut to the upper gas spring
u
n
o support. (See
it o
an
Illustration HO20.) B
M
e— the hood bumper to duc
e
3. Loosen the nut attaching
l
c (See Illustration HO25.)
ic
i
o
the bumper guide.
v
r
r
p
eh
e
e
V
4. Adjust the fender to fit the cowl castingr and
S
r and torque all nuts to 5dftlb.
y
e
quarter
panel
t
d
e
s
o
(See
Illustration
HO50.)
iz
a
r
B
o
m
i
—
l
h
i
t
le
Frontt Hood Stops
u
c
U
a
i
n
n stops set
h
NOTE: The front U
hood
e
it o
V
the gap between the quarter panel ra
r
o
and fender. (See Illustration
te
p
s
r
HO50.)
a
Illustration HO15
o
w
m
a
C
Support
Strut Support Brace
i
l
l
1. To adjust the gap between the
r quarter panel
ti
enuts
t
U
and fender, loosen the four
to
the
by
s
a side). (See
d
bumper mounts (two each
e
m
t
Illustration HO25.)
ili
bi
t
i
U stops may be set
NOTE: The hood
oh
2
r
w
in place with
0 a setscrew. Remove
p
la
0
n
2
the setscrew
before continuing.
n
t
io
o
by
(SeehIllustration HO30.)
i
t
t
c
d
a
ig
u
e
r
r
2. yAdjust the mounts until the surfaces in the gap
d
it
o
o
b
p
p
i
r
between
the
quarter
panel
and
fender
are
r
h
o
Co parallel when the hood is closed. (See
ep
o
C
r
r
r
p slots to
Illustration HO50.) Use the vertical
d
e
t
e
widen the gap by raising the mounts
s
on or
iz
i
a
r
t
narrow the gap by loweringcthe mounts.
Illustration
HO20
o
imSupport
h
u
l
Upper Gas Spring
t
i
d snug against the u
t
3. Make the rubber bumpers
o
U
a
r
ed
lower hood support.
They should be flush n
p
2
v
U
and perpendicular
reto the extrusion at all points
er
00
s
2
d Illustration HO30.)
of contact. (See
t
e
re
h
z
i
4. Torque all
r nuts to 14-18 ftlb.
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Fender to Quarter Panel
118
l
l
A
ts
h
rig
ed
v
r
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
Hood
d
ti e
ib
Mount
h
o
pr
n
it o
Setscrew
c
u
od
r
p
re
by
w
la
Lower Hood
Support
ce
i
rv
e
S
l
a
u
an
M
y
er Illustration HO25 ed
t
d
s
Illustration
HO30
z
o
Hood Stops
i
a
r
B
Hood Stop
Alignment
o
m
i
—
l
h
i
t
le
ut
c
U NOTE: To secure thealocation
after adjustment,
dill
a
new
7/32"
hole behind the
i
n
n
h
o
adjustment slot and
Torx screw
e (P/N 11300177) or use a
U secure with a newtiself-tapping
V
a
new 1/4-20 x 3/4 bolt and locknut as
a
setscrew
instead
of
the
r Torx screw. (See
r
e
o
Illustration HO30.)
p
st
r
a
o
w
m
a
C
i
l
l
ti
y
er
Grille (Stone Guard) Replacement
t
U
b
as
d
Grille Removal
e
m
t
ili drill bit, remove the rivets on the screen (be sure to remove all ofibthei rivets).
1. Using a #11 or 3/16"
t
h
U
o
2. Remove the2grille (stone guard).
r
w
0
p
a
l
0
Grille Installation
n
2
n
y
o
t
i
o
b
i
t
h
1. Attach
d oversize heads. uc
at
ig the new grille with 3/16" POP rivetstewith
r
r
d rivets with flat washers.
i not available, use standard
y NOTE: If rivets with oversize heads are
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
®
119
Gas Spring (Strut) Replacement
l
w
d
a
a
e
l
u
v
n
rand
y
1. Lift the hood
secure it so that it will staya
e
3. Disconnect thebhood wiring (two places) from
s
M
open when
d (See Illustration HO45.)
the cowl harness.
re the gas springs are removed.
e
e
t
c
i
s
t insert a small flat-blade screwdriver
2. Carefully
vi
4. Remove
ib the bolts on the hood hinge, working
h
r
h
e
g
from
iunder the clip at the bottom of the gas spring.
o the center out. Discard all fasteners. l
r
ll r (See Illustration HO35.) y S
p(You may have to remove insulation to reach a
A 3. Lift up slightly on the clip.odThe spring will slide
n
the bolts.)
nu
o
i
B
a
t 5. While supporting the hood from bothMsides,
off the ball stud. —
c
leremove the clip from the du
carefully remove the two outside 1/420
ce Torx
NOTE: Do NOT
c
i
i
o
screws and move the hood away
h it is difficult to reattach.pr
rv from the
spring because
e
e
vehicle.
V
re
S
4. Repeat rthe same steps for the top ofdthe
y
e
Installation
t
d
e
spring.
s
z
o
i
a
r
1. Position the hood on
B the front of the vehicle.
Installation
o
m
i
—
l
h
i Snap the top of spring onto
t the ball stud.
2. Align the hinge
t
leholes with the holes on the
u
1.
c
U
a
i
cowl.
n
h
2. Repeat for the bottom
e
Unof the gas spring. tio
3. Insert V
new Torx screws with washers in each
a
r
r
Hood Replacement
outside
te hinge hole. Do NOT tighten compo
s
pletely.
(See Illustration HO43.)
r
a
Hood Removal
o
w
m
a
C
i
l
4.
Fasten
new
bolts
and
new
two-way
locknuts
l
1. Lift the hood and secure it sor that it will stay
ti and washers on the cowl side of each ofybolt.
eare removed.
t
U
b
open when the gas springs
as
d
5. Snug the bolts but do not tightentcompletely
at
e
2. Disconnect the hood
mgas springs.
i
i
l
this
time.
i
ib
h
Ut
2
ro
w
0
p
a
l
0
Hood
n
2
n
y
o
t
Wiring
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
Disconnect
d
it
y
ohere
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
Lamp
im
h
u
l
t
i
Assembly
d
t
Fit screwdriver
u
o
U
a
ed
blade under clippr
n
2
v
U
to release gas
re
er
00
s
2
spring from
d
t
e
re
h
socket
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
Illustration HO35
Illustration HO40
a
ll
C
n
A
Release Gas Spring
Hood Wiring
U
Removal
®
120
ed
v
r
e
s
re
l
a
u
n
a
M
w
la
CAUTION: Lifting the hood too high can damage the wiper arms or even break the
windshield. Use extreme caution in this process.
by
d
e
e
t
c
i straps, lifting the hood, and
s
Hood should be opened
by releasing the hold-down
tWARNING:
bengaged
vi
i
h
engaging the prop rod. Be rsure the prop rod is properly
before working on the
h
e
ir g vehicle.
o
S
r
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
rV
y
d
e
t
d
e
s
o
ir z
a
B
o
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
aIllustration HO43 r V
r
Use Torx Screws
o to Center Hood onteTruck Body
p
r
as
o
w
m
a
C
i
l
l
r
ti
y
echeck
6. Lower the hood gently and
the
t
U
b
alignment with the fender
as guides. (See
d
e
m
t
Illustration HO50.)
ili
bi
t
i
h
Uto ensure that it is centered on
7. Check the hood
o
2
r
the structure.
0 If the hood is not centered on
p
aw
l
0
the body,
loosen
the
hood
hinge
bolts
and
n
2
n
t the hood.
io
reposition
o
by
i
t
h
c
at
u
r
rig both sides of the hood straight up ited
8. yLift
d
o
o
b
p
p
simultaneously.
i
r
r
o
Co9. Tighten the two outside Torx screws.roh
ep
C
r
r
p
d
e
t
e
n the hood
10. Tighten the remaining bolts across
s
iz
it o
r
hinges.
IllustrationaHO45
o Connect Electrical Harnesses
c
h
u
lim and Gas Springs
t
i
11. Connect the headlight wire
harnesses. (See
d
t
u
d
U
a
Illustration HO40.)ro
e
n
p
2
rv
U
e
0
e
12. Attach the hoodrgas springs on either side.
0
2
d HO35.)
es
(See Illustration
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
121
13. Lower the hood again to check for the alignment of
d with the hood guide al
the hood guide bumpers
e
brackets. (See
nu
rvIllustration HO50.)
w
la
a
e
by
s
M
14. See the RIM
e Hood Adjustment sectioneto align as
d
r
e
t
necessary.
c
i
s
t
vi
ib
h
r
h
e
g
RIM Fender
S
ri Replacement
ro
l
l
y
l
p
Fender
Removal
a
d
A
u
n
NOTE: Removing the
it o
Bohood first is not
an
M
necessary but it may
— make the parts and uc
e
e
l
fasteners easier
ic
ic to get to. (See the Hoodrod
v
Replacementhsection.)
r
p
e
e
e
V
S
1. Remover the bolts holding the stiffener rto the fender.
y
d
e
t the bolts holding the gaszspring
d
e upper
s
2. Remove
o
i
a
r
B
support bracket to the fender.o (See Illustration
m
i
—
l
h
i HO53.)
t
t
le
u
c
U 3. Remove the pin-and-collar
a
i
n the
n fasteners attaching
h
o
e
i
U
t
fender to the center section and grille bars.
(See
V
a
r
r
Illustration HO70.)
Illustration HO50
e
o
t
p
Check
Hood Alignment
r
4. Remove the headlight.
as
o
w
m
a
C
i
l
l
5. Remove the front turn light. r
ti
y
e
t
U
b
s
6. Remove the side marker
a light.
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00 HO55
s
Illustration
2
Illustration
t Bumper Bracket Adjustments re
ed HO53
Hood Guide
Upper z
Support
Bracket
h
ir
ts
ig
r
o
h
y hold-down straps, liftingigthe hood, and
WARNING:
Hood should be opened by releasing the
h
t
p
engaging
the
prop
rod.
Be
sure
the
prop
rod
is
properly
engaged before working
u
o
l r on the
a
l
vehicle.
C
A
Un
122
l
w
d
a
a
e
l
u
1. Mate the aluminum
in place.
n fender along the seam. Clamp
rv center section to the RIM
y
a
e
b holes into the fender.
sexisting holes in the aluminumMcenter section as a template,ddrill
2. Using the
e
r
e
c
itealigning the drilled holes.
s
i
3. Position
the
interior
angle
support
bracket
to the inside of the hood,
t
b
v
i
h
h
eravailable, use stainless-steel
4.rig
If a Huck fastening system is S
not
1/420
x 3/4" Phillips-head truss bolts to
o
r
l
ll attach the fender to the aluminum
y flat washers, and locknuts.
p
a
d
A
u
n
o
5. Install the side markerBlight.
it o
an
c
M
6. Install the front turn
u
e—light.
e
l
d
c
ic
i
o
v
r
7. Install the headlight.
h
r
p
e
e
e
r using existing holes and attach with bolts.S
8. Position
r Vthe interior angle support bracket
y
d
e
t the strut bracket using existing
d
e holes and attach with bolts.
9. Position
s
z
o
i
a
r
B
o using existing holes and attach with bolts.
m
10.
hbracket
ili Position the rubber bumper
t
e—
t
l
u
U 11. Position upper gas spring
holes and attach with
a support using existing
icbolts.
n
n
h
12. Reinstall the hood.U(See the Hood Replacement
tio section.) Ve
a
r
er
o
t
RIM Fender Repair
p
r
as
w
Use this process if the hood has a hole,ogouge, or scratches. m
a
C
i
l
l
tihood may not be repairable.
y
NOTE: Depending on the
er severity, a damaged
t
U
b
as
d
1. Purchase a flexible bumper/fender
repair kit at an auto supply store.
e
m
t
ili preparation instructions carefully.
bi
2. Follow the kits tsurface
i
h
U
o
2
3. See the Paint
Repair section for touch-up.
r
0
p
aw
l
0
n
2
Fiberglass Repair
n
t
io
o
by
i
t
h
t
c experienced technicianrausing
If the fender
drepairs can be made byuan
ig has a small crack, hole, gouge, or scratch,
e
r
d
a commercially
available body filler repair kit. it
y
o
o
b
p
p
i
r
r
Larger
available fiberglass
o repair kit.
Co repairs can be made by an experienced
ep
ohtechnician using a commercially
C
r
r
r
p store.
1. Purchase a repair kit at an auto supply
d
e
t
e
n
s
iz
it o instructions carefully.
2. Follow the kits surface preparation
a
r
o
c
h
u
lim
t
3. If paint repair is necessary,
see
the
Paint
Repair
section.
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Fender Installation
123
RIM Fender Reinforcement
l
aw
l
CAUTION: ySome steps are timesensitive,bso it is important to have all
d and materials at hand before
the tools
te
starting.
i
ib
h
o
l
pr
a
u
n
it o
B
an
If the crack is less—
than 2-1/2" long, adhere c
M
u
e
e
l
and fasten an aluminum
reinforcement
d
c
ic
i
o
v
r
strap (RIM Hood
Fender
Reinforcement
Kit,
r
p
eh to the back side ofethe
e
P/N 23002135SK)
V
S
r prevent further cracking.d rIf the
fendereto
y
t is over 2-1/2" (but less than
d
e
crack
s
o
iz 4-1/2"
a
r
B
o backer (not
mlong), an additional aluminum
i
—
l
h
i supplied in the kitorder
t P/N 06924625
e
t
u
cl
U separately) should be aadhered behind the n
i
h
crack above the strap.
e
io
Un If the crack is over
t
V
4-1/2" long, the fender should be replaced.
a
r
r
te
po
NOTE: Read all instructions before
s
r
a
o
w
starting.
m
a
C
i
l
l
Illustration HO60
y
NOTE: Safety and application
er instructions Uti
t
b
Crack
Length
s
provided with sealants,
a adhesives, and
d
e
other products should
always
supersede
m
t
ili by Utilimaster.
bi
information provided
t
i
h
U
NOTE: All2work should be completed on one side before
starting the processro(with an
w
0kit) on the other side.
p
la
additional
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
y WARNING: Adhesive supplied in thebikitt is flammable. Keepoitdaway from heat, sparks,poand
p
i
r
o
open flames.
h
pr
o
C
e
o
Adhesive is an irritant to eyes and
gloves and wash C
r
r hands
pr skin. Use chemical-resistant
thoroughly after use.
d
e
t ventilation or
e vapor. Use with adequate
n and avoid breathing
s
z
Do NOT take adhesive internally
o
i
i
a
r
use proper respiratory tequipment.
o
c
m
i
u
Put the vehicle's transmission
in Park and set
th the parking brake before
il working on the ved
t
u
hicle.
U
a
ro glasses while working
ed
n
p
2
Always wear safety
on the vehicle.
v
U working under the hood.
re hold-open devices before
er
00
Always secure
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
d
e environments or harsh ua
NOTE: In extreme
v
r the RIM hoods on an
driving conditions
e
M
Aeromaster
es van bodies may developecracks
r
at either
c hood
s of the outside corners ofvithe
t
support
(bar under the grille opening),
r
gh at the very bottom ofSethe
ir starting
hood and
ll progressing upward. (See yIllustration
A HO60.)
od
124
ed
v
r
e
s
re
l
a
u
n
a
M
WARNING: Secure hold-open device
(prop rod or locking strut) before
working under the hood.
by
w
la
d
e
e
t
c
s
i
tCAUTION:
Some trucks havev an
bi
i
h
r
locking gas strut.
Do NOT
h
e depressing
ig automatic
o
S
r
close the hood without first
r
l
l
l
p
the orange button on y
the passenger
a
d
A
u
side gas strut to disengage
the safety
n
locking mechanism.
it o
Bo Failure to do so
an
could result in—
M
e damage to the hood. duc
e
l
c
ic
i
o
v
r
h
r
p
1. Release theehoods hold-down straps, open
e
e
r
S
the hood,
r Vand secure the hold-openddevice.
y
Illustration HO62
e
t The hood will be opened
d Opening
e
Align with Grille
s
NOTE:
o
ir z
a
B
o
mand closed several times during
i
—
l
h
i this process. This will unott be noted
t
le
c
U each time.
a
i
n
n
h
o
e
i
U
t
2. Test the fit of the aluminum reinforcement
V
aandby
r
r
aligning one edge with the grille opening
o
te
p
s
closely following the fender profile
(especially
r
a
o
w
in the corner) to see how far the
strap
m
a
C
i
l
l
r
overhangs the back of the fender.
(See
ti
y
e
t
U
b
Illustrations HO62 and
HO65.)
as
d
e
3. If the strap extendsim
past the rear part of the
t
il
bi
fender, cut it offtapproximately
1" back from
i
h
Ufender. (See Illustration HO
the rear of the
o
2
r
0
65.)
p
aw
l
0
n
2
Illustration
HO65
n
o
4. Usingt an F-bit, drill off the heads of the three by
i
o
Strap
Cut
Short
of Fender
i
t
h
t
c
pin-and-collar
fasteners along the front. (See d
a
ig
u
e
r
r
d
it
y Illustration HO70.)
o
o
b
p
p
i
r
r
h
p
o
Co 5. Put on chemical-resistant gloves and,rowith
e
C
r
isopropyl alcohol and a clean rag,pwipe
r
d
e
thoroughly the aluminum strapnand RIM
t
e
s
iz
io grille
hood fender. (Although thethood
a
r
o
c applied to it
support will not have adhesive
h
u
lim
t
i
d
t
and does not need toobe thoroughly cleaned, u
d
U
rcaked-on dirt from it asna
e
remove all loose or
p
2
rv
U
0
well.) (See Illustrations
HO75 and
re
e
0
2
HO80.) ed
es
t
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration HO70
C
n
A
Remove Fasteners
U
125
ts
h
ig
r
l
Al
d
e
rv
e
s
re
ce
i
rv
e
S
l
a
u
n
a
M
6. Insert the adhesive cartridge into the adapter
sleeve. (See Illustration
aw HO85.)
l
7. Place the plunger
by into the back of the
cartridge. d
te
8. Remove
bi the cap of the cartridge and replace
i
the h
ocap with the mixer tip. (See Illustration
rHO85.)
l
a
n
the assembly into a caulking gun. (See
nu
it o 9. Place
a
Illustration HO85.)
c
M
u
e
ic
od
v
r
r
p
e
e
CAUTION: Steps 10 through
14 are
r
S
r Illustration HO75
time-sensitive. Theyadhesive will cure
d
e
t Clean Aluminum Strap ze
dsix minutes once it is
in approximately
s
o
i
a
exposed to air.
Do
NOT interrupt or
r
B once
o
m
delay the process
i
—has begun. the adhesive
h
il
t
e
application
t
u
cl
U
a
i
n
h
e
io
Un
t
V the adhesive on a scrap piece of
a
10. Dispense
r
r
te
cardboard
until the mixture comes out green.
po
s
r
a
(The bead will be approximately the length of
o
w
m
a
C
i
the mixer tip, and this means the compound
is
l
l
r
i
t
y
adequately mixed.) (See Illustration b
HO-90.)
te
U
s
a
d of the
11. Apply adhesive down the full length
e
m
t
aluminum strap. (See Illustration
ili
bi HO95.)
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
Plungero
io
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it Sleeve
y
o
o
b
p
p
i
Adapter
r
r
h
o
Co
ep Cartridge
o
C
r
r
r
p
d
e
t
e
n
s
z Sleeve Cartridge Plunger
i
io
a
r
t
Mixer
Tip
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
IllustrationpHO80
2
v
U
e Fender
Clean RIMrHood
er
00
s
2
d
t Caulking Gun
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
Illustration HO85
o
a
ll
C
Caulking Gun Assembly
n
A
U
126
y
d
Bo
e—
l
ic
h
Ve
p
l
d
a
aw
e
l
CAUTION:v Too much clamp load will u
r
y
leave indentations
in the RIM hood an
e
b
s
fender.
M
d
re
e
e
t
c
i
ts place the aluminum straprvbetween
bi
i
h
12. Carefully
h
e grille
igthe RIM hood fender and the lower
o
S
r
r
l
l support. (See Illustration HO100.)
y
l
p
a
d
A
u
n
13. Clamp the corner bend
Boof the strap in place, tio
an
M
—clamp load possible. uc
first using the lightest
e
e
l
Make sure theicorner
c tightly follows the rod
ic
v
h and clamp the strap in at least
fender profile
r
p
e
e
e
four places.
r
S
Illustration HO90
r V (See Illustration HO105.)
y
d
e
Purge Mixer
t off any excess adhesive immediately.
d Tip
e
14. Wipe
s
z
o
i
a
B
NOTE:
If the crack is between
or
m
i
—
l
h
i 2-1/2" and 4-1/2" long,udispense
t
t
le
c
U adhesive on a 2 x 3" aaluminum
i
n
n
h
e
backing plate (notUsupplied in the
io
t
V
a
kitorder P/N 06924625
r
r
te
separately), adhere the plate po
s
r
a
behind the crack above the strap,
o
w
m
a
C
i
and clamp the plate in place
until
l
l
r
ti
y
the adhesive is cured. te
U
b
as holes through the
d
15. Using an F-bit, drill three
e
m
t
strap, using the pin-and-collar
fastener holes
ili
bi
t
i
as a guide. (See
h
U Illustration HO110.)
o
2
r
0
p
aw
l
0
n
2
Illustration
HO95
n
y
o
t
i
o
b
Apply
Adhesive
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration HO100
Illustration HO105
C
n
A
Put Strap in Place
Clamp in Place
U
127
16. Using an F-bit, drill one hole through the
d of the fender. (See
strap along the side
e
Illustration HO120.)
rv
l
a
aw
l
u
n
a
e
by
s
M
17. Install the
e four stainless-steel truss-heade bolts
d
r
e
t
and locknuts.
The bolt on the side should
c
i
s
t a washer under the locknut.r(See
vi
ib
have
h
h
e
g
iIllustration HO115.)
S
ro
l
ll r
y
p
a
d
A18. Torque the nuts to 6585oinlb.
n
nu
o
i
B
a
t
19. Make sure the hood is closed and secured.
c
M
—
u
e
e
l
d
NOTE: Total cure
c takes
ic
i
o
v
r
approximately
r
eh eight hours, but the ep
e
Illustration
HO110
truck canVbe put into use
S
r after the fasteners ared r
Drill Front Holes
y
immediately
e
d
e
st (if a backing plate is not
inaplace
o
iz
r
B
used over a longer crack). o
m
i
—
l
h
i NOTE: Disposing of leftover
t
t
le
u
c
U
a
i
n
n
adhesive is environmentally
safe if
h
o
e
i
U
t
it is dispensed from the cartridge
V
a
r
r
and allowed to fully cure.
te
po
s
r
a
NOTE: If desired for cosmetico
w
m
a
i
reasons, after the adhesive isCcured,
l
l
ti
y
er be
the outside of the crack tcan
U
b
s
routed into a V-shaped
a groove, and
d
e
m
filled in with a flexible
bumper/
t
ili the filler is
bi
fender filler. After
t
i
U sanded smooth and
cured, it can2 be
oh
r
w
0match the rest of the
painted to
p
la
0
n
hood. 2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t HO120
u
Illustration
od
U
a
r
ed
Drill
Side Hole
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h Illustration HO115
ig
t
p
r
u
o
a
ll
Attach Fasteners
C
n
A
U
128
ed
v
r
e
s
re
l
a
u
n
a
M
w
la
WARNING: Secure the hold-open device (prop rod or locking strut) before working under the
hood.
by
d
e
e
t
c
i Do NOT close the hood without
s
Some trucks havevian automatic locking gas strut.
tCAUTION:
bgas
i
h
first depressing the orange rbutton on the passenger side
strut to disengage the safety
h
e
ir g locking mechanism. Failure
to
do
so
could
result
in
damage
to the hood.
o
S
r
l
l
y
l
p
a
d
A
n
o
nu
o
i
B
a
t
Hood Stops Upgrade
c
M
—
u
e
e
l
NOTE: OrdercRIM Hood Bumper Stops d
ic
i
o
v
r
Kit 2.5 OD,hP/N 23002147SK.
r
p
e
e
e
V hood hold-down straps, open
r the
S
1. Releaser the
y
d
e
hood,t and secure the hold-open device.
d
e
s
o
ir z
a
B
2. m
Remove the four rubber hood
o stops. (See
i
—
l
h
i Illustration HO125.) ut
t
le
c
U 3. If there is a setscrew, itaneeds to be removed.
i
n (See
h
e
io
Un
Illustration HO145.)
t
V
a
r
r
o
4. Loosen both mount brackets. (See Illustration
te
p
s
r
HO130.)
a
o
w
m
a
C
i
l
l
5. Directly below each hood strap
r catch, locate the ti
y
e(9/16"
t
U
center of the hood support
from
the
back
b
as (See Illustration
d
edge of the hood support).
e
m
t
Illustration HO125
HO135.)
ili
bi Stops
t
i
Remove Existing Hood
h
6. Using a 5/16" U
bit, drill two holes through the
o
2
r
bottom of0the hood support. (See Illustration
p
aw
l
0
n
2
HO140.)
n
t
io
o
by
i
t
h
t
7. Attach
c
d
a
ig one 2-1/2" rubber bumper to the hood
u
e
r
r
d
it x
y support with two washers, a spacer, a 5/16-18
o
o
b
p
p
i
r
1-1/4"
bolt,
and
a
5/16-18
flange
locknut.
(See
r
o
Co Illustrations HO145 and HO150.)rohFor each
ep
C
r
r
p the bumper,
hood stop, the spacer goes through
d
e
t
nbumper, the bolt ize
washers are on both sides of the
s
o
i
a
r
t
goes through the spacer, and
(after
inserting
the
bolt
o
c
h
u
lim
through the hood support)
the
locknut
goes
on
the
t
i
d
t
d
o for the other side. au
end of the bolt. Repeat
U
r
e
n
p
2
rv
U
e 57 ftlb.
0
8. Torque the nutsrto
e
0
2
d
es
t
9. Remove thee two bolts that hold each strap mount
r
h
iz and discard the locknuts. (See
g
to the bumper
r
ts
i
r
o
h
Illustration
y
h HO145.)
ig
t
Illustration rHO130
p
u
o
Loosen Mount
a
ll Brackets
C
n
A
U
129
l
Al
ts
h
rig
d
e
rv
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
te
i
ib
h
o
pr
by
w
la
ce
i
rv
e
S
l
a
u
an
M
er
t
dy
ed
Illustration HO135
Illustration o
HO140
s
z
aCenter with Strap Catch ri
Drill B
Holes
o
m
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h
e
it o
Un
Vmount without removing the mount
CAUTION: Attempting to drill outra
the rivets on the strap
r
from the bumper could potentially
te or another part of the vehicle.
po damage the radiator
s
r
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
h
U
Hex Bolt
o
2
r
w
Hood
0
p
la
Locknut 20
n
n
y
o
t
i
o
b
i
t
h
t
Hood Stop
c
d
a
ig
u
e
r
r
Strap
(Rubber Bumper)
d
it
y
o
o
b
p
p
i
r
r
Washer
h
o Nuts,
Co
ep
o
Bolts,
C
r
r
r Washers
p
and
d
e
Mount
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
d
t
Setscrew
u
o
U
a
r
ed
Washer
Spacer
n
p
2
v
U
re
er
00
s
2
d
Adjustment Slots
t
e
re
h
ir z
ts
ig
o
Illustration HO145 r
h
y
h
ig
t
Hood Stop in Placep
r
u
o
a
ll
C
n
A
U
130
10. Place each mountdin a vise and drill out the rivets,l
a
e
attaching the v
hold-down
strap to the mount. u
an
r
e hold-down strap so that the rubber
11. Reverse the
s
M
re away from the grille. (SeeceIllustration
knob faces
HO145.)
ts
vi
h
er
igReattach the hold-down strapSto each mount with
12.
ll r the stainless-steel 10-24 x 3/4"
y bolt, washer, and
d
A locknut.
o
d
ti e
ib
h
o
pr
by
w
la
l
a
u
an
M
n
it o
B
—to the bumper, using new uc
13. Reattach the mounts
e
l
d
bolts and locknuts.
ce
c Torque the locknuts toro1418
i
i
h
ftlb.
rv
p
e
e
e
V
S
14. Adjustrthe mount supports so that therstops are
y
d
e
t
d HO150
flatsagainst
the top surface and soethat there is
Illustration
o
a an equal spacing in the gaprizbetween the
also
B
Attach Replacement
Bumpers
mquarter panel and the fender.ho(See Illustrations
i
—
l
i HO145, HO155, anduHO160.)
t
t
le
Pushing the
c
U
a
i
n
n the vertical slot adjusts
mount up or down along
h
o
e
i
U
t
the gap between the quarter panel and a
the fender
V
r
r at the
(pushing the mount up increases theogap
te
p
s
bottom). Pushing the mount sideways
along
the
r
a
o
w
horizontal slots adjusts the alignment
of
the
mount
m
a
C
i
l
l
and the hood stop.
ti
y
er
t
U
b
15. Secure the location after
asadjustment by drilling a
d
e
m
new 7/32" hole behind
the
adjustment
slot
and
t
iliself-tapping Torx screw (P/N
bi
secure with a new
t
i
h
11300177)2orUuse a new 1/4-20 x 3/4 bolt and
o
r
locknut 0
as0a setscrew instead of the Torx screw.
p
aw
l
n
2
(See Illustration
HO145.)
n
t
io HO155
Illustration
o
by
i
t
h
t
c Poor Alignment
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
llHO160
C
Illustration
n
A
U
Good Alignment
®
131
Keys
l
w
d
a
a
e
l
u
Abloy Keys
n
rv
a
e
by
Abloy squarecutskeys are supplied by Transport
M
d
re case of vehicles equipped with
ea
Security or, in the
e
t
c
i
s
t Control System (VACS), rbyvi
Vehicle Access
ib
h
h
e
Utilimaster.
g
S
ri
ro
l
lImportant!
y
l
Record the key number
p
a
Astamped on the key for eachodtruck. For
n
nu
o
i
B
a
t
security reasons they are usually not
c
M
—
u
stamped on the lockle
cylinder, and you
e
Illustration KY10 c
d
c to obtain
i Vehicles
must have this number
i
o
Rear
Door
Entry Keys for VACS
v
r
h
r
replacement keys.
e
ep
V
r
Se
r
To maintain security
you should contact
tedirectlycontrol,
dy
edcasethe
s
lock company
for replacements.izIn
of
o
a please reuse the lock assemblies
r
B
unit damage,
o
m
i
—
l
h
i possible.
t
whenever
t
le
u
c
UTransport Security, Inc. a
i
n
n
h
o
e
i
U
t
508 Industrial Blvd.
V
a
r
r
Waconia, MN 55387
te
po
s
Phone: 612-442-5625
r
a
o
w
Fax: 800-328-3442
m
a
C
i
l
l
ti
er
VACS (Vehicle Access Control System)
t
U
by
s
d
The wristband transponders areasupplied through
e
m
t
Utilimaster. For programming
ili and other service
bi
t
i
Illustration
KY20
information on the transponder
see the Vehicle
U
VACS Wristband Transponder
oh
2
r
Access Control System
for
Utilimaster
Walk-In
w
0and Service Manual, P/N
p
la
0
VansOperation
n
2
n
03102103, fort more VACS information.
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
Illustration KY30 re
h
ir z
VACS Operation and
ts
ig
r
o
h
Service
Manual
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
132
ed
v
r
e
s
re
l
a
u
n
a
M
CAUTION: Always replace lights with one
of the same size, shape, and wattage.
ts
h
Headlight
rig Replacement
l
Headlight
Al Removal
Lights
ce
i
rv
e
S
by
w
la
d
ti eRemove screws
ib
h
o
pr
l
y
a
d
u
n
o
n
o
i
B
a
1. Turn off the ignition and all lights.
t
Disconnect
c
M
—
u
e
2. Open the hood. le
electrical
d
c
ic
i
o
harness
v
r
h electrical harness from thep back of
r
3. Disconnectethe
e
e
the headlight
r
S
r V unit.
y
d
e
ta Phillips-head screwdriverzeand a wrench,
d
4. With
s
o
i
a
r and nuts from
B
the four retaining screws
o
mremove
Illustration
LI5
i
—
l
h
LI5 and
i the retaining ring. (See Illustrations
t
e
Disconnect
Headlight
Unit
t
l
u
c
U LI10.)
a
i
n
h
e
io
Un unit from the retaining
5. Remove the used headlight
t
V
a
r
ring.
r
o
te
p
s
Headlight Installation
r
a
o
w
m
a
1. Place the new headlight unit inCthe retaining ring. li
l
r
ti
y
e
t
U
b
2. Secure the four retaining
screws
and
torque
the
s
d
nuts to 1218 inlb. a
e
m
t
ili harness at the back of
bi
3. Reconnect the electrical
t
i
h
U
the headlight2unit.
o
r
0
p
aw
l
0
Headlight Adjustment
n
2
n
o
t any load the vehicle is carrying.
i
o
by
1. Remove
i
t
h
t
Illustration
LI10
c
d
a
ig
u
e
r
r
Headlight
Retaining
Screws
2.y The vehicle should have approximately a half
d
it tank
o
o
b
p
p
i
r
of
fuel.
r
o
Co 3. Check that the tires are properly inflated
ep
oh to the
C
r
r
r
pinflation.
d
e
tire manufacturers recommended
t
n
s
ze
o
i
i
a
r
4. Clean the headlights if theyctare dirty.
o
im
h
u
l
t
i
d
t
5. Park the vehicle on aolevel surface.
u
d
U
a
r
e
n
p
2
6. Use a headlight-aiming
rv
U
e tool to gauge correct
0
r
e
0
alignment of the headlights. Follow the
2
d instructions for the device as
es
t
e
manufacturers
r
h
iz no headlight-aiming tool is available,
g
needed.r(If
ts
i
r
o
h
y
perform
h steps 8 through 11 as a temporary
ig
t
p
r
u
solution
until
a
tool
can
be
obtained.)
o
l
a
lLI15
C
Illustration
n
A
U
Headlight Adjusting Screws
133
l
Al
ts
h
rig
d
e
rv
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
te
i
ib
h
o
pr
by
w
la
ce
i
rv
e
S
l
a
u
an
M
y
er
t
ed
Illustration LI20
Illustrationod
LI25
s
z
i
a
r
Improperly
Aligned Pattern
Properly Aligned
B Pattern
o
m
i
il
th
e—
t
l
u
U 7. Turn the adjuster screwsa to move the
ic
n
n
h
headlights up or down
e
U and left or right as tio
V
necessary. (See Illustration LI15.) ra
er
o
t
NOTE: Steps 8 through 11 should
rp be used
as
o
w
only until a properly calibrated
headlightm
a
C
i
l
l
aiming tool can be obtained.
ti
y
er
t
U
b
s
8. If no headlight-aiming a
tool is available, park
d
e
m
the vehicle on a level
surface
near
a
wall
and
t
ili the center of each
bi
mark the point opposite
t
i
headlight. 2 U
ohharness
r
Disconnect
wire
w
p
la
00 a cross through each mark.
9. Draw or2tape
n
n
t
(See Illustration
LI20.)
io
o
by
i
t
h
c LI30
at
ig the vehicle a distance (measured from ted
Illustration
u
10. Park
r
r
d Turn Signal
ythe headlight) of 25 feet from the wall. bi
o
Forward
o
p
p
i
r
r
hthe
oa definite
Co11. Adjust the low-beam headlights so that
ep
o
CAUTION:
Many lights have
C
r
r
r check the
p
top and bottom. Always
majority of the beam is below the horizontal
d
e
t
e
of the light sbefore removing
target marks and centered on the
onvertical
iz position
i
and install right side
a up.
r
t
target marks. (See Illustrations
LI20 and
o
c
m
i
u
th
LI25.)
il
d
t
u
U
a
ro
ed
Front Turn Signal Replacement
n
p
2
v
4. Push the light
r
U
e
0 unit through the grommetefrom
r
0
the
rear.
s
2
d
t
e
re the
h
z
2. Open theihood.
5.
Replace
the
unit
by
pushing
it
through
r
ts
ig (on the outside) of the grommet.
r
o
h
front
y
3. Disconnect
h the electrical harness at the back
ig
t
p
r
u
of
the
turn
signal
light
unit.
(See
Illustration
o
6.
Reattach
the
electrical
harness
l at the back of
a
l
C
n
A
the unit.
U LI30.)
134
l
w
d
a
a
e
l
u
n
rv
y
a
e
b
s
M
d
re Light Replacement ce
e
Front Side Marker
t
ts
bi
vi
i
h
r
1. Turn
off the ignition and all lights.
h
e
ig
o
S
r
r
l
l2. Lightly spray the outer grommet
y and marker light surfacep
l
a
d
A with soapy water to easeothe removal of the marker light
u
n
n
o
i
B
a
unit.
t
c
M
—
u the
e
e
3. Slip a flat-blade lscrewdriver
between the lightdand
cgrommet to pry the marker rlight
ic
i
o
inner lip of the
up
so
that
v
h
r
pIllustration LI
e
e
it can be pulled
out
of
the
grommet.
(See
e
V
r
S
35.) er
y
d
t
d
e
s
o
4. Disconnect
the old light unit from
ir zthe electrical harness.
a
B
o
m
i
—
l
h
i5. Check the rear (inside theuthood) of the grommet before
t
le
if
c
U installing the new light aand adjust the grommet,
i
n
h
necessary.
e
io
Un
t
V
a water.
r
6. Lightly spray the grommet again with rsoapy
Illustration LI35
e
o
t
Front
Side Marker Light
p
s
r
7. Plug the new light unit into the harness.
a
o
w
m front of the grommet with the weep hole down.
a
C
i
l
8. Replace the light unit by carefully
pushing
it
through
the
l
ti
y
er
t
U
b
s
d with
CAUTION: Lightsa that have a reflector inside must be installed with the reflector e
parallel
m
t
the ground when
ili the hood is in the closed position.
bi
t
i
h
U
o
2
r
0
p
aw
Clearance and 0
Identification Light Replacement
l
n
2
n
toff the ignition and all lights.
io
1. Turn
o
by
i
t
h
t
d
ig
uc that attach the lightounit
ra to
2.yrUse a medium-sized Phillips screwdriver itoteremove the two outsidedscrews
p the vehicle. (See Illustration LI40 andibLI45.)
ro
rp
o
h
p
o
C
e
o
C
r
r
r
p
d
te
e
n
s
z
a
ri
tio
o
c
m
u
th
ili
d
t
u
d
U
a
ro
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
Illustrationll LI45
Illustration LI40
C
n
A Light
Rear Identification
Front Clearance Light
U
CAUTION: The slit on the rear of the grommet must be pointed down when the hood is closed
to allow water to drain.
135
NOTE: The light assembly is a sealed unit and
must be replaced
al
edas a unit.
w
a
l
u
n
rvlight unit from the electrical harness.
3. Disconnectethe
a
by
s
M
d
rethe new light unit and attachciteto the vehicle
4. Connect
e
t
i
s
using
t two Phillips-head screws. rvi
ib
h
h
e
g
i
Stop/Turn/Tail/Back-up
Light Replacement
S
ro
l
ll r
y
p
a
d
Permanent
Mount
A
n
o
nu
o
i
B
a
t
c
M
—
u
e
e
l
2. Using a #11 or 3/16"
d of
c drill bit, drill off the heads
ic
i
o
v
r
the three rivets
holding
the
light
unit
to
the
rear
of
the
r
p
ehIllustration LI50.)
e
e
vehicle. (See
V
r
S
r
y
d
e
t the electrical harnesszate the back of the
3. Disconnect
d
s
o
i
a
unit.
r
B
o
m
i
—
l
h
i Attach the electrical harness
4.
t to the back of the
eIllustration LI50
t
l
u
Brake
Light
(Permanent Mount)
c
U replacement unit. a
i
n
n
h
e
io and
5. Align the predrilledU
holes of the new light tunit
V
a
Insert
r the screwdriver
r
POP-rivet the unit in place.
e
o
t
the inside lip
p
sunder
r
Grommet Mount
a
of the grommet
o
w
m
a
C
i
l
l
NOTE: Lightly spray the outer
grommet
and
r
ti
esoapy
t
marker light surface with
water to easeUthe
by
s
a
d
removal and installation.
e
m
t
iliand all lights.
1. Turn off the ignition
bi
t
i
Uscrewdriver under the inner lip of
oh
2. Slip a flat-blade
2
r
w
0grommet to pry the light unit up so that it la
p
the outside
0
n
2
n
can bet pulled out of the grommet. (See Illustrationy
o
i
o
b
i
t
h
t
LI55.)
c
d
a
ig
u
e
r
r
d
it at the
yDisconnect the light from the electrical harness
o
3.
o
b
p
p
i
r
r
h
o
Co back of the unit.
ep
o
C
r
r
4. Plug in the replacement light.
r
p
d
e
t
e
Illustration LI55
s
on the outside riz
5. Replace the unit by pushing itithrough
a
t
Back-Up Light (Grommet
Mount)
o
(front) of the grommet. c
m
i
h
u
l
t
d
ti
u
o
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
136
l
w
d
a
a
e
l
u
Sealed Unit Light
n
rv
y
a
e
b
s
1. Turn off the
ignition and all lights.
M
d
re
e
e
t
c
2. On teither
the
leftor
right-hand
side,
slip
a
small
s
i
bi
vlens
i
h
r
flat
blade screwdriver between ethe
and the
h
igplastic base clip holding the lens
o
S
and pop the
r
r
Insert screwdriver blade here l
l sealed light unit off its base.y(See Illustration
l
p
a
d
A LI60.)
u
to retract base clip holding
n
o
n
io
B
sealed light unit a
t
M
NOTE: If necessary,
e— carefully score the duc
Illustration LI60 e
l
c
sealant between
c the sealed light unit androthe
Sealed Unit License PlateiLight
i
v
hthe light unit for removal.p
r
base to free
e
e
e
S
r Vany sealant remaining on dtherbase.
3. Cleaneoff
y
t
d
e
s
o
4. Replace
ir z the unit into
a the sealed unit by pressing
B
o
mthe base.
i
—
l
h
i
t
le
ut using a polyurethane
c
U 5. Reseal around the lightaunit
i
n
h
sealant.
e
io
Un
t
V
a
Replaceable Bulb Light
r
r
o
te
s
1. Turn off the ignition and all lights. rp
a
o
w
m
a
C
2. Pinch the lens from the sides just
enough to pop li
l
y
er(See Illustrations Uti
the lens off the light fixture.
t
b
LI61 or LI62.)
as
d
e
m
t
3. With a half turn, remove
ili the used bulb.
bi
t
i
Illustration LI61
h
U bulb.
4. Inert the replacement
o
Replaceable
Bulb
License
Plate Light
2
r
w
0
p
a
l
0
5. Snap the
n
2 lens back into place.
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2 Illustration LI62 es
d
t
e
Replaceable Bulb License PlaterLight
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
License Plate Light Replacement
137
Cab/Cargo Light Bulb Replacement (Removable Lens)
l
w
a
a
l
u
n
rv
a
e
2. Remove the
three
Phillips-head
screws
holding
the
by
s
M
d
dome light
re lens and remove the lens. c(See
e Illustrations
e
t
i
s
LI65
t and LI66.)
vi
ib
h
r
h
e
g
3.riRemove the bulb with a half turn.
S
ro
l
l
y
l
p
a
d with a bulb of the same
A 4. Place the bulb in the lightofixture
u
size and voltage. Match
on
B the numbers on printed ontithe
an
base of the bulb. —
c
M
u
e
e
l
dlens.
c
ic
5. Use three Phillips-head
screws to reattach the
i
o
v
r
Illustration
LI65
rLight
p Mount)
eh
e
Cab (Dome)
e
Cab/Cargo Light V
Assembly Replacement (Permanent
r
S
r
y
d
e
t the ignition and all lights.ze
1. Turn off
d
s
o
i
a
r
B
2. m
Remove the three rivets holding
o the unit to the bulkhead.
i
—
l
h
i (See Illustrations LI65 and
t LI66.)
t
le
u
c
U 3. Disconnect the used lighta from the electrical harness
i
n at
n
h
o
e
i
U
t
the back of the unit.
V
a
r
r
o of the replace- te
4. Plug the electrical harness into the p
back
s
r
ment light unit and then align the o
unit with the previous a
w
m
a
C
mounting holes.
i
l
l
r
i
te the unit.
Ut
by
5. Use small POP rivets to sreattach
a
d
e
t
Cab/Cargo Light Assemblyim
Replacement (Grommet Mount)
il
bi
t
i
NOTE: The light
IllustrationhLI66
U assembly is a sealed unit and must
Wall Mounted
2
roCargo Light
be replaced
as
a
unit.
w
0
p
a
l
0
n
NOTE:2Lightly spray the outer grommet and y
n
o
t
i
o
b
i
t
h
marker
light surface with soapy water to
t
c
d
a
ig the removal and installation.
u
ease
e
r
r
d
it
y
o
o
b
p
p
i
r
r
1.
Turn
off
the
ignition
and
all
lights.
h
p
o
Co
o
C
re
r inner lip of the
2. Slip a flat-blade screwdriver underpthe
er
outside grommet to pry the lightnunit up so that it can be ed
t
s
io Illustration LI67.) riz
pulled out of the grommet. (See
a
t
o
c
im
h
u
l
t
3. Disconnect the used light
from
the
electrical
harness
at
i
d
t
u
U
the back of the unit. ro
a
ed
n
p
2
v
U
4. Plug in the replacement
re light.
00 Illustration LI67 ser
2
d by pushing it through the outside (front)
t Ceiling Mounted Cargo Light
e
re
5. Replace the
unit
h
z
i
r
ts
of the grommet.
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
d
1. Turn off the ignition
e and all lights.
138
l
w
a
a
e
l
u
Removal
n
rv
y
a
e
b
s
1. Removeethe Torx fasteners on the floorM
d
r angle or plate (depending once
e
mat s
trim
t
i
t the mat is to be replaced).rv(See
bi
where
i
h
h
e
igIllustration MA5.)
o
S
r
r
l
l
y mat joints.
l
p
a
2.
Cut
sealant
bead
between
the
d
A
u
n
(See Illustration MA10.)
it o
Bo
an
c
M
—
3. Peel off the floorle
mat.
u
e
d
c
ic
i
o
v
r
4. Scrape the floor
surface
to
remove
any
h
r
p
e
e
remaining
glue
or
mat.
e
r
S
rV
y
d
Illustration
MA5
e
5. Clean
t the surface with a lacquer-based
d Strip
e
s
Floor Mat Trim
o
ir z
solvent.
a
B
o
m
i
—
l
h
Installation
i
t
le
ut
c
U 1. Spray adhesive on the abottom
i
of the
n
n
h
e
io
U
matting.
t
V
a
r
r
2. Lay matting down into place.
o
te
p
s
r
a
3. Replace all aluminum tread plateotrim using
w
m
a
C
i
l
Torx fasteners.
l
ti
y
er
t
U
b
4. Use gray or black polyurethane
sealant
on
asby a tread plate trim
d
any edges not covered
e
m
t
piece to seal outtwater.
ili (See Illustration
bi
i
h
U
MA10.)
o
2
r
0
p
aw
l
0
n
2
n
o MA10
t
i
o
by Seal Floor MatIllustration
i
t
h
t
Seam
c with Polyurethane Sealant
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Matting (Cab Floor) dReplacement
®
139
Mirror Replacement
l
w
d
a
a
e
To receive maximum benefit
from
the
outside
mirrors,
have
someone
l
u
n the passenrvthe mirror mounts and adjusting
assist you by loosening
a
e
by
s
M
ger-side and driver-side
mirrors while you sit back in the drivers
e
d
r
esee the side of the
e
t
chair. Adjuststhe driver-side mirror so you can
c
i
t
vi
ib
vehicle. h
r
h
e
g
i
Sthe mirror is just loose enoughro
To adjust
l
ll r a mirror, loosen the nut until
y
p
a
to A
turn, then grab the outside edge d
of the mirror and gently pullnin the
u
desired direction. Retighten the
Bonut when the mirror is in thetiodesired
an
c
M
position.
u
e—
e
l
dsurface is
c convex. A convex mirrors
ic
o
Some exterior mirrors iare
v
r
r
p but it makes
ehmore from the drivers seat,
curved so you can see
e
e
V
r
S
things appear farther
r away than they really are.
y
d
e
t
d
e
s
o
iz
a
r
B
o
m
i
Mirror Removal
—
l
h
i
t
t
le
u
c
U 1. Using a 1/2" socket wrench,
remove the mirror loop from
a
i
n
n
h
the mirror mountingUbrackets.
(See Illustration
e
it o MI10.)
V
a
r
Mirror Installation
r
o
te
pthe
s
r
1. Using a 1/2" socket wrench, tighten
upper mirror loop
5/
a
o
w
Illustration MI10
1618 x 2 hex-head bolt and locknut
to
200250
inlb.
m
a
C
i
l
Side
Mirror
l
ti
er
t
U
by
s
CAUTION: Do NOT
a reuse two-way locknuts or bolts;
d
e
always replaceim
with new fasteners.
t
il fasteners to mount mirrors.
bi
t
i
Use stainless-steel
U
oh
2
r
w
0
p
la
0
n
2
n
y
2. The lower
o
t 5/1618 x 1 hex head bolt and locknutbshould
i
o
i
t
h
begtightened to 100150 inlb.
t
c
d
a
i
u
e
r
r
d
it two new
o
3. yIf mirror mount brackets were removed, use
o
b
p
p
i
r
r
steel Phillips pan-head screwshand new locknuts
o
Co stainless
ep
o MI15.)
C
on each of the brackets. (See Illustration
r
r
r
p
d
e
t
e
NOTE: An alternative wouldnbe to remove the
s
ioa unit by removing riz
a
mirror loop and brackets as
t
cscrews and locknuts ho
im
the four Phillips panhead
u
l
t
i
t
u
(two each on the upper
od and the lower brackets).
U
a
r
ed
n
p
2
v
NOTE: Rotatere
the mirrors as little as possible
U
er
00
s
for the first 72
hours
after
installation.
2
d
Illustration MI15 e
t
e
Use
Stainless
Steel Fasteners onr Exterior
h
ir z
g
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
140
l Overhead Shelf CoverwReplacement
a
la
u Cover Removal
n
y
a
b
M
1. Drill off the
d heads of the rivets across the top
e
e
and
the
bottom
of the cover using a #11 or
t
i
s
ic
t
b
v
3/16"i [5 mm] drill bit. (See Illustration
h
r
h
e
ir g
OS10.)
o
S
r
l
l
y
l
p
a
Cover
Installation
d
A
u
n
it o 1. Use a POP-rivet gun to install the cover.
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
r V Illustration OS10
y
d
e
t Overhead Shelf with Coverze
d
s
o
ir
a
B
o
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
ed
v
r
e
s
re
141
l
w
d
a
a
e
l
u
rvventilation is required whenanworking in a confined areaywith paint and paintAdequate
e
b
related
s chemicals.
M
e
d
r
te
ce
i
s
i
t
ib
h
rv
Paint Repair
h
e
g
i
S to
ro
l
ll r NOTE: This procedure applies
y
p
a
A aluminum surfaces, RIModhood
u
n
n
o
i
B
a
material, and fiberglass hood
t
c
M
—
material.
u
e
e
l
ic
ic the Decals section. rod
NOTE: See h
also
v
r
p
e
e
e
V
Substrate Preparation
r
S
r
y
d
e
t
d
1. If necessary,
follow the procedure e
in the
s
o
iz from the
a section to remove any decals
Decals
r
B
o
m
i
—
affected
area.
l
h
Illustration
i
t
e3900S andPA10
t
l
u
Use
DuPont
3901S Cleaners
c
U 2. Use a clean rag soakedain DuPont 3900S n
i
n area and the area
h
e
Cleaner to clean the
io
Urepair
t
V
surrounding the repair. Using a secondra
clean
r
o it
te
dry rag, wipe off the 3900S cleanerpbefore
s
r
a
evaporates. If the 3900S dries before
it is
o
w
m
a
C
i
removed, re-wet and wipe dry.
(See
l
l
ti
er
Illustration PA10.)
t
U
by
s
a
d
e
m
t
ili sure the area
bi
t
CAUTION: Make
i
cleaned isUbigger than the spray area.
oh
2
r
w
0
p
la
0
n
2
n
t defective area with 320-grit sand
Illustration
3. Sand the
io PA15
o
by
i
t
h
t
Sand Area
c to Be Prepared
d
paper.
a
ig (See Illustration PA15.)
u
e
r
r
d
it
yNOTE: If necessary, use a finer (600-grit)
o
o
b
p
p
i
r
r
h
p
o
Co sandpaper to smooth the blend area
e
o
C
r
r
surrounding the repair area.
r
p
d
e
t
e
s
4. Repeat cleaning with a clean irag
onsoaked in
iz
a
r
t
DuPont 3901S Cleaner to remove
sanding
c
im
ho
l
t
i
dust. (See Step 2.) du
t
u
o
U
a
r
ed
5. Mask all fixtures (lights,
grille, bumper, etc.)nto
p
2
v
U
protect from overspray.
re (See Illustration PA
er
00
s
2
d
20.)
t
e
re
h
z
i
ts
NOTE:orUse masking tape and a paper
ig
r
h
Illustration PA20
y
h
thattcannot
be penetrated by paint.
ig Oil Paper
p
Protect
with
Masking Taperand
u
o
a
ll
C
n
A
U
WARNING: Utilimaster recommends that a professional body shop do all paint repairs. The
service technician should read this entire procedure before working on the vehicle.
®
142
ts
h
rig
ed
v
r
e
s
re
ce
i
rv
e
S
l
a
u
n
a
M
d
ti e
ib
h
o
pr
by
w
la
l
y
a
d
u
n
it o
Bo
an
c
M
— PA25
Illustration
u
e
e
l
Use TackcCloth for Final Wipe
d
ic
i
o
v
r
harea with the tack cloth to make
Illustration PA30 r
p
6. Wipe a wide
e
e
Three
Ounces of Paint
V to be sprayed are clear ofr dust
Se
sure allrareas
y
te (See Illustration PA25.)
and debris.
d
ed
s
z
o
i
a
r
B
7. mIf the base or substrate is exposed
by
sanding,
hoand 2505S
ili apply DuPont 2510S Primer
t
e—
t
l
u
U Activator.
a
ic
n
n
h
e
io
U
tensure
V
CAUTION: Mix paint thoroughly to
a
r
proper application and paint performance.
er
o
t
p
r
as
o
w
Paint Preparation
m
a
C
i
l
l
y
er measuring cup, Uti
1. Using a graduated (9-ounce)
Illustration PA35
t
b
One Ounce of Activator
pour 3 ounces paint (DuPont
as Imron 5000) to 1
d
e
m
t
ounce activator (DuPont
193S). (See
ili and PA35.)
bi
t
i
Illustrations PA30
h
U
o
2
r
2. Add 1/8 ounce
of accelerator (DuPont 8989S
w
p
la
00 to the paint mixture. (See
gallon 2can)
n
n
t PA40.)
Illustration
io
o
by
i
t
h
t
c
d
a
ig a paint stick, stir paint mixture thoroughly.
u
e
r
3. rUsing
d
it
y (See Illustration PA45.)
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
limPA40
t
i
Illustration
d
t
u
d
o
Add U
Accelerator
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
Illustration PA45
n
A
U
Stir Well
l
l
A
143
4. Place the paint strainer in the touch-up gun cup and pour the paint through the strainer. (See
al
Illustration PA50.)
aw
ed
l
u
v
n
r
y
NOTE: A drop
a Additive may be addedb if there is a problem
e or two of DuPont 359S Paint
s
M
with fish
eyes
or
other
contaminant-related
imperfections.
d
re
e
e
t
c
i
s
t
5. Reassemble
the touch-up gun.
vi
ib
h
r
h
e
g
6.riCheck the blender gun to makeSsure it has sufficient blender
ro(DuPont 3401S).
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
M
CAUTION: Clear
e— nozzle before spraying.duc
e
l
c
ic
i
o
v
r
r
p
eh
e
e
V
r
S
r
y
d
e
t
d
e
Paint Application
s
o
iz
a
r
B
o 222S
1.lim
Using the cup gun with DuPont
—
h
i Adhesion Promoter, do autest
t spray directed
e
t
cl
U away from the vehicle toa make sure the gun n
i
h
e
io
Un
nozzle is clear.
t
V
a
r
r
2. Spray DuPont 222S Adhesion Promoter
o
te
p
s
r
across the area to be repaired and extend to
a
o
w
m
the area surrounding the repairCto ensure
a
i
l
l
adequate adhesion of the new
er to old paint. Uti
t
by
s
a
d
3. Air dry for 1 to 2 minutes.
e
m
t
iligun containing DuPont
4. Using the touch-up
bi
t
i
Illustration PA50h
U do a test spray directed
Imron 5000 Paint,
Use Paint Strainer
2
ro
w
away from0the vehicle to make sure the touchp
a
l
0 is clear.
up gun nozzle
n
2
n
y
o
t
i
o
b
i
t
h
t
5. Apply
c
g the first coat of paint. (See Illustrationed
a
i
u
r
r
d
it
yPA55.)
o
o
b
p
p
i
r
r
h
o
Co6. Air dry for 1 to 2 minutes.
ep
o
C
r
r
r
7. Using the blender gun with DuPontp3401S
d
e
t
e
Blender, do a test spray directednaway from
s
iz
io nozzle is
a
r
t
the vehicle to make sure the blender
o
c
im
h
u
clear.
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
r
U
0
re
e
0Illustration
s
2
PA55
d
t
e
re
Apply
Paint
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
144
8. Apply a first coat
d of blender. (See Illustrational
e
PA60.) v
u
w
la
n
r
y
a
e
b
9. Air dry s
for 1 to 2 minutes.
M
e
d
r
e
e
t
c
10. Apply
a
second
coat
of
paint,
covering
an
area
ts
bi
vi
i
just beyond the first coat of color.
h
r
h
e
ig
o
S
r
r
l
l 11. Air dry for 1 to 2 minutes.y
l
p
a
d
A 12. Apply the final coat ofoblender, extending just
n
nu
o
i
B
a
t
beyond the previous spray patterns.
c
M
—
u
e
e
l
d
13. Air dry 3 to 4ichours before removing masking
ic
o
v
r
materials. h
(See Illustration PA65.) p
r
e
Illustration PA60
e
e
V
S
Apply Blender
14. If the rrepair is not glossy enough afterr drying,
y
d
e
tbuffing compound and buffztoe achieve the
d
use
s
o
ir
adesired appearance.
B
o
m
i
—
l
h
i NOTE: See also the Decals
t
le
ut section.
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
Illustration PA65 te
m
i
Air Dry 3 to 4 Hoursb
ili
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
145
Positive Pressure System
l
w
d
a
a
e
l
u
Positive Pressure
rv
y Chamber
an
e
Some vehicles aresequipped with an optional
b
M
d
positive pressure
resystem. Two types of thesece
e
t
i
s
systemsmanual
and electricare currently
vi in
ib
ht
r
service ingUtilimaster
vehicles. (See Illustrations
h
e
ri PP10.) The manual systemS has a
PP5l and
ro
l
y
l
p
a
lever
A in the cab to open or closeothed vent. The
u
n
Drain Tube
electric version has a power fan
it o
Bseen from the
an
cargo side of the bulkhead wall.
c
M
u
e—
e
Illustration
PP5
l
d
c
ic
This unit has two functions:
i
Electric Positive Pressure System
o
v
r
h
r
p
e
· To create V
ae
positive pressure in the re
S Lever
Manual Intake Control
r helping to prevent dust, d
cargo e
area,
y
t
d
dirt,sand water from entering. ize
o
a
r
Cab B
o fresh
· lim
With cab vents open, to provide
h
i air to the cab area, allowing
t the doors
Vents
e—
t
l
u
U and windows to be closed,
a and
ic
n
n
h
e
Uentering the cab. tio
preventing dust from
V
a
r
Drain Tube
er
NOTE: The rear door, bulkhead o
t
p
rmust
door, and cargo-area side vents
as
o
w
m
Illustration PP10
a
be closed during operation inCorder
i
l
l
Manual Positive Pressure System
ti
to have positive pressureteinr the cargo
y
U
b
s
area. Having slidingawindows or cab
d
e
side vents open will
decrease
m
t
i
bi
performance. til
i
U
oh
NOTE: The2manual system is totally
r
w
0on the vehicles forward
p
dependent
la
0
n
2
n
speedt for effectiveness.
io
o
by
Air Intake
i
t
h
t
c
d
a
Operationig
of Electric System
u
e
r
r
d
it
y
o
o
p
Start p
or stop the airflow by opening or closing ib
r
r
the
Codoor on the cargo side of the bulkhead. roh
ep Illustration PP20Co
r
(See Illustration PP35.) The fan will turnpon
r
Positive Pressure e
Intake
d
t
e
automatically.
s
on
iz
i
a
r
t
Operation of Manual System
o
c
im
h
u
l
t
i
t
Start or stop the airflow by opening
u
od or closing
U
a
r
ed
the Intake Control Lever in
the cab area. (See
n
p
2
v
U
Illustration PP10.)
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration PP30
C
n
A
Manual
Positive
Pressure
Filter
U
Overview
146
l
w
d
a
a
e
l
u
v system is dependent on a clean
Proper operation of rthe
y
an
e
b
intake and filter. s
M
e
d
e the
e
1. Withsarstream of water from a hose, cclean
t
t
bi
vi
airhintake.
(See Illustration PP20.)
i
r
h
igRemove the filter at the rear ofSethe assembly by
o
r
2.
r
l
l
y and pulling out
l
p
Filter
a
grabbing
the
metal
filter
frame
d
A
u
n
o In the earlier
(toward the rear of theBtruck).
it o
an
models the filter is —
M
e held in place with Velcro. duc
e
l
c models there may also rbeo a
ic
NOTE: In early
i
v
h up by the cab vents. Reach
r
screen inside,
p in
e
e
e
r out, and
S
(from filter
r V opening), pull the screen
y
d
e
cleant this screen with water before
d
e
o
reinstalling
the filter frame. riz
as
Illustration
B PP35
o
m
Electronic Positive
Pressure Filter
i
—
l
h
i3. Clean the filter under running
t water.
e
t
l
u
U 4. Shake out the water anda reinstall the filter. n
ic
n
h
e
U
tio
V
5. The drain tube goes from the bottom of
the
a
r and
er
o
assembly, down the front of the bulkhead,
t
rp
through the cab floor. Clean asonecessary
by
as
w
a
blowing compressed air through
it from the top. lim
C
l
ti
(See Illustration PP10.)ter
y
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
Illustration PP40
n
2
n
Positive Pressure
t
io Drain
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Maintenance
147
Roof
l
w
d
a
a
e
l
u
rv Removal and replacement aofn roof could result in roof leaks.
y If a vehicle requires
CAUTION:
e
b
s
M
major
or structural repair, check with Utilimaster for a recommendation
on returning the
d
re roof
vehicle
to Utilimaster or repairinge damage at a body shop. te
i
ic
ts
b
v
i
h
h
er
ig
o
S
r
r
l
l
y
p
a
d
Al
u
n
it o
Bo
an
c
M
u
e—
e
l
d
Roof Panel ic
c
i
o
r
h
Roof Vent
rv
p
e
e
V
re
S
r
y
d
e
t
d
e
s
o
Corner
Casting
iz
a
r
B
o
m
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h
Edge Cap
e
it o
Un
V
a
r
Front
r
e
o
t
rp
as
o
Light Backer
w
m
a
C
End Cap
i
l
l
ti
End Rail
er
t
U
by
s
a
d
Edge Rail
e
m
t
ili
bi
t
i
U
Roof Bow
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
Roof
Liner
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
Wire
u
l
End Rail
t
Insulation
i
d
u
Channel t
d
o
U
a
r
e
n
p
2
v
Cab Light
U
0
re
er
0
Corner Gusset
s
2
d
Vinyl Insertt
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
Illustration RO10
a
ll
C
n
A
Roof Assembly
U
148
l
w
d
a
a
e
l
u
Casting Removal
n
rv
y
a
e
1. Remove s
the rivets on the roofs side andMend caps (not the rails) with ab
#11 or 3/16" drill bit.
d
re
e
e
t
c
2. Using
a
utility
knife,
cut
the
sealant
around
the
casting.
Pull
off
the
casting.
ts
bi
vi
i
h
r
h
Castingig
Installation
e
o
S
r
r
l
l1. Scrape off the old sealant and
y clean the bonding surfacepwith a lacquer-based solvent.
l
a
d
A
u
n
NOTE: For new casting,
io old casting as a model (if possible) or mark
Bo drill new holes using tthe
an
con the frame.
M
hole locations from
u
e—test-mounting the casting
e
l
dsurface where the casting will mate with theicframe.
c sealant along the bonding
i
o
2. Apply polyurethane
r
h
rv
p
e
e
e the side and end caps using the same rivet
3. While holding
V the corner cap in place,rrivet
S holes.
r
y
tea bead of sealant where the
d
4. Apply
edcap attaches to the roof.
s
z
o
i
a
r
B
5.imSeal the perimeter of the corner
castings.
—
ho
i6.l After an eight-hour waiting
t
e
t
l
u
water-test the roof. With all doorsc and windows closed tightly,
U
atop ofperiod,
i with water. Check for leaks.
n
n
spray the roof and the
the side structures
near
the
affected
area
h
e
Uany leaks appear.) tio
(Reseal and retest if
V
a
r
er
o
t
p
r
Exterior Roof Panel Replacement
as
o
w
m
Rivet Location
a
C
i
l
l
NOTE: If the entire roof panel
r is translucent ti
te
Kemlite . Utilimastersrecommends
the use U
by
d
of a patch kit such asa SunPatch (P/N
e
m
t
i
01900680) where
ilipossible.
b
Roof
Crossmember
t
i
Side
h
Exterior Panel RemovalU
Cap
o
2
r
0 or 3/16" drill bit, remove the rivets law
p
1. Using a #11
0
n
2
n
on the
t side and end caps (not the rails).
io
o
by
i
t
h
Front View of
c
NOTE:
at
ig Be sure to remove all of the rivetsted
u
r
r
Sidewall to Roof Section
d
i
y during these steps.
o
o
b
p
p
i
r
r
o
Co 2. Remove the corner castings.
ep
oh
C
r
r
r
p
d
3. Remove the side caps. (See Illustration
e
t
e
n
s
RO15).
iz
it o
a
r
c the roof panel to ho
Illustration
imRO15
4. Remove each rivet securing
u
l
t
i
Roof
Cross-Section
t
u
the side and end rails.od
d
U
a
r
e
n
p
2
rv
5. Remove the exterior
U be required to break the
0 panel loose from the roofebows).
re panel (some prying may
0
2
dof a heat gun will help break the adhesive bondt holding
es to the
NOTE: Use
the translucent panel
e
r
h
iz and rails.
roof bows
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Rear Corner Casting Replacement
®

149
Exterior Panel Installation
d
l
w
la
1. Scrape the rails,ecaps, and roof bows to remove
uathe old sealant.
rv
ancleaner and allow to dry. by
e
2. Clean the ssealant areas with a lacquer-based
M
d
re
e
e
t
c
i
s
tCAUTION: For Steps 3 and r4,vido not remove the tape paper
ib until the panel is in the proper
h
h
e
g
i position. Once the tape Ssticks to a surface, you willronot be able to reposition it without
l
ll r starting over and possibly
y damaging the new Kemlite
p .
a
d
A
u
n
it o
Bo
an
c on all the roof bows.
M
3. Apply the 1/2"-wide
u
e—adhesive tape (P/N 12605933)
e
l
d
c adhesive tape (P/N 12605927)
ic
i
o
v
r
4. Apply the 1"-wide
around
the
roof
perimeter
on
the
side
extrusion
rails
h
r
p
e
e
and the front
V and rear end rails.
re
S
r
y
d
e
5. Peel off
t just a few centimeters ofzthe
d
e tape paper at each tape end of the roof perimeter.
s
o
i
a
r
B
6. m
Peel off just a few centimeters
o of the tape paper at each end of the roof bows.
i
—
l
h
i
t panel.
t
le
7. Lay down the new translucent
u
c
U
a
i
n sure you can reachh (from the interior or the
n
NOTE: As you areUlowering
the panel, imake
o
e
ttape strip.
V
exterior) the peeled-off paper on every
a
r
er
o
t
8. Carefully pull out all the remainingrp
tape paper.
as
o
m with a roller) to firmly adhere the tape ltoaw
9. Apply pressure around the perimeter
(by hand or preferably
C
i
l
ti
the roof.
er
t
U
by
s
a caps in place, rivet the side and end caps using the same rivet holes.
d
10. While holding the corner
e
m
t
ili where the cap attaches to the roof.
bi
11. Apply a bead of tsealant
i
U
oh
12. Seal the corner
castings.
2
r
w
0
p
laWith all doors and windows
0
13. After an2eight-hour waiting period, water-test the roof.
closed tightly,
n
n
y
o
t
i
o
b
spray
the
roof
and
the
top
of
the
side
structures
with
water.
Check
for
leaks.
(Reseal
and retest if any
i
t
h
t
c
d
a
ig appear.)
leaks
u
e
r
r
d
it
y
o
o
b
p
p
i
r
Exterior
Panel
Repair
r
o
Co NOTE: Quick and easy fiberglassrrepair
ep for permanently repairing
oh kits are now available
C
r
small
r
p
d
e
tears and punctures. These kits,
repair kit (P/N 01900680),
work in
t
n such as Kemlite SunPatch
s
ze of resins.
a wide range of temperatures
(See also
the
Utilimaster
it oand do not require therimixing
a
o
c
m
Quick Reference Parts Guide.)
i
u
th
il
d
t
u
U
a
ro
ed
n
p
2
v
U appropriate breathing0apparatus
e rubber gloves and any
0
WARNING: rUse
as recommendedrby
e
the manufacturer of the kit.
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
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u
o
a
ll
C
n
A
U
®
®
150

l
w
d
a
a
e
l
u
NOTE: There
rv is fiberglass insulation an
y
e
b
behind these
panels.
s
M
e
d
e
e
Liner Removal r
t
c
ts
bi
vi the
i
h
r
1. Using
a Phillips screwdriver, remove
h
e to the
igthree screws holding the cab light
o
S
r
r
l
l ceiling.
y
l
p
a
d
A
u
n
o
n
o
i
B
a
2. Detach the cab light unit from the electrical
t
c
M
—
harness and set aside
for
later
reassembly.
u
e
e
l
d
c the interior panel, use a #11
ic
i
o
3. While supporting
v
r
h
r
p
e
e
or 3/16" drill
bit
and
drill
to
remove
the
rivets
e
r
S
r toV remove all of the rivets).d (See
(be sure
y
e
Illustration
RO20
t RO20.)
d Interior
e
Illustration
s
Roof Liner of Cab
o
ir z
a
B
o
4.imLower the panel.
—
l
h
i
t
le
ut
Liner
c
U Installation
a
i
n
h
1. Reusing the fiberglass
on the panel. e
io
Uninsulation, lay the fiberglass
t
V
a
r
r
2. Reposition the panel.
o
te
p
s
r at 1/2".
a
3. Drill new holes using a drill stoposet
w
m
a
C
i
l
l
ti
y
er
t
U
b
CAUTION: The drill
stop
is
critical;
otherwise
a
hole
can
be
drilled
into
the
exterior
skin.
as
d
e
m
t
ili
bi
t
i
4. Rivet into place.
h
U
o
2
r
0 cab light.
5. Replace0the
p
aw
l
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Interior Roof Liner Replacement
151
Seats and Seat Belts
l
w
d
a
a
e
NOTE: The seat
and
seat
belt
sections
in
this
manual
apply
only
to
Utilimaster-installed
l
u
rvAeromaster walk-in vans.an
equipment eon
by
s
M
d
re
e carefully. Failure to install
e
WARNING:
Read vendor instructions
and inspect can result in
t
c
i
s
i
t
b
v
injury
or
death
of
user.
i
h
r
h
e
ir g
S
ro
l
l CAUTION: Do NOT remove
cardboard spacer untilpthe retractor is mounted. The retractor
y
l
a
d
A
must be mounted ato the proper angle before web
n will freely extend. Cardboard spacer must
nu
be removed after B
seat belt is fully installed. io
a
t
c
M
—
u
e
e
l
d
c
ic
i
o
v
r
r
p
eh
e
e
V
r
S
r
y
d
e
t
d
e
s
o
iz
a
r
B
o
m
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h Seat
e
it o
Un
V
a
r
r
te
po
s
r
a
o
w
m
a
C
i
l
l
D-Loop
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
Buckle
oh
2
r
w
0
p
la
0
n
2
n
t
io Retractor
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
Pedestal
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
rePedestal
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
Illustration
SB5
a
ll
C
Drivers Seat Installation
n
A
U
152
l
w
d
a
a
e
l
u
n
rv
y
a
e
b
s
M spacer until the retractor
d is mounted. The retractor
CAUTION:
Do NOT remove cardboard
re
e
e
t
c
must
be
mounted
at
the
proper
angle
before
web
will
freely
extend.
Cardboard spacer must
i
s
i
t
b
v
be
removed
after
seat
belt
is
fully
installed.
i
h
r
h
e
ir g
o
S
r
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
D-Loop
rV
y
d
e
t
d
e
s
o
ir z
a
B
o
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
Upper
a Seat
o
w
m
Back
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
wJump
Lower
0
p
aSeat
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d Seat Belt
a
ig
u
e
r
r
d
it
y
o
Buckle
o
b
p
p
i
r
r
o
CoRetractor
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration SB10 C
n
A
Jump Seat Installation
U
WARNING: Read vendor instructions carefully. Failure to install and inspect can result in
injury or death of user.
153
Overview
l
d
w
a specifically for deliverylavehicles. The high usage
Your occupant restraint e
system has been developed andutested
v
n of this seat belt to severeyenvironmental conditions
r vehicle application and exposure
associated with delivery
a
e
b
sinspect the seat belt system regularly.
M
make it crucial to
The seat belt system
must be inspected during
e
d
r
every routine
ce
ite
s maintenance.
t
vi
b
i such as cuts; fraying; extreme or
hsystem should be replaced immediately
r
A seat belt
if it shows any problems,
h
e
g
i
Sdue to ultraviolet exposure; significant
unusual
dirt; abrasion to the seat belt
ro
l
l r wear; significant discoloration
y
l
p
a
webbing;
A or damage to the buckle,dlatch plate, retractor, or hardware.
u
n
o
o
i
B
an
Replace the seat belt only with a belt recommended by Utilimaster.
If any part of the seat belt requires
t
M
— must be replaced. uc
replacement, the entirelebelt
e
c
ic must be
odbelt. If the seat belt is replaced, all components
v
r
An installation guidehisi attached to every replacement
r
p
esame position as the originalecomponents.
e
mounted back in the
This
will
maintain
the
design
integrity
of the
V
r
S
r
mounting points
for
the
seat
belt
assembly.
te
dy
ed
s
z
o
a WARNING: Belts must beriinspected during every routine maintenance.
B Failure to properly
oseat belts can cause serious injury or loss
m inspect and maintain the
i
life. The seat belt in a
—
l
h
i delivery vehicle application
t
e asofneeded
t
has a finite life and must be replaced
throughout the
l
u
c
U
i
life of the vehicle.a
n
n
h
o
i
U
Whenever a vehicle is involved in an
accident, the entireVe
seat belt system must be
t
evaluated for replacement, even rifa there is no visible wear
er or damage to the seat belt
o
system.
t
rp
as
o
w
m
a
C
i
Maintenance
l
l
ti
y
er
Webbing (cut, frayed, or
t
U
b
The
following
maintenance guidelines detail how to
inspect
s
worn at Latch area)
a
d found,
seat belts. If any of these problem conditionseare
m
t
the entire seat belt system must be replaced.
ili
bi
t
i
U
Seat Belt Webbing
oh
2
r
w
0
p system for cuts,
Examinelaseat belt webbing in the seat
0
n
2
y extreme or unusual wear,
fraying,
o significant dirt, or ion
t
i
b
t
h
t
extreme
d faded color due toucexposure to ultraviolet rays.
a
ig
e
r
r
(See
Illustration
SB15.)
d
it
y
o
o
b
p
p
i
r
r
D-Loop
Web
Guide
o
h
o
CBuckle
ep
o
Latch Plate
C
r
r
The D-Loop Web Guide is an area whererthere is a
p
teduring the use of
significant amount
ed of webbing movement
n
s
z
o
the seat belt
ri system. If the web is cuta or frayed at the
ti
o
c
imsystem must be
D-Loop
Web Guide, the entire belt
h
u
l
t
i
t
u (See Illustration SB20.)
replaced.
od
U
a
r
ed
n
p
2
v
U Retractor System 00
re
er
s
2
d
The retractor, the heart
of the occupant restraint system,
t
e
re
h
z
contains
a
locking
mechanism
and
serves
as
a
storage
i
Illustration
r or LatchSB15
ts the
ig when not in use. Check
device for the rwebbing
o
Webbing
Plate Wear
h
ystorage device operation toigensure that it is
h
t
retractor
web
p
u
o
lr
a
l
C
A
Un
154
not locked up. The seat belt
l
d webbing must spool out freely
a
e
and retract properly. v
(See Illustrations SB5 and SB10.)
u
r
an
e Locking Retractor) belt system is
An ELR (Emergency
s
M
re decelerations of the vehicle.
sensitive to sudden
An ALR
e
c
s
i
(AutomatictLocking Retractor) system is sensitive
to sudden
h
rv let it retract,
pulls onigthe belt. If it locks, release theebelt,
and
S
r
slowly
y
ll pull it out again.
d
ti e
ib
h
o
pr
by
w
la
Webbing cut, frayed, or
worn at D-Loop Guide
l
a
d
A
u
n
Seat Belt Buckle
it o
Bo
an
Check the buckle for proper
c
M
—operation by inserting the ulatch
e
e
l
and listening for an audible
Illustration SB20 c
d is not
c click. Verify that the buckle
i
i
o
D-Loop Wear
v
r
damaged and that the
plastic
casing
is
not
broken
or
h
r
ethe seat belt buckle cable strap
e
cracked. Examine
ep to
V
r
S
determine if there
y
d is damaged,
er is unusual wear, if the cable
t
d
e
or if the cable
is cut or frayed. (See Illustration
SB25.)
Buckle (cracked
s
z
o
i
a
r
B
or broken)
Buckleim
Latch Plate
ho
il
t
e—
t
l
u
Check
U the buckle latch plate fora excessive wear. Make
ic
n
h
sure the buckle latch is neither
bent nor deformed.oItn
e
U
ti
V
must latch properly into the buckle. (See Illustration
a
r
er
SB15.)
o
t
p
r
as
Seat Belt Height Adjuster
o
w
m
a
C
i
l
l
Check the height adjuster for properr operation, making ti
y
e adjuster does notU
t
b
sure there is no damage. If the height
s
d
move up and down freely andalock at different height
e
m
t
positions, the seat belt must
ili be replaced. (See Illustration
bi
t
i
SB30.)
h
Cable damaged
U
o
2
or
frayed)
r
0 Replacement
p
aw
Pedestal Seat Belt
l
0
n
2
n
t The outboard side refers to the side by
NOTE:
io
o
Illustration
SB25
i
t
h
t
c Buckle Wear
d
closest
a
ig to the door. The inboard side is the
u
e
r
r
d
y side toward the center of the vehicle. bit
o
o
p
p
i
r
r
Seat
o
Co Belt Removal
ep
oh
C
r
r
r
p to the seat belt mount
1. Remove the bolt attaching the D-Loop
above the seat on the outboard
side. (See
d
e
t
e
n
Illustration SB30.)
s
iz
io
a
r
t
c and remove the bolt.ho(See Illustration SB40.)lim
2. Snap open the retractor u
cover
t
i
d
t
u
o
3. Remove the bolt holding
U side of the seat. (See ed
a attached to the outboard
r the seat belt end bracket
n
p
2
Illustration SB45.)
rv
U
0
re
e
0
2
d When a seat belt is replaced, both halves must
es
t
WARNING:
be replaced.
e
r
h
z
ithe
g
r
ts old
i
Use
new
mounting
hardware
furnished
with
the
replacement
belt. Do NOT use
r
o
h
hardware
when installing replacement seat belts. y
h
ig
t
p
r
u
o
a When installed, the D-Loop must rotate freely.CThe D-Loop must return tollthe horizontal
n
A
U position when the belt is retracted.
155
4. On the inboard side of the seat, remove the bolt holding the seat
l
belt buckle assembly.
ed (See Illustration SB50.) a
w
a
l
u
v
n
Seat Belt Installationer
a
by
s
M
e seat belt D-Loop in the existing
1. Mount rthe
e hole in the seat belt ted
c
s
i ftlb. (See Illustration bi
mounting
t bracket. Torque bolt tor3550
v
i
h
h
e
g
ir SB30.)
o
S
rthe
l
l Snap open the retractor cover
2.
and insert the locating pin at
y
l
p
a
d mounting bracket in the bulkhead
A back of the retractor intoothe
n
nu
o
i
B
a
wall.
t
c
M
—
u
emounting bolt and tighten the
e
l
3. Insert the retractor
bolt
to
3550
d
cNm]. (See Illustration SB40.)
ic
i
o
v
r
ftlb [47.567.5
r
p
eh
e
e
V
r
S
4. Snap ther retractor cover down into place.
y
d
e
t the safety belt bracket in the
d
5. Mount
s
zeexisting hole on the seat
o
i
a
r
B
pedestal. Torque bolt to 3550
o ftlb. (See Illustration SB45.)
m
i
—
l
h
i
t the inboard side of the seat with the
t
le
6. Mount the seat belt latchuon
c
U release button facing away
a
i
n Torque bolt h
n from the seatediodriver.
e
U
to 3550 ftlb. (See Illustration SB50.)t
V
a
r
er
o
Illustration SB30
t
Jump Seat Belt Replacement
p
s
r
Loop Attached to Height Adjuster
a
o to the side closestmto
w
NOTE: The outboard side refers
a
C
i
l
l
the door (jump seat occupants
r right-hand side).ti The
te the center of the
U vehicle.
by
inboard side is the sidestoward
a
d
e
Jump Seat Belt Removal
m
t
i
li
i
b
t
i
1. Remove the bolt
the D-Loop to the bulkhead
Uonattaching
oh
above the seat
the
outboard
side.
2
r
w
0
p
la
0
2. Snap open
the retractor cover and remove the bolt.y (See
n
2
n
t SB40.)
io
o
b
Illustration
i
t
h
t
c
g
d
a
i
u
e
r
r
3. yRemove the bolt holding the seat belt bracket
d
it to the seat belt
o
o
b
p
p
mount
just
below
the
seat
on
the
outboard
side.
(See
i
r
r
h
o
Co Illustration SB55.)
ep
o
C
r
r
r
p the bolt holding thed
IllustrationeSB40
4. On the inboard side of the seat, remove
t
e
n
Retractor sUncovered
seat belt buckle assembly. (See
io Illustration SB60.) riz
a
t
o
c
m
i
u
th
il
d
t
u
o
a in the proper position onUthe bracket for the seat ed
rretractor
WARNING: The
must be located
n
p
2
v
r
belt web to extract
U
0
re and function properly.
e
20
d
When a seat
belt is replaced, both halves must be replaced.
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
156
l
w
d
a
a
e
l
u
1. Remount therv
seat belt D-Loop using the existing
n hole in
y
a
e
b
the bulkhead.
s
M
d
re the retractor cover and insert
e
e
2. Snaps open
the
locating
pin
t
c
i
t back of the retractor into thervmounting
bi
aththe
bracket in
i
h
e
igthe bulkhead wall.
o
S
r
r
l
l
y tighten the nut to 3250 ftlbp
l
a
3.
Insert
the
mounting
bolt
and
d
A
u
n
[4367.5 Nm].
it o
Bo
an
c
M
4. Snap the retractor
cover down into place.
u
e—
e
l
d
c
ic
i
o
v
r
5. Mount the seat
belt
end
bracket
to
the
seat
belt
mount
h
r
pIllustration
e
e
e
below the
seat
on
the
outboard
side.
(See
r
S
rV
SB55.)
y
d
e
t
d
e
s
o
iz
a the nut to 3550 ftlbr[4367.5
6. Tighten
Nm].
B
Illustration SB45 Safety Belt End Bracket
o
m
i
—
l
h
i7. Mount the seat belt buckle
t assembly on the inboard side
t
le
u
c
U of the seat with the release
button facing away from the
a
i
n
n bolt to 3550 ftlbio[4367.5
h
occupant. TorqueU
the
e
t
V
Nm]. (See Illustration SB60.)
a
r
r
o
te
p
s
r
a
o
w
CAUTION: Do NOT remove
the cardboard spacer
m
a
C
i
l
l
until the retractor is mounted
and
seat
belt
is
fully
tibind.
y
er belt will retract and
installed; otherwise tthe
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
Illustration SB50 Seat Belt Latch
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll SB60
Illustration SB55
C
n
Illustration
A
UEnd Bracket Attached to Seat Belt Mount
Jump Seat Belt Buckle Assembly
Jump Seat Belt Installation
157
l
Al
ts
h
rig
d
e
rv
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
d
te
i
ib
h
o
pr
n
it o
c
u
od
r
p
reIllustration SB65
by
w
la
ce
i
rv
e
S
l
a
u
an
M
dSeat to Pedestal Fasteners
er
t
dy
e
s
z
o
i
Pedestal Seat
a Replacement
r
B
o
m
i
—
l
h
Seat Removal
i
t
t
le
u
U 1. Remove and retain the afour nuts and washersnattaching the seat to theicpedestal.
(See Illustration
h
e
SB65.)
it o
Un
V
a
r
r
2. Pull the seat off the pedestal.
te
po
s
r
a
Seat Installation
o
w
m
a
C
i
l
l
1. Set the replacement seat in place.
ti
y
er
t
U
b
s
NOTE: Do NOT usealocknuts to hold the seat to the
d
e
pedestal.
m
t
ili
bi
t
i
2. Fasten the fourUnuts and washers and torque nuts to 12
oh
2
14 ftlb [16.518.5
Nm].
r
w
0
p
la
0
n
2
Pedestal Replacement
n
t
io
o
by
i
t
h
t
Pedestal Removal
c
d
a
ig
u
e
r
r
d
itthe pedestal
yRemove and discard the four bolts attaching
o
1.
o
b
p
p
i
r
r
h
o
Co to the cab floor. (See Illustration SB70.)
ep
o
C
r
r
r
2. Remove the one bolt attaching thepseat belt to the
d
e
t
e
n
pedestal. (See Illustration SB45.)
s
iz
io
a
r
t
Illustration
SB70
o
m Pedestal
3. Pull out the pedestal seat.uc
i
h
l
Four
Bolts
Attach
Seat
to Floor Base
t
i
d
t
u
Pedestal Installation
U
a
ro
ed
n
p
2
v
U
1. Reverse the removal
re procedure.
er
00
s
2
d with new Grade 5 or better fasteners and torque
2. Replace fasteners
t them to 70 ftlb [95 Nm].
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
158
l
w
d
a
a
e
l
u
Jump Seat Removal v
n
r
a
e
by back, and remove the 1/420
1. From thescargo area, brace the two-wayMlocknuts attaching the jump seat
d
re
e
e
bolts attaching
the back to the bulkhead.
t
c
ts
bijump seat to the bulkhead.
vi
i
h
2. Remove
and discard the 3/816erbolts and locknuts attachinghthe
ig
S
ro
Jump
l
ll rSeat Installation
y
p
a
d
A 1. Align the jump seat witho holes on the bulkhead and attach
n with new 3/816 bolts (Grade 5 or better)
nu
o
i
B
a
t
and two-way locknuts.
c
M
—
u
e
e
l
d
2. Torque fasteners
c to 2832 ftlb [3843 Nm].
ic
i
o
v
r
h seat back with holes on the
p bulkhead and attach with 1/420 screws. er
e
3. Align the jump
e
V
r
S
rfasteners
y
4. Torque
to
89
ftlb
[1113
Nm].
d
e
t
d
e
s
o
ir z
a
B
o
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
a
r
r
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Jump Seat Replacement
159
Shelving
l
w
d
a
a
e
Some cargo shelves can
be
flipped
up
to
accommodate
l
u
n
rv
larger parcels.
a
e
by
s
M
d
reSpring-Loaded Bolt Latches
e
Shelf Operation,
e
t
c
i
s
tshelf, reach under to the locking
vi lever (located
ib
h
To raise the
r
h
e
g
in the center
ri of the long shelves and toSthe left side on the
ro
l
l
y
l
p
a
short shelves). (See Illustration SH5.)
Pull the springd
A
o lift the shelf up. Lift the ion
loaded locking bolt to the side and
nu
B
a
shelf toward the sidewall until
you hear the bolt click into ct
M
—
u
e
place.
e
l
d
c
c
i
o
Illustration SH5 vi
r
h its upright position, pull thep springTo lower the shelf from
Spring-Loaded ShelferLatch
e
e
V
loaded locking bolt to the side and lower the shelf
r to its
S
r until you hear the bolt click
y
d
horizontal position
into
place.
e
t
d
e
s
o
iz
a
r
B
o
m
i
—
l
h
iOperation, Rubber Jeep uStrap
t Latches
t
Shelf
le
c
U
a
i
n Jeep
n and release the rubber
h
To raise the shelf, reach under
o
e
i
U
t
V
strap latches. Lift the shelf toward the sidewall to
a the full
r
r
upright position and secure all (usually at least
two) of the
te
po
s
r
upper rubber straps. (See Illustration SH10.)
a
o
w
m
a
C
i
l
To lower the shelf from the upright position,
release
the
l
r
ti
rubber straps and slowly lower theteshelf. Secure all of the
U
by
s
straps to hold the shelf down. a
(See Illustration SH15.)
d
e
m
t
NOTE: Using all
iliof the straps available
bi
t
i
h
U the upright or down
to hold the shelf
o
2
Illustration
SH10
r
w
position will
0 reduce vibration and wear on
p in the Upright Position
la Rubber Shelf Latch Locked
0
the contact
parts.
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
Illustration
SH15
ir z
ts Position
ig Shelf Latch Locked in thehDown
Rubber
r
o
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
160
l
w
d
a
a
e
l
u
v
Switch (Dash Toggle)rReplacement
n
y
a
e
b
s
Mof the
1. Disconnect
the Negative (Black) terminal
d
re
e
e
battery.
t
c
Switch
Body
Actuator
i
s
i
t
b
v
i
h
r
2. g
h
ir Remove the instrument panelSifenecessary.
Actuator snaps
Detach
o
r
onto Switch Body l
l Detach the electrical harnessy from the back of the Harness
3a.
l
p
a
d
A switch body.
u
n
o
io
B
an
t
3b. Identify and tag the—
connectors at the back of thec
M
Squeeze tabs to release
u
e
e
l
switch bodies so
switch body from Bracket or Bezel c
din
c that they can be reconnected
i
i
o
v
r
the same order.
h
r
p
e
e
Illustration SW10
e
V
r
S
4. Squeeze
the
top
and
bottom
of
the
switch
body
to
Switch
Components
y
erit from the panel. (See Illustration
remove
t
d
ed SW
s
z
o
i
10.)
a
r
B
o
m
i5.li Pop off the actuator. uth
e—
t
l
c
U 6. Snap the actuator ontoathe new switch body,nthen reverse the aboveiprocedure.
n
h
e
U
tio
V
7. Reconnect the battery.
a
r
er
o
t
8. Test the function of the switch. rp
as
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
s
a
d are very
e
CAUTION: On m
three-way switches the order in which the wires connect to the switch
t
important. Failure
ili to reconnect properly will cause the three-way switch system
bi to fail.
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Switches
161
Vent
l
Al
ts
h
rig
d
e
rv
e
s
re
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
te
i
ib
h
o
pr
by
w
la
ce
i
rv
e
S
l
a
u
an
M
er
t
dy
ed
s
z
o
i
a
r
B
o
m
i
—
l
h
i
Illustration tVE10
t
le
uMounted from Inside
c
U
Two-Way Hingeless Vent
a
i
n
n View)
h
(Exterior
o
e
i
U
t
V
Illustration VE15
Two-Way Hingeless
a
r
r
Two-Way
Hingeless Vent
e
o
t
Vent (Two-Way Hingeless) Replacement
p
(Interior
View
in Quarter Panel)
s
r
a
o
w
Vent Removal
m
a
C
i
l
l
ti
NOTE: The two-way hingeless
y
er vents
t
U
b
s
may be mounted fromathe inside or
d
e
outside, dependingm
on the location on
t
ili
the vehicle.
bi
t
i
U of the vehicle, using a #11 or
oh
1. From the exterior
2
r
w
0 remove all the rivets securing the la
p
3/16" drill0bit,
n
2
n
vent. t(See Illustrations VE10 through VE20.) by
io
o
i
t
h
t
c
d
a
ig the vent.
2. Remove
u
e
r
r
d
it
y
o
o
b
p
p
3.
Remove
any
excess
sealant
from
vent
mounting
i
r
r
h
o
Co area.
ep
o
C
r
r
p
d
er
4. Clean contacting surfaces with anlacquer-based
t
e
s
iz
solvent.
io
a
r
t
o
c
im
Vent Installation
h
u
l
t
i
t
odthe contacting surfaces.au
U
1. Apply sealant between
r
ed
n
p
2
v
U
e
er
2. Align the hole inrthe vent and the panel opening.
00
s
2
t
ed using (solid brazier-head) buck
re
3. Attach thezvent
h
i
Illustration
VE20
s
ig Hingeless Vent Mountedhtfrom
rivets. or
r
Two-Way
Outside
y
h
g
(Interior
View
in
Cargo
Area)
p
ri
4. From
ut the exterior, apply a bead of sealant to the
o
l
a
l
C
joint between the vent and the wall.
n
A
U
162
l
w
d
a
a
e
l
u
Removal
n
rv
a
e
by
1. From thesexterior of the vehicle, removeM
the four
d
re steel #8 x 1" Phillips pan-head
e screws
e
(4) stainless
t
c
tsattach the roof vent to the backer
that
bi
vi plate. (See
i
h
r
h
e
igIllustration VE25.)
o
S
r
r
l
l2. Gently cut the sealant around
y the circumference of p
l
a
d
A the vent before removingo the vent from the roof. n
u
it o
B
an
c
M
3. Remove any excess
u
e—sealant from the vent mounting
e
l
d
area.
c
ic
i
o
v
r
h
r
p
e
e
4. Clean with
a
lacquer-based
solvent.
e
V
r
S
r
Illustration
VE25
y
d
e
5. Fromt the cargo area, remove foure(4) #8 x 1/2"
Roof Vent (Exterior
View)
d
z vent (if
o
pan-head
as screws to replace therigarnish
B
mnecessary). (See IllustrationhoVE30.)
i
—
l
i
t
le
ut
Installation
c
U
a
i
n
h
1. On the outside of the
e
Unvehicle, apply graytio
V
a
polyurethane sealant around the circumference
of
r
r
o
te
the roof vent flange.
p
s
r
a
o
w
2. Align the vent with the holes in
the
roof
and
the
m
a
C
i
l
l
vent backing plate.
ti
y
er
t
U
b
3. Using stainless-steel #8
asx 1" Phillips pan-head
d
e
m
screws, reattach the
vent
to
the
roof.
(See
t
ili
bi
Illustration VE25.)
t
i
h
U
o
2
r
4. From the exterior,
apply
a
bead
of
sealant
to
the
0 the vent and the roof.
p
aw
l
0
joint between
Illustration
VE30
n
2
n
y
o
t
Roof Vent
(Interior View)
i
o
b
i
t
h
5. From
the cargo area, reattach the garnish vent to
t
c
d
a
ig vent plate using four (4) #8 x 1/2" pan-head
u
the
e
r
r
d
it
y screws. (See Illustration VE30.)
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Roof
163
Visor Replacement
l
w
d
a
a
e
l
u
n
rv
a
e
NOTE: The
visor
arms
and
pad
are
by
s
M
d
replaced
reas a unit. (See IllustrationceVI10.)
e
t
i
s
t the overhead storage cover.
vi
1. Remove
ib
h
r
h
e
g
i
S cover off the
2.
ro
l
ll r With a flat blade, pop the plastic
y
p
a
VI15.)
d
A visor arm brackets. (SeeoIllustration
n
nu
o
i
B
a
3. Remove the four #10-24 Phillips screws and
t
c
M
—
KEPS nuts.
u
e
e
l
d
c
ic
i
o
Visor Installation
v
r
r
p
eh
e
e
V
1. Using the existing holes in the shelf, position
r
S
Illustration VI10
r assembly and attach with the
y
d
e
the visor
four
Sun Visor d
Unit
t
enuts.
s
z
o
#10-24
Phillips
screws
and
KEPS
i
a
r
B
o
m
i
—
l
h
NOTE:
The
arms
on
some
visors
are
i
t
t
le
u
collapsed
into
the
pad
when
shipped.
c
U
a
i
n
n hole pattern on the
h
Adjust the arms to the
o
e
i
U
t
V
shelf by pulling them straight out. (See
a
r
r
Illustration VI20.)
te
po
s
r
a
2. Pop the plastic over the outside visor
arm
o
w
m
a
C
i
l
brackets.
l
ti
er
t
U
by
3. Replace the overhead storage
cover.
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
Illustration p
VI15
la
0
Pop Cover Off Visor
Arm Bracket
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ig Illustration VI20 hts
r
o
y Adjust Visor to Holes in Header
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Visor Removal
164
l
w
d
a
a
e
l
u
Windshield/Quarterrv
Window Tools and Materials n
y
a
e
b
s
M is critical to the structural
CAUTION:
A properly bonded windshield
integrity of the vehicle.
d
re
e
e
Utilimaster
recommends that professional
automotive
glass
specialists
replace the windshield
it
s
ic
t
and windows.
b
v
i
h
r
h
e
ir g Glass adhesives and sealants
attention must be paid to cleaning
S have a short shelf life.roCloseinformation
l
surfaces and to timingy during installation. The following
can be shared with autol
l
p
a
d
glass
shops.
A
u
n
o
io
B
an
t
c
M by
—rubber gloves and any appropriate
WARNING: Use
breathing apparatus as recommended
u
e
e
l
d
the manufacturer
of the kit.
c
ic
i
o
v
r
h To avoid injuring yourself
r glass and the
WARNING:
p or others, use extreme care when handling
e
e
e
window-removal
tool!
r
S
rV
y
d
e
t The windshield and quarter
d walk-in
e window sections apply only to Aeromaster
NOTE:
s
z
o
i
a
before working on the vehicle.
B
or
mvans. Please read entire hprocedure
i
—
l
i do the job yourself, you will
If you
t
le
ut need:
c
U
a
i
h
· Replacement glass n
on
e
i
U
t
· Rubber trim molding
V
a
r
r
· Glass replacement tools
o
te
p
s
· Isopropyl alcohol
a
or
w
· Glass bonding replacementCkit
m
a
i
l
l
r
ti
e
t
U
by
Kits and Replacement Glass s
a
d
e
Tool Kit (P/N 23005014SK)m
t
ili replacement tool kit (see
The Utilimaster bondedtwindow
bi
i
h
U of:
Illustration WI5) consists
o
2
r
Illustration
0 support block (#1)
p KitWI5
aw
· Windshield
l
0
Tool
n
2
n
y
· Quarter-window
spacer block (#2)
o
t
i
o
b
i
t
h
t
· Poly-stick
(#3)
c
g
d
a
i
u
e
r
r
· y Utility knife (#4)
d
it
o
o
b
p
p
·
Window
removal
tool
(#5)
i
r
r
o
Co
ep
oh
C
r
r
r
Not included: masking tape, caulking
p gun, Medium d
e
t
n surfaces), clean cotton
Red Scotch Brite (to roughen
s
ze
o
i
i
a
r
t
rag or lint-free paper towel,
wooden block
o
c
h
(approximately 2" x 4"ux 6" to square glass surface
lim
t
i
d
t
u (for
flush with the molding),
d
o and squeegee or roller
U
a
r
e
n
p
2
bonding the trim).
rv
U
0
re
e
0
Illustration WI10
s
2
d
e
Material Kit
t
e
r
Glass Bonding Material
h
z Kit (P/N 23005015SK)
i
s
g
r
i
The Utilimaster
bonded
window
replacement
material
kit
(see
Illustration
WI10) consists of: ht
r
o
y
h Activator (#1) P/N 12605953
ig
t
p
· Sika
r
u
o
ll
· na
Sika Primer 210T (#2) P/N 12605827
C
A
·U SikaTack Ultrafast Urethane Adhesive Sealant (#3) P/N 12605916
Windows

®
®
®
165
Not included in kit: Sika Primer 206 P/N 12605969, aluminum sealant P/N 12400713,
l (used to fill in any gapswin the trim
d and Kent® Liquid Rubber 10240
a
isopropyl alcohol,
e
la Body Parts
v the Front Structure sectionnuin the appropriate Aeromaster
seam). (See ralso
a
by
Manual.) se
M
re
e
d
te glass and perimeter trim
c will need to order replacement
In addition tostools, adhesives, and sealants, iyou
i
t
ib
molding from
h Utilimaster.
rv
h
e
ig
o
S
r
r
The lwindshield
glass is 1/4"-thick laminated
safety glass. The quarter-window glass and the glass in sliding
l
l
y
p
a
d
doors
cannot be cut after tempering.
A are tempered safety glass that
n
o
nu
o
i
B
a
t trim molding and 3 feet of flat center trimMare
For replacing the entire windshield, about 21 feet of perimeter
c
—
required (depending on the
e half of
le size of the vehicle). If caredisutaken in removing the glass, only the replaced
c
c
i
the windshield needs toi have new molding applied.ro
Each quarter-window glass replacement requires
v about 9
hmolding.
r
p
e
feet of perimeter trim
V
re
Se
r
te
dy
ed
s
z
o
a CAUTION: Bonding glass risi a sensitive process. All steps should be Bfollowed closely and
o
m
—recommended.
it li without substitutions.uthProfessional automotive glass installers are
e
cl
U
a
i
n
n
h
o
e
i
U
t
V
Bonded Glass Replacement
a
r
r
te
Bonded Glass Removal
po
s
r
a
o
w
1. From the outside of the vehicle,
insert
the
blade
of
the
m
a
C
i
l
l
window-removal tool through
r the urethane sealanttand
i
ewindow,
t
U
by
work your way around the
cutting
the
sealant.
s
a After pushing the blade into the
d
(See Illustration WI15).
e
m
t
i
sealant, use the other
ili hand to pull the tool toward you.
b
t
i
To avoid injuring
U yourself or others, be very careful
ohWI15
while using2the tool! Try to leave at least a 1/8"-thick w
r
Illustration
0
p
la
Cut Old Sealant
section of0sealant on the window frame.
n
2
n
t remove the damaged glass.
io
o
by
i
2. Carefully
t
h
t
c
g
d
a
i
u
e
r
r
Prepareythe Mounting Surface
d
it
o
o
b
p
p
i
r
r
the old adhesive is bonded firmly to the
h frame and not
o
Co1. Ifpeeling
ep
o
C
r
r
from the surface, trim the bead
down to 1/16" to
p
er
1/8". (See Illustration WI20.) nIf the old adhesive is ed
t
s
loose, remove all adhesive down
io to the metal surface. riz
a
t
o of
c
im
h
2. Use Medium Red ScotchuBrite to roughen the surface
l
t
i
d mounting flange. u
t
any bare metal area of
othe
U
a
r
ed
n
p
2
v
U
e
0
3. Clean the entire raluminum
bond area with isopropyl
er
0
s
2
alcohol. Allow
d 2 minutes drying time. (Do NOT use
e
t
e
Illustration WI20 r
lacquer thinners
h
ir z or mineral spirits.)
Trim Sealant Bead
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
166
4. Apply Sika activator
d to the exposed metal of theal
e
mounting frame,
u
v using a clean cotton rag or lint-free
n
r
paper toweleand wiping in one direction. Turn
rag
s to avoid transferring dirt andMaoil. Drying
several e
times
r
e
timesis 10 minutes.
ic
w
la
4-1/8"
3/4"
by
3/16"
d
e
t
t
bi
v
i
h
r
5. ig
Brush a light coat of Sika Primer
e 210T on the exposed oh
S
r
l
l metal of the mounting frame.y Drying time is 10 minutes. pr
l
a
d
A 6. Apply aluminum sealanto (P/N 12400713 ordered n
nu
o
i
B
a
separately) to any open aluminum joints, seams, c
ort
M
—
u
e post rivets.
center windshield
e
l
ic
Illustration WI25
ic
od
v
r
Glass Preparation h
r Support Block
Dimensions of Windshield Glass
p
e
e
e
r
S
1. For windshield
of two
r V replacement, cut adminimum
y
e
woodt windshield support blocks (see
d
e Illustration
s
z
o
i
WI25)
when
installing
the
a to be used as glass supports
B
orthe nylon blocks
mnew windshield glass. (Orhuse
i
—
l
i available from Utilimaster.)
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V Beveled side
a
r
r
down
e
o
t
p
r
as
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
as
d
e
m
t
ili
bi
t
i
h
U
o
Support Blocks
2
r
0
p
aw
Illustration WI30
l
0
n
2
Placement of Windshield Glass
Support Blocks
n
t
io
o
by
i
t
h
c of the windshield, spacing
d the trough at the bottom
at
ig the support blocks (beveled edge down)teinto
2. rSet
u
r
i Illustration WI30.) od
y them along the bottom of the opening. (See
o
b
p
p
i
r
r
o
Co 3. For quarter-window replacement,rocuth one wood quarter-window
ep spacer block (see Illustration
C
r
rinstalling the
p 5/16" gap between the
WI35) to be used to establish proper
glass and the frame when
d
e
t
n blocks available ize
new quarter glass. (Or use theonylon
s
i
a
r
t
from Utilimaster.)
o
c
im
h
u
l
t
i
d
t
4. For the quarter glass,oset the spacer block ontouthe
d
U
a
r mount (see Illustration
e
flange around the window
n
p
2
rv
0
WI40) and tape
reto secure (see IllustrationUWI45).
e
0
2
d window for fit.
es
t
e
5. Check replacement
r
h
iz
g
r
ts
i
r
6. Cleanothe glass with a 2-to-1 mixture of isopropyl
h
h and water. Allow to dry for 2 minutes. Avoid py
ig
t
alcohol
r
u
o
aheavy soaps or ammonia. Auto glass replacement C
ll WI35
Illustration
n
A
Dimensions of Quarter-Window Spacer Block
U dealers also have recommended cleaners.
7/8"
4-3/8"
2-1/4"
1"
7/16"
4"
1/4"
5/16"
5/16'
1"
1/4"
7/16"
167
Spacer Blocks
d
e
rv
e
s
re
7. Wipe the bonding (frit band) area of cleaned glass with
lactivator, using a clean cottonwrag or lint-free paper
Sika
a
la Turn the rag several
u
towel and wiping in one direction.
n
a
by and oil. Drying time is 10
dirt
M times to avoid transferring
e minutes. Finish installation
ed process within 2 hours.
it
b
i
NOTE: Glass purchased
from Utilimaster should
h
have a black rceramic
frit band around the perimeter
o
l
y
p
of
the
mounting
side
of
the glass. If you sourced the a
d
n and there is no frit band, mask off a 1"glass locally,
nu
o
i
Bo
a
t around the perimeter of the mountingMside
widecarea
—
of u
the glass. Apply Sika Primer 206 G&P (P/N
le
d
ce as a
c
i
i
o
12605969
ordered
separately)
to
glass
perimeter
r
h
rv
p
e
block
of
ultraviolet
rays.
Drying
time
is
e
V
re approximately 5 minutes. (See Illustration
S WI50.)
r
y
d
e
t
d
e
Illustration
WI40
s
o
iz Bonded Glass Installation
a Quarter-Window
Location of
Spacer Blocks
r
B
o
m
i
—
l
h
i
t
1. Using a caulking gun, apply
t
lea bead of urethane adhesive
u
c
U
a
i
n(approximately 5/16" hwide by 1/2" tall) directly to the glass
e flange. Use a V-shaped nozzle
it o frit band or the mounting
Un
V
a
r shape. (See Illustration WI50.)
r for the optimal ebead
o
t
rp 2. Close any voids
as at corners or elsewhere by smoothing over
o
w
with a Poly-stick.
m
a
C
i
l
l
tithe glass onto the frame and align to the correct
er
3. Install
t
U
by
s
position using the support blocks.
a
d
e
m
t
ili
bi
t
i
U
oh within 10
CAUTION: Glass must be installed
2
r
w
0
p to ensure a
minutes
of applying the adhesive
la bond.
0
Illustration
WI45
good
n
2
n
t
Secure Quarter-Window
Glass Spacer Block
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
Adhesiveon
s
iz
i
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
Frit Band
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
l
Illustration lWI55
a Illustration WI50
C
n
Frit Band and Adhesive
InstallA
Glass
U
ts
h
ig
r
l
Al
168
ic
v
r
Se
ts
h
rig
ed
v
r
e
s
re
l
a
u
n
a
M
Exterior Side
Frit Band
ce
i
rv
e
S
aw
l
Windshield Glass Panels
by
d
ti e
ib
h
o
pr
Windshield
l
y
a
d
Centerpiece
Adhesive
n
nu
of Windshield
o
i
Bo
a
Structure
t Interior Side
c
M
—
u
e
Illustration
WI60
e
l
dWindshield Centerpiece.
c
ic
Cross-Section of
i
o
v
r
h
r
p
e
e
e
4. Press gently
around
the
entire
perimeter
of
the
glass
to
make
good
adhesive
contact.
(See
V
r
S Illustration
r
y
WI55.)
te Use the Poly-stick to clean
d
ed up any excess adhesive.
s
z
ocenter section
i must have a full bead of adhesive in the
a Windshield installations
NOTE:
r
B
m
ho (See Illustration WI60.)
ili between the two glass panels.
t
e—
t
l
u
U NOTE: Recommended
a minimum thicknessn of the adhesive layer
icafter installation is 1/4". (See
n
h
Illustration WI60.)
e
U
tio
V
a
r the adhesive sets up.
r with masking tapeeuntil
5. The quarter window can be held in place
o
t
s
rp
6. Allow at least eight hours for theoadhesive
to cure when ainstalling a windshield or a quarter window. w
C
im
la
l
r
i
7. Clean up with a mild soap solution
(used sparingly).
Do NOT use mineral spirits or alcohol. y
t
te
U
b
s
8. Replace window trim.aSee the Trim Molding Installation section.
d
m
te
i
i
l
i
ib
h
Ut
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
l
l
A
1/4"minimum
169
l
WARNING: Use extreme
care when hana
aw
dling glass!
l
u
an
by
M Sliding Side Window Replacement
d
e
e
t
c
i
s
Sliding
Window
Removal
t
vi
ib
h
r
h
e
g
1. Removeothe MONOBOLTS around the sliding
i
S
r (See the Fasteners section for proper l
ll r
window.
y
p
a
d
A
u
removal.)
n
o
io out the window.
B
an
t
2.
Lift
c
M
u
e—
e
l
d 3. Scrape off the old foam tape from the door
c
ic panel.
i
o
v
r
r
p Sliding Window Installation
eh
e
e
V
r
S
r
y
1.
Place
the
replacement
window
in
door frame
d
e
t
d rivettheholes
e
s
z
and,
from
the
inside,
mark
the
around the
o
i
a
r
B
circumference of the replacement window.
m
ho
it li
t
e—
l
u
2.
Drill
holes
into
the
replacement
window frame for the
c
U
a
i
n
MONOBOLT fasteners.
h
e
io
Un
t
V opening on the door with foam
a
3. Line the exterior
r
r
Illustration WI65
tape. ste
Sliding Side Door Windows
po
r
athe new window into the opening.
o
w
4.
Place
m
a
C
i
l
l
i
er
5.t Attach the window to the door frame using by
t
U
MONOBOLT rivets.
as
d
e
m
t
i
LEXAN Window Replacement (Bonded) b
ili
t
i
U
LEXAN Window Removal
oh
2
r
w
0
p the Side Sliding
la the door handle. n(See
0
1. Remove
2
n
t
io
o
byDoor Hardware section.)
i
t
h
c frames surrounding the rat
d2. Remove the perimeter
ig
u
e
r
d
it
y
o
window. (See Illustration
WI70.)
o
b
p
p
i
r
r
h
p
o WI75.)
Co
elocking
o
3. Remove the
trim. (See Illustration
C
r
r
r
p
d
e
4.
From
the
outside,
insert
the
blade
of
the windowt
e
n
s
ir z tool through the urethane
it o
removal
sealant
and work
a
o
c
m
i cutting the sealant.
hyour way around the window,
u
l
t
i
d
t
u Push the blade into theUsealant and, with the other d
o
a
r
e
Illustration WI70
n hand, pull the tool toward
p
2 you. (See the Bonded
v
r
U
e
0
Interior Window Trim ofrLower Bonded Window
Window Removal
e
0 section.)
s
2
d
e and
t is bonded firmly to therframe
e
5. If the old adhesive
h
ir z
not peeling
ts down to
ig from the surface, trim thehbead
r
o
y 1/8". If the old adhesive iisgloose, remove
1/16" to
h
t
p
u
all o
adhesive down to the metallsurface
lr
a
C
A
Un
d
e
rv
e
s
re
®
®
170
l
w
d
a
a
e
l
u
rv window for proper fit.an
1. Check replacement
y
e
b
s
e glass with a 2-to-1 mixture ofe M
d
2. Clean rthe
isopropyl
e
t
c
alcohol
ts and water. Allow to dry for
bi
vi2 minutes.
i
h
r
Avoid
heavy
soaps
or
ammonia.
h
e
ig
o
S
r
r
l
l3. Wipe the bonding (frit band)y area of cleaned glass p
l
a
d
A with Sika activator, using
u
o a clean cotton rag or lint-ion
n
B
a
free paper towel and wiping in one direction. Turnt
M
the rag several times
ucoil.
e—to avoid transferring dirtdand
e
l
c minutes. Finish installation
Drying time isi10
process
ic
o
v
r
h
r
within 2 hours.
p
e
e
e
S
r Vmounted from the insided ofr the vehicle
Windows
y
e
t require a frit band around
d
e the perimeter.
do snot
z
o
i
a
B
from the outside
orof the vehicle, mask
mIfoffmounted
i
—
l
h
a 1"-wide area around
i
t the perimeter of the
e
t
u
cl
U mounting side of the awindow. Apply SikanPrimer
i
n ordered separately)
h
206 G&P (P/N 12605969
e
io to
U
t
V
the window perimeter for protectionaagainst
Illustration WI75
r
r
e
ultraviolet rays. Drying time is approximately
5
o
Locking Trim
t
p
s
r
minutes.
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
LEXAN Window Installation
as
d
e
m
t
This window is installed in
way as the quarter-panel window, except that six 0.20" rubber
spacers are
ili a similar
bi
t
i
used instead of spacer blocks
and trim molding.
h
U
o
2
r
1. Using a caulking
(approximately 5/16" wide
by 1/2" tall)
0 gun, apply a bead of urethane adhesive
poptimal
aawV-shaped
l
0
completely
around
the
perimeter
of
the
window.
Use
nozzle
for
the
bead shape.
n
2
n
y
o
t
i
o
b
i
t
h
2. Close
any voids at corners or elsewhere by smoothing over with a Poly-stick.
t
c
d
a
ig
u
e
r
r
dapplication.
it 10 minutes of adhesive
y NOTE: Window must be installed within
o
o
b
p
p
i
r
r
h
o
Co 3. Install the window onto the mountingrosurface.
ep
C
r
r
p of the window to dmake good adhesive contact.
4. Press gently around the entire perimeter
e
t
e
n
s is 1/4".
iz
it o thickness of the adhesive
a
NOTE: Recommended minimum
layer after installation
r
o
c
h
u
lim
t
i
5. Use a Poly-stick to clean
up any excess adhesive.
d
t
u
d
o
Uup.
a
r
e
n
6. The window can be
held in place with masking
tape until the adhesive sets
p
2
rv
U
e
0
r
e
0
7. Clean up with
d a mild soap solution (used sparingly). Do NOT uset 2mineral spirits or alcohol.res
e
h
z trim to the frames.
8. Reapplyrilocking
g
ts
i
r
o
h
h the window perimeter frames to the door. py
9. Reattach
ig
t
r
u
o
10.na
Reattach the handle to the door. (See the Side Sliding
C Door Hardware section.)All
U
Window Preparation
171
11. To complete the window seal, apply a bead
dadhesive with a caulking
of white urethane
e
gun to the outside
rv rim of the window.
l
a
aw
l
u
n
a
e
by
s
M
12. Allow ateleast 8 hours for the adhesive to
d
r
e
e
t
cure.s
c
i
t
vi
ib
h
r
13. iSee
the Cleaning LEXAN Windows
section.
h
e
g
S
ro
l
lr
y
l
p
a
d
A
u
n
o
n
o
i
B
a
WARNING: Use extreme care
t
c
M
when handling—
glass!
u
e
e
l
d
c
c
i
o
Illustration WI80 vi
r
rAdhesive
p
Trim Ends Sealed with Urethane
eh
Window (Rubber Mounted)
e
e
V
r
S
r
y
Removal
d
e
t
d
e
s
o
a the old window and therizwindow
1. Remove
B
o
m
i
rubber.
—
l
h
i
t
e
t
u
cl
U 2. Remove any adhesive that
may still remain n
a
i
n
h
from the ends of theUwindow rubber. (Seeio
e
t
V
a
Illustration WI80.)
r
r
te
po area
3. Clean the aluminum around the window
s
r
a
o
w
with a two-to-one mixture of isopropyl
m
a
C
i
l
l
alcohol and water. Turn the rrag several times
i
te oil.
Ut
by
to avoid transferring dirtsand
a
d
e
Installation
m
t
i
li
i
b
t
i
Illustration
WI85
1. Cut a length ofU
window rubber and fit it
Lower Window Trim
oh
around the metal
frame on which the window
2
r
w
0 Trim off any excess. (See
p
is to be installed.
la
0
n
2
n
Illustration
t WI85.)
io
o
by
i
t
h
t
c
d
a
ig a caulking gun, apply a bead of
2. Using
u
e
r
r
d
it
yurethane adhesive inside the window channel
o
o
b
p
p
i
r
r
h
o
Co to provide an extra seal for the window.
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
Illustration WI90
Illustration WI95
o
a Window Trim Sealing Tool
ll Trim
C
Locking the Window
n
A
U
172
3. Pull back the window
the frame.
l replacement window into w
d rubber locking lip and set the
a
e
lalocking lip under the short
u
v
4. Using a sealing
tool, seal the window into thenrubber lock by folding the long
r
y
a and WI95.)
ethe window). (Illustrations WI90
b
lip (nearest
s
M
e
d
r
e
e
t
5. Apply
a
bead
of
urethane
adhesive
to
the
ends
of
the
window
rubber
c
i to complete the window seal.
s
i
t
b
v
i
(See
Illustration
WI80.)
h
r
h
e
ir g
o
S
r
l
l
y
l
p
a
d
A
n squeegees, razor blades, or other sharpnu
CAUTION: Never scrape
o the LEXAN window iwith
o
B
objects! Do NOT scrub, use brushes, or usetabrasive cleaners. Do NOT clean in the hot asun
c soap or detergent and a clean sponge orMsoft
or at elevated —
Use only a mild
u
e temperatures.
l
cloth. See details
below.
d
ce
c
i
i
o
r
h
rv
p
e
e
LEXAN Window V
Cleaning
re
S
r
y
d
e
t in the side sliding door
d
emay be made of LEXAN to provide for higher-impact
The lower window
resistance
s
z
o
i
a
than laminated or tempered safety glass.
LEXAN is less scratch-resistant
B than glass so extra care
or However,
imtaken when cleaning thistwindow.
mustilbe
Never scrape the LEXAN window—
with squeegees, razor
h
le
u
blades,
c
Ut or other sharp objects!
a
i
n
n
h or soft cloth. Rinse well with
e
Wash the LEXAN windowUwith a mild soap or detergent,
using a clean sponge
io
t
V sponge. Do NOT scrub or use
clean water. To prevent water spots, dry withraachamois or moist cellulose
r
o at elevated temperatures!
te
brushes! Do NOT clean in the hot sunpor
s
r
a be removed easily before drying by rubbingw
o
Fresh paint splashes, grease, and smeared
glazing
compounds
can
m
C
li also works with labels and stickers. Butyl la
r
i
lightly with a grade of VM&P naphtha
or
isopropyl.
Naphtha
t
y
eof paints and marking-pen
t
U
b
cellosolve works well for removal
inks.
Afterward,
a
warm
final
wash
should
be
s
a
d
made, using a mild soap or detergent solution and ending with a thorough rinsing with clean water. e
im
it
l
i
b
t can be minimized by using a mild automobile polish, such as Johnson
Paste
Scratches and minor abrasions
i
h
U
Wax. Be sure to follow
2 the manufacturers instructions.
ro
w
0
p
a
0 the following on a LEXAN window: l
Never use any2of
n
n
y
o
t
· Abrasive
cleaners
i
o
b
i
t
h
t
c
d
· Highly
a
ig alkaline cleaners
u
e
r
r
d
· y Benzene
it
o
o
b
p
p
i
r
r
·
Gasoline
o
Co· Acetone
ep
oh
C
r
r
r
p
· Carbon tetrachloride
d
e
t
e
n
s
izlong as the manufacturersarecommendations
it o
The following cleaning agents are compatible
with LEXAN, as
and
r
o
c
m
instructions are followed:
u
th
ili
d
t
u
· Joy
d
U
a
ro
e
· Top Job
n
p
2
rv
U
0
· Palmolive Liquid
re
e
0
2
dAmmonia D
· Windex with
es
t
e
r
h
· Freon T.F.
iz
g
r
ts
i
r
o
h
· VM&P-grade
naphtha
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
®
®
®
®
®
173
l
w
d
a
a
e
l
u
n
rv
a
e
by
s
M
d
Crank-up Window
re Replacement
e
e
t
c
i
s
t This process describes the
viSlide Sliding
NOTE:
ib
h
r
h
e
g
iDoor option, but it can also be used for the
Front
ro
l
ll r Doorless Panel option. y S
p
a
Guide
d
A
u
n
Removal
it o
Bo
an
M
— place on a flat padded uc Door
1. Remove the dooreand
e
Seal
l
d
surface (interior
cside up). (See the Side Sliding
ic
i
o
Access
v
r
r
Door Replacement
Crank
p
eh Section.)
Plate
e
e
V
Handle
r
S
rKeep window rolled downduntil
NOTE:
y
e
t otherwise.
d
e
instructed
s
o
iz
a
r
B
2.im
Remove the two screws fromothe front guide. (See
—
l
h
i Illustration WI100.) ut
t
le
c
U
a
Illustration
WI100
i
n
h
3. Pull the glass channelnstrip out of the front guide
Sliding
Door
with
Roll-up
Window
o
e
i
U
t
V
only.
r
ra
e
o
t
4. Remove the front guide.
rp
as
o
w
5. Loosen one screw on the regulator
access plate and remove
m the second screw.
a
C
i
l
l
ti are visible in the access opening.
ertwo regulator plate Uscrews
6. Roll the window up until the
t
by
s
a
d
7. Remove these two screws.
e
m
t
ili
bi
i
8. Remove glass (iftnot broken) by tipping forward and pulling upward out of the opening.
h
U
o
2
r
w
NOTE: If0the window is removed in once piece, reverse
steps to install
p the window.
a previous
l
0
Continue
the
process
to
remove
any
broken
glass
fragments
from
the
bottom
n of the door.
2
n
y
o
t
i
o
b
i
t
h
9. With
d spring, and spacer.uc
at
ig a Torx bit, remove the window crankthandle,
e
r
r
d
i or 3/16" bit.
o
10.yDrill out the Magna-Lok fasteners with ab#11
o
p
p
i
r
r
o
Co11. Remove the interior door panel. roh
ep
C
r
r
d
12. Carefully remove any broken glasspfragments from the bottom
of the door.
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
WARNING: Use extreme care
when handling glass!
®
®
174
l
w
d
a
a
e
l
u
1. Slide the glass
n align the regular plate holesy with the holes in the
rvinto the lower glass channelaand
e
b
regulator.s
M
e
d
r This may be easier with thecewindow regulator in the rolled
NOTE:
ite down position.
s
i
t
b
v
i
h
r the regular plate to the regulator.
2. g
h
e
ir Reinstall the two screws connecting
o
S
rearlier.
l
l 3. Install the front guide and secure
the two screws removed
(See Illustration WI100.)
y
l
p
a
d
A
u
n
4. Replace the glass channel
Bo strip into the front guide.tio
an
c holes in the door frame.
M
— panel holes with the existing
5. Align the interiorledoor
u
e
d
c
ic
i
o
v
r
6. Secure interior
panel
with
new
POP
rivets.
h
r
p
e
e
e
r plate and tighten the second screw. S
7. Replace
r Vthe screw on the regulatordaccess
y
e
t
d
e handle, spring, and spacer.
8. Temporarily
secure the windowizcrank
s
o
a
r
B
m
houp.
il9.i Roll the window completely
t
e—
t
l
u
U 10. Remove the crank handle
that the knob is towards
a and reposition it so
ic the front (or catch side) of the
n
n
h
door. (See Illustration
WI100.)
e
U
tio
V
a
r up as the door slides
NOTE: This should keep window rolled
er against the rear brush seals when
o
t
p
opened.
r
as
o
w
m
a
11. Secure the crank handle withC
a Torx bit.
i
l
l
r
i
te (See the Side Sliding
12. Install the door onto thesvehicle.
Ut Door Replacement section.)
by
a
d
e
m
t
ili
bi
t
i
h
U
o
2
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
o
c
h
u
lim
t
i
d
t
u
d
o
U
a
r
e
n
p
2
rv
U
0
re
e
0
2
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Installation
®
175
Window Regulator Replacement
d
l
a
NOTE: This process
e describes the Side Sliding
u
v
n
r but it can also be used for the
Door option,
a
e
M
Doorlesses
Panel option.
by
w
la
d
r
e
e
t
c
i
s
t
vi
ib
h
r
h
e
g
1. iRemove the door and place on a flat padded
Sthe Side Sliding
ro
l
ll r surface (interior side up). (See
y
p
a
d
A Door Replacement Section.)
n
o
nu
o
i
B
a
t
NOTE: Keep window
rolled down until
c
M
—
u
e
e
instructed otherwise.
l
d
c
ic
i
o
v
r
h on the regulator accesspplate
r
2. Loosen oneescrew
e
e
V
and remove the second screw.
r
S
Illustration WI105
r
y
d
e
Crank-up Window
t window up until the two zregulator
d Regulator
e
3. Rollsthe
plate
o
i
a are visible in the accessropening.
B
screws
o
m
i
—
l
h
i4. Remove these two screws.
t
t
le
u
c
U
a
i
n
h
5. Slide the glass into thenfull up position.
e
it o
U
Vspacer.
a handle, spring, and
r
6. With a Torx bit, remove the window crank
r
o
te
pwith
s
r
7. Drill out the Magna-Lok fasteners
a #11 or 3/16" bit.
a
o
w
m
a
C
i
l
8. Remove the interior door panel.
l
ti
er
t
U
by
9. Remove the six Phillips-head
screws holding the regulator.
s
a
d
e
m
t
Installation
ili
bi
t
i
1. Fasten the regulator
h inlb.
U to the interior door panel with six pan-head screws. Torque too3545
02 door panel on top of the door. law
2. Place the0interior
pr
n
2
n
y holes of the interioridoor
o
4. Installtaluminum Magna-Lok fasteners in the predrilled
panel.
o
b
i
t
h
c
d the access opening.
at
ig the regulator until holes are accessibletethrough
u
5. Adjust
r
r
d
i
y
o
o
b
p
p
i
r
r
6.
Slide
the
window
down
and
secure
to
the
regulator
with
two
screws.
h
p
o
Co
o
C
re align the window crank
r
7. With the same two screws visiblepthrough
the access opening,
handle
in a
r
d
e
horizontal position with the knob
t WI100.)
e vehicle. (See Illustration
n toward the rear ofizthe
s
o
i
a in the forward
r the Torx bit with the knob
t spring, and spacerowith
8. Secure the window crank handle,
c
m
i
uWI100.)
th
position. (See Illustration
il
d
t
u
U
ro with two screws. na
ed
9. Reinstall the accesspplate
2
v
U
reinto the truck. (See the Side
er
00 section.)
10. Reinstall the door
Sliding
Door
Replacement
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Removal
®
®
®
176
l
w
d
a
a
e
l
u
1. After adhesive
rv has dried, scrape any excessanadhesive from glass
y
e
b
edges andssurface with a utility knife.
M
d
re
e
e
t
c
s
tCAUTION:
Be sure not to nick
bi
vi or cut the glass when installi
h
r
e to cracks developing overohtime.
ig ing the trim. This can lead
S
r
r
l
l
y
l
p
a
d
A 2. With a lint-free paper towel
n the glass
o and isopropyl alcohol, clean
nu
o
i
B
a
around the trim molding bonding surface and let dry
t for 2 minutes.
c
M
—
u
e
e
l
NOTE: The center
c of the windshield hasroadwide flat trim. If
ic
i
v
you are replacing
the
windshield,
you
will
need
to
replace
this
h
r
p
e
as well. Ve
e
r
S
r
y
d
e
3. Avoid
t touching the adhesive while
d
eremoving the adhesive backing
s
z
o
i
strip.
a Apply the self-adhesive rtrim. (See Illustrations WI110
B
o
mthrough WI120.) Avoid stretching
the trim.
i
—
l
h
i
t
ut the trim. Take care to hold the knife icle
U 4. Miter-cut corners and aoverlap
with the cutting edge
on (See Illustrations eh
Unpointing away fromtiyou.
V
WI115 and WI120.) Do NOT cutra
through the lip of the
r
o of glass.
trim; allow it to wrap around the edge
te
p
s
r
athe angles.
o
w
5. On the quarter-window seam, miter-cut
the corners and
m
a
C
i
l
l
(See Illustration WI120.) r
ti
y
e
t
U
b
s center of the windshield should be placed
6. The wide flat trim for a
the
d
e
flush against the top
trim.
Check
how
well
the
trim
will
fit
before
m
t
li the glass.
bi
applying the trimtito
i
h
U
o
7. Press down2on the trim using a roller or squeegee to ensure
a
good
r
0 a second time. Cut the bottom end oflathewcenter
p
bond. Repeat
0
n
2
n
WI110
trim flush
t with the bottom trim.
io Illustration
o
by
i
t
h
Apply Trim
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
CAUTION:
Do
NOT
wash
the
windows
for
at
least
24
hours
following
installation
or
application
h
o
Co
of the window trim. Chemicals o
like those found in washer
epfluid can retard the adhesives.
C
r
r
r
p
d
e
t
e
n
s
iz
it o
a
r
ofill the seams
cmitered seams and joints,
8. If there are any gaps in the
h
u
lim
t
i
d
t
and joints with liquid rubber.
u
d
o
U
a
r
e
n
p
2
9. If the quarter-window
the mirror
rv
U
e trim interferes with remounting
0
e
bracket, cut justr enough lip off the trim to allow the bracket to fit. 20
d
es
t
e
r
h
iz
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration
WI115
C
n
A
Trim
Corners
U
Trim Molding Installation
177
Application direction
l
Al
ts
h
rig
d
e
rv Start here
e
s
re(for center trim only)
er
t
as
m
ili
t
U
y
d
Bo
e—
l
ic
h
Ve
ce
i
rv
e
S
l
a
u
n
a
M
n
it o
c
u
od
r
p
re
d
te
i
ib
h
o
pr
by
w
la
ce
i
rv
e
S
l
a
u
an
M
dy
o
B
—
Start here
le
c
i
n
h
e
it o
V Peel trim back and discard this piece
a
r
r
te
po
s
r
a
o
Discard
w
m
a
C
i
l
l
ti
Miter-cut face (only) at y
er
t
U
b
corners
s
a
d
m
te
i
i
l
i
ib
h
Ut
2
ro
w
0
p
a
l
0
n
2
n
y
o
t
i
o
b
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
Discard
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
On all corners except starting/stopping
s
2
d through lip of trim; keep
point, dont e
cut
t
re
h
attached and
ir z wrap around corner of glass
ts
ig
r
o
h
y
h
ig
t
Illustration WI120p
r
u
o
Trim Diagram
a
ll
C
n
A
U
178
ed
z
ri
o
th
u
a
n
U
l
w
d
a
a
e
l
u
n with an internal thermal yoverload protection switch
rv The wiper motor is equipped
a
CAUTION:
e
b is not unplugged, the motor
s the wiper motor in caseMof overload. Thus, if the motor
thatestops
d
r activate itself without warning.
e Always unplug the motor
may
c
ite when working on or
s
i
disconnecting wiper linkages.
t
b
v
i
h
r
h
e
ir g
S
ro
l
l
y
l
p
a
d
A
u
n
it o
Bo
an
c
M
u
e—
e
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
rV
y
d
e
t Wiper
d
e
s
o
ir z
a Blade
B
Linkage
o
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
e
io
Un
t
V
Wiper
a
r
r
Arm
o
te
p
s
r
a
o
w
m
a
C
i
l
l
ti
y
er
t
U
b
asinstall wiper
d
CAUTION: Always
e
m
t
arms and blades
according
to
the
ili instructions to
bi
manufacturers
t
i
h
U
avoid interference
with the
o
2
windshield
molding.
r
0
p
aw
l
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
Washer
o
b
p
p
i
r
r
h Tee
o
Co
ep
o
C
Windshield
r
r
r
p Washer Hose
d
e
t
e
n
s Bottle
Washer
iz
it o
a
r
o
c
m Bracket
i
h
u
l
t
i
Washer
d
t
u
d
o
Bottle
U
a
r
e
n
p
2
rv
U
e
0
r
e
0
CAUTION: Always use the correct wiper harness plug and 2wiper switch when bench-testing
s a
d
motor. eAccidental
hot wiring of the wrong wiper motor terminal
may cause damagereto the
t
h
internal
iz components of the wiper motor.
g
r
ts
i
r
o
h
y
h
ig
t
p
r
u
o
a
ll
Illustration WS5
C
n
A
Wiper System
U
Wiper System
179
Troubleshooting Procedure
d
e
rv
e
s
re
l
a
u
n
a
M
w
la
The following troubleshooting and repair procedure should be followed when encountering problems with wiper
systems.
by
d
te
i
CORRECTIVE
ib ACTION
h
1.
ro
l
l
y
l
p
Remove and replace a
Remove and replace
d
motor inoperative
No
A Wiper
u
Fuse OK?
n fuse.
wiper switch. n
at high or low speed.
it o
Bo
a
c
M
u
e—
e
l
Yes
d
c
ic Yes
i
o
v
r
r
p
eh
e
Power available e
at high
Power available at high
Power
V
r
S available from
No
and low speed terminal of No
and low speed wiper
ignition switch to wiper
r
motor connector?
switch terminals?
te
dy switch?
ed
s
z
o
i
a
r
B
o
Yes
m
Yes
No
i
—
l
h
i
t
e
t
u
cl
U
Repair open circuit
Repair open circuit
a
i
n
Remove and replace
n
between wiper switch
and
between ignition and
h
o
e
wiper motor. i
U
wiper motor connectors.
wiper switch connectors.
t
V
a
r
er
o
t
rp
2.
as
o
w
mLinkage moves freely
a
C
i
l
Remove
and
replace
l
r crank broken or Noti when disconnected from No linkage and/or pivot
Wiper motor runs, but wiper
eMotor
t
loose?
arms do not move.
U
by
motor shaft?
assembly.
s
a
d
e
m
t
Yes
Yes
ili
bi
t
i
U
oh
2
Check motor shaft
r
w
and replace
0
p
aRemove
splines for damage and
l
0
wiper motor.
replace damaged parts.
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
3.
d
it
y
o
o
b
p
p
i
r
r
Power availablehat low
Power available
low
p ofatwiper
Remove and
replace
oswitch.
inoperative at
No
No
CoWiper motor
speed terminal
of motor
speed terminal
e
o
wiper
C
r
low speed.
connector?
switchr connector?
r
p
d
e
t
e
n
s
iz
Yes
io Yes
a
r
t
o
c
im
h
u
l
t
i
Repair open circuit
t
od Remove and replace au between
wiper switch and
U
r
ed
wiper motor.
n
p
2
v
U
re
er
00
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
ts
CONDITION
h
rig
180
ce
i
rv
e
S
l
a
aw
l
u
y
an No Power available at high
Power available at high
b
Remove and replace
No
speed terminal ofM
motor
speed terminal of wiper
wiper switch.
d
connector?
e
switch connector?
e
t
c
bi
vi
i
r
Yes
oh Yes
Se
r
l
y
pRepair open circuit
a
d
n wiper switch and
Remove and replace
nu
it o between
Bo wiper motor.
a
c
M
—
u
e
e
l
d
c
ic
i
o
5.
v
r
h
r
p
e
e
e
Vbut do not
RepairSopen circuit between
available at park
r Power
Wipers operational
No
wiper
and wiper motor
terminal of wiper motor
y switch
d
er position.
return totpark
connectors.
connector?
d
e
o
iz
as
r
B
m
Yes
ho
ili
t
e—
t
l
u
U
a
ic
n
n
h
Remove
and
replace
wiper
e
U
tio motor.
V
a
r
er
o
t
p
r
6.
as
o
w
m
a
C
i
l
Remove
wiper
motor
crank,
l
Wipers operational but
Wiper motorticrank in the
No
check motor shaft y
for
er
always park incorrectly in the
t
correct U
park position?
b
damaged
splines,
replace
same position.
damaged parts, d
and reinstall
as
crank in thete
correct park
m
i
Yes
ili
bposition.
t
i
h
U
o
2
r
Remove wiper motor
crank,
0
p
awfor
check motor shaft
l
0
damaged splines, and replace
n
2
n
y Run motor
o
t
damaged parts.
i
o
b
i
t
h
and park. Reinstall wiper
t
c
d
a
ig
arms inecorrect park position,
u
r
r
d
and
it torque to 16.5 N•m.
y
o
o
b
p
p
i
r
r
o
Co
ep
oh
C
7.
r
r
r
p
d
e
t
Correct park position of wiper
n
Wipers oversweep or
No
s and/or wiper motor
zearms
Park position of wiper
i
arms
it o
a
undersweep.
r
correct?
crank.
o
c
m
i
h
u
l
t
i
d
t
u
d
o
U
a Yes
r
e
n
p
2
rv
U
0
re
e
0
Check for loose or worn
2
d
es
linkage and/or excessive play t
e
r
in pivot shaft assembly, and h
iz
r
replace damaged parts. See
ts
ig
r
o
h
the Coupler Addendum.
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
ed
v
r
e
Wiper motor inoperative
s at
high speed.
re
ts
h
ig
ll r
A
4.
181
Coupler Addendum for 78.5"-Wide Vehicles (Troubleshooting)
d
e
rv
e
s
re
l
a
u
n
a
M
by
w
la
d
e
e
t
c
i
vi
ib
r
h
Wiper Oversweep or e
ro
Undersweep. y S
l
l
l
p
a
d
A
u
n
it o
Bo
an
Park Position
Nouc
Correct Park Position of Wiper e M
e— of Wiper
l
d
c OK?
Arms
Arms and/or Motor Crank. ic
i
o
r
h
rv
p
e
e
V
re
S
r
Yes
y
d
e
t
d
e
s
o
iz
a
r
B
o
m
Coupler loose?
i
—
l
h
i
t
t
le
u
c
U
a
i
n
h
e
it o
Un
V
a
r
r
te
po
s
r
a
o
w
m
a
C
i
l
l
Check for Other Loose/Worn
ti
er
t
U
by
No
Linkage, Excessive Play in Pivot
s
a
d
Shaft Assemblies , and Replace
e
m
t
Coupler
Damaged Parts as Necessary.
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
a
ig
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
Yes
i
t
u
od
U
a
r
ed
n
p
2
v
0
Torque Screw
re to 910 ftlb [12.5 U
er
0
s
2
13.5 Nm]
d or Replace Linkage.
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
ts
h
rig
182
l
w
d
a
a
e
l
u
Motor Removal
n
rv
a
e
by
s
1. Disconnect
the Negative (Black) batteryMcable.
d
re
e
e
t
c
2. Disconnect
the
electrical
connectors
from
the
wiper
motor.
ts
bi
vi
i
h
r
h (See Illustration WS10.)
3. ig
Remove the wiper motor driveeshaft nut with a 13 mm wrench.
o
S
r
r
l
l4. Remove the motor crank from
y the motor drive shaft. p
l
a
d
A
u
n
o
n
o
i
B
a
5. Remove the three motor mount screws with a 10 mm
t wrench.
c
M
—
u
e motor.
e
6. Remove the wiper
l
d
c
ic
i
o
v
r
h
r
p
e
e
e
r
S
rV
y
d
e
t
d
e
s
o
ir z
a
B
Motor Cranko
m
i
—
l
h
i
t
le
ut
c
U
a
i
n
h
Motor Drive Shaft
e
io
Un Nut
t
V
a
r
r
Motor Mount Screw
o
te
p
s
r
a
o
w
m
a
C
i
l
l
i
IllustrationtWS10
y
er
t
U
b
Motor
Mount
and
Crank
as
d
e
m
t
Motor Installation
ili
bi
t
i
h
Ux 1" bolts and two two-way locknuts to
o
1. Use two 5/16
2
r
0wiper motor against the inside of the cowl law
p
fasten the
0
n
2
n
y to 5
channel
o
t and against the lower cowl channel. Torque
i
o
b
i
t
h
7g
t
c
d
a
i ftlb.
u
e
r
r
d
it
o
2.y Install the pivot assembly with two 1-1/8" locknuts
and two
o
b
p
p
i
r
r
washersone on each side. Torque
h to 2230 ftlb. ep
o
Co flat
o
C
(See the Pivot and Link Assembly section.)
r
r
r
p
d
e
t
3. Install the rain shields onto the n
pivot assemblies. (See ze
s
i
it o
a
r
Illustration WS15.)
o
c
h
u
lim
t
i
4. Connect the motor crank
with one motor drive shaft
nut.
d
t
u
d
o(See Illustration WS10.)
U
a
Torque to 917 ftlb.
r
e
n
p
2
U
e
0 Illustration WS15 erv
NOTE: If the rwiper linkage moves while torquing the
0
2Install Rain Shield on Pivot Assembly
dcrank, when the ignition is switched back
es
motor drive
t
e
r
iz system will rotate once to park itself. igh
on, the rwiper
ts
r
o
h
y
h the wiper motor harness to the jumper harness.
5. Reconnect
ig
t
p
r
u
o
a
ll
C
n
A
U
Motor Replacement
183
d
e
rv
e
s
re
l
a
u
n
a
M
w
Pivot a
Cranks
by
l
d
e
e
t
c
i
i
bLinks
Motorrvand Bracket
i
h
eAssembly
o
S
r
l
l
y
Illustration WS20p
a
d
Al
u
n
Park Position
it o
Bo
an
M
e— turn on the ignition, anddurunc the wiper system to check for the correctcePark
6. Reconnect the battery,
l
i
ic the wiper control to the Offroposition to allow the wiper motor to park itself.
position. Return
v
h
r
e
ep and fasten with arm-retaining nuts. (See
7. Install theVwiper arms onto the pivot assemblies
r
Se the Wiper Arm
r
Replacement
te section.)
dy
ed
s
z
o
i
a arm-retaining nut to 14.816.2
r
8. Torque
ftlb.
B
o
m
i
—
l
h
i
t
t
le
u
c
U
a
i
n
Section of
h
o
e
i
Un
Wiper t
V
a
r
Heador
te
p
s
r
a
Rain
o
w
m
a
C
i
l
Shield
l
Head
Washer
ti
er
t
Cover
Pivot Body
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
n
2
n
t
io
o
by
i
t
h
t
c
d
Arm-Retaining
Nut
a
ig
u
e
r
r
d1-1/8" Locknut po
it Locknut
y (14.8–16.2 ft•lb)
1-1/8"
o
b
p
i
h(22–30 ft•lb)
pr (Do NOT remove) or
Co
e
o
C
r
pr Illustration WS25 d r
te
e
Pivot Assembly
n
s
z
o
a
ri
ti
Link Assembly Replacement
o
c
m
i
u
th
il
d
t
Link Assembly Removal
u
d
U
a
ro
e
n
p
2
v
1. Disconnect the Negative
(Black) battery cable.
U
0
re
er
0
s
2
2. Remove the head
d covers. (See Illustration WS25.)
t
e
re
h
z
i
3. Loosen and
r remove the arm-retaining nuts with a 14 mm wrench
ts
ig and remove the wiper arms.
r
o
h
y
h the rain shields.
ig
t
4. Remove
p
r
u
o
a
ll
C
n
A
U
ts
h
rig
184
5. Remove the 1-1/8"
WS25.)
w
d locknuts and washers from thel pivot assemblies. (See Illustration
a
e
la WS10.)
u
v
6. Remove therwiper motor drive shaft nut with
a 13 mm wrench. (See Illustration
n
y
a
e
b
s
7. Removee the motor crank from the wiperMmotor drive shaft.
d
r
e
e
t
c
i assembly.
8. Remove
ts and replace the pivot andrvlink
bi
i
h
h
e
ig Installation
Link Assembly
o
S
r
r
l
l
y and push pivots through 0.81"
l
p
a
1.
Position
the
linkage
assembly
holes
in
the
body.
d
A
n
o
nu
o
i
B
a
2. Assemble pivots as follows:
t
c
M
—
u
e
e
l
a. Place a c
steel washer onto each pivot body.
d (See Illustration WS25.)
ic
i
o
v
r
ha 1-1/8" locknut onto the pivot
b. Place
p assembly and torque to 2230 ftlb. er
e
e
r
S
r V a rain shield onto the pivot
c.ePlace
body.
y
d
t
s
ze on, and run the wiper system. Return othed wiper control to the
3. Reconnect
the battery, turn theriignition
a
B
o motor to park itself.
mOff position to allow the wiper
i
—
l
h
i
t
t
le shaft and torque the motor
U 4. Disconnect the battery.auReinstall the motorncrank to the wiper motoricdrive
h
drive shaft nut to 917
e
io WS10.)
Un ftlb. (See Illustration
t
V
aon, and run the wiperrsystem.
r
5. Reconnect the battery, turn the ignition
Return the wiper control to the
e
oPark position. In the tcorrect
p
Off position to check for the correct
Park
position, the pivot cranks
s
r
a
o Illustration WS20.m
w
should be positioned as shown in
a
C
i
l
l
6. Replace the wiper arms on
y
erthe pivot assembly. Uti
t
b
s
d
7. Start the wiper systemaand test all the functions.
e
m
t
ili
bi
Wiper Blade Replacement
t
i
h
U
o
Wiper Blade Removal
2
r
0
p
aw
l
0
End of Wiper
1. Pull the2wiper arm away from the
n
n
o Assembly
t and lock the arm into
1. To remove,
iArm
o
by lock Arm
windshield
i
t
h
t
into the
c
d Service position
a
ig Service position.
the
u
e
r
r
d
it
y
3. Slide Arm Hook o
out
o
b
p
p
2.
Rotate
the
blade
about
90°
and
i
r
of
Blade
Assembly
r
o
Co push the blade toward the
ep
oh Plastic Retaining Clip
C
r
r
r
windshield about 1". (The
p
d
e
t
rubber insert will bow outwardn
s
ze
o
i
i
a
r
t
from the arm pushing against
it.)
o
c
h
u
(See Illustration WS35.)
limWiper Blade Assembly
t
2. Push
i
d
t
u
o from
U toward the Windshield ed
a
r
3. Unhook the blade assembly
n
p
2
rv
U
0
the arm.
re
e
0
Illustration
2 BladeWS35
d
es
Wiper Blade Installation
t
Install Wiper
Assembly
e
r
h
iz
ts
ir g
1. Hookoinr a new blade and push it
h
hfrom the vehicle until the blade locks in place. py
away
ig
t
r
u
o
ll
2.naRotate the new blade to its normal position and lower
C the arm.
A
U
185
Wiper Arm Replacement
l
w
d
a
a
e
l
u
n
rv
a
1. Remove theehead cover. (See Illustration WS25.)
by
s
M
re the washer hose from thecT-fitting
e pump assembly. ted
2. Disconnect
i
s
i
t
b
v
i
h
3. Remove the arm-retaining nut with
h the wiper arm.
er a 14 mm wrench and remove
ig
o
S
r
r
Wiperl Arm Installation
l
y
l
p
a
d
A 1. Ensure that the wiper system
u
n
it o as shown. (See Illustration WS20.) an
Bo is Parked with pivot cranks
c the arms facing outward from the center ofMthe
2. Push the arm heads—
over the tapered knurl shaftuwith
e
l
dWS25.) The blades should be approximately
windshield at Park
ce 4"
c position. (See Illustration
i
i
o
rto the outer end of the blade tip. (See Illustration
h of the windshield glass
from the bottom
rv
p
e
e
WS40.)V
re
S
r
y
d
e
t the two arm-retaining nuts
d
3. Replace
e and torque to 1516 ftlb with a 14 mm wrench.
s
o
iz
a
r
B to the T-fitting washer
4. im
Push the washer hoses through
o the holes provided in the body and connect—them
l
h
i pump.
t
t
le
u
c
U
a
i
5. Replace the head cover
h Illustration WS25.)
on on the arm heads. e(See
Un over the retainingtinuts
V
a
r
r
te
po
s
r
a
o
w
m
a
C
i
l
l
ti
er
t
U
by
s
a
d
e
m
t
ili
bi
t
i
U
oh
2
r
w
0
p
la
0
4"
n
2
n
t
io
o
by
i
t
h
t
c
d Position
a
ig
78.5 Park
u
e
r
r
d
it
y
o
o
b
p
p
i
r
r
h
o
Co
ep
o
C
r
r
r
p
d
e
t
e
n
s
iz
io
a
r
t
o
c
im
h
u
l
t
i
t
u
od
U
a
r
ed
n
p
2
v
U
re
er
00
s
2
4" e
d
t
e
r
h
ir z
s
g
t
i
r
o
h
86.5 and 93.5 Park Position
y
ig
th
p
r
u
o
Illustration WS40
a
ll
C
n
A
Park Positions
U
Wiper Arm Removal
186
l
w
d
a
a
e
l
u
Pivot Removal
n
rv
a
e
by
s
1. Disconnect
the Negative (Black) batteryMcable.
d
re
e
e
t
c
2. Remove
the
wiper
arms.
ts
bi
vi
i
h
r
h
3. ig
Remove the head covers. (SeeeIllustration WS25.)
o
S
r
r
l4. Loosen and remove the twoyarm-retaining nuts with a 14pmm wrench and remove the wiper arms. al
l
d
A
u
n
o
n
o
i
B
a
5. Disconnect the link from the pivot by applying even
on the
t pressure, using two flat-blade screwdrivers,
c
M
—
underside of the plastic
ball
cap.
(See
Illustration
WS45.)
u
e
le
d
c
c
i
i
o
6. Remove theh
rain shield.
v
r
rRain
Armp
e
e
Retaining Nut
7. RemoveV
the 1-1/8" AF
re
S Shield
r
y
d
e
locknut
t from the pivot.
d
e
s
z
o
i
a
B
8. Remove the pivot
or
massembly.
1-1/8—
"AF
i
l
h
i
t
Locknut
t
le
u
c
U
a
i
Pivot Installation
Pivot Assembly
n
n
h
o
e
i
U
t
1. Place the new pivot
Flat-Blade` V
a
r
Screwdriver
assembly on the pivot.
er
o
t
p Link
r
as
2. Replace the 1-1/8" AF
o
w
m
a
C
i
locknut and torque to
l
l
Plastic
ti
y
er
2230 ftlb.
Ball Cap
t
U
b
s
d
3. Grease the plastic balla
e
m
t
i
li or
cap with Castrol iLM
b
t
i
Illustration WS45
Shell RetinaxUA grease
h
o
Pivot Assembly
2
r
or equivalent.
0
p
aw
l
0
n
2
4. Placet a 3/4" socket over the plastic ball cap and push
y the cap onto the pivotioball. Using a pair of on
t together until the balltiis
h
multigrips
or tongue-and-groove pliers, squeeze b
the socket and the pivot crank
c
g seated in the ball cap. (See IllustrationedWS50.)
irfirmly
u
ra
t
d
i
y
o
p5. Replace the rain shield.
ib
ro
rp
o
h
p
o
C
e
o On, and
C
r
r
6. Reconnect the battery, turn the ignition
r
p
d
run the wiper system. Return the
wiper control to
te
e
n
Pivot
s
z
o motor to park ri
the Off position to allow thetiwiper
a
Pivot Crank
Assembly
o
c
m
itself.
h
Pivot Ball ili
u
t
d
t
u
o
U
7. Replace the wiper arms.
a
Pliersed
r
n
p
2
3/40"
rv
U
Link
re
e
[190mm]
2
d
Socket
es
t
e
r
h
iz
g
r
ts
i
r
o
h
Illustration WS50
y
h
ig
t
p
Squeeze
Socket and rPivot Crank
u
o
a
ll
C
n
A
U
Pivot Assembly Replacement
187
C
l
d
a Cargo lights 138 law
Indexrve
u
n Clearance lights 135y
a
e
b
s
M
Control module 74,
75, 77, 92, 93
e
d
r
e
e
t
Coolant 20 i
ic
ts
v
ib 20
Coolant, engine
h
r
h
e
g
i
Cover, overhead.
Overhead shelf cover
S
A lr
ro service See
l
y
l
p
Customer
14,
16, 18
a
d
A
n
A/C. See Air conditioning o
nu
o
D
i
B
a
t
Access, fuel sending unit 71
c
M
—
Actuator, switch 161 le
u
D-Loop, seat belt. See Seat belt
e
d Decals 26, 41
c
ic
Address 132
i
o
v
r
r
p
National Highway
eh Traffic Safety AdministraDefrost duct 73, 79, 87
e
e
V
r
S
tion 17, 20
Dome (cab) light 138
r
y
d
e
t
U.S. Department
of Transportation e17, 20
Door, bulkhead 42
s
od
iz
a
Utilimaster
Door, hardware 18 B
r
Customer
service 18
Door, maintenance —
lim
ho
itParts
t
e22, 23, 24
l
department
14
u
Door,
roll-up
24,
43
U Publications departmenta 3
ic
n
n
Adjustment
50
h
e
io
U 16
Warranty department
t
Cable replacement
46
V
a
r
r
Air conditioning 87
Counterbalance
44
te 54
po
Controls 92
s
Pull strap
r
a 53
o
w
General information 88
Rollers
m
a
C
i
l
l
Safety 19, 94
ti Spring 45
er
t
U
by
Specifications 111
Winding spring 47
s
d
System components 90 a
Door, side sliding
e
m
t
i
Tests 99
Adjustment 59, 62
ili
b
t
i
Alarm, back-up (Echovision)
11, 65
Handle 58
U
oh
2
r
Replacement
59
w
0
B
p
la swing 25
0
Door,
n
2
n
y
Back-up alarm
t (Echovision) 65
io
o
bDrain
i
t
h
t
Batteriesig34
c
d Kazoo 64
a
u
e
r
r
Blowery motor 74, 75, 78, 92, 93, 105
Positive pressure
d system 147
it
o
o
b
p
p
i
r
Body
mounting
bolts
26
r
DuraPlate
10
h
o
Co serial number 12
Body
ep
o
C
r
r
E
r
p
BOM fastener 28
d
e
t
e
Buck rivets 28
Echovision
65
s
on
iz
i
a
r
t
Buckle, seat belt. See Seat belt
Electrical.
See
Wiring
o
c
im
h
u
l
Bulkhead 42
t
Electrical
components
18
i
d
u Email 14, 16, 18 Ut
d
Bumper, step rings 11 ro
a
e
n
p
2
v
Bumpers, hood 23 e
U Emergency repairs
0 20
er
0
Bumpers, rear 37 r
End
cap
67
s
2
d
t
e
re
h
ir z
ts
ig
r
o
h
y
h
ig
t
p
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u
o
a
ll
C
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A
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188
lL
w
d
a
a
e
l
u
Fan 22, 70, 146.rvSee also Blower motor n
LEXAN 170
y
a
b
Fasteners 27 se
License
plate
light
137
M
d
re
Federal Certification
Label 12
Lights 22
e
e
t
c
i
Fender repair
Back-up b
136
ts 123
vi
i
h
r
Fender
Cargo h
138
e
igreplacement 122
o
S
r
r
Forms
Clearance 11, 135
l
l 14, 16
y
l
p
a
d
Fuel
sending
unit
access
71
Dome
(cab)
138
A
n
o
nu
o
Identifcation
11,
135
i
B
a
t License plate 137
G
c
M
—
u
e
e
l
d Side marker 11, 135
Glossary of terms 18
c
ic
i
o
v
r
Grab handles 26,h72
Stop 11, 136
r
p
e
e
e
Tail
136
Grease. See Lubricants
r
S
r V 119
y
Grille (stone
guard)
Turn
134,
136
d
e
t
d
e
s
Liner, roof 151
o
ir z
a
H
B
Locknuts 29
o
m
i
—
l
h
i grab 11, 25, 72 ut
Locks 23, 42, 56
Handle,
t
le
c
U
a
Lubricants
Headlights
133
i
n
h
Castrol 187
Heater 18, 22, 74. See
e
io
Unalso Air conditioning
t
V 25
a
Exxon 23,
Heater, block 11
r
r
o
te 23
Graphite
Height adjuster, seat belt 155
p
s
r
a 187
Grease
Hinges 25
o
w
m
a
C
i
NUTO 23, 25
Hood 23
l
l
ti Oil 23, 24, 25
y
er
Adjustment 118, 131
t
U
b
Retinax 187
Bumpers 116, 129
as
d
e
m
Shell
187
Fiberglass 117
t
li
bi
Gas spring 120 ti
i
M
h
U
Prop rod 116, 2117
o
r
Magna-Bulb
30
Repair 123 00
p
aw
l
n
2
Magna-Grip 31
Replacement
n
t 120
o
byMagna-Lok 30 tio
i
RIM 116h
t
g
d Maintenance 22 uc
a
HVAC.riSee Air conditioning
e
r
d
it
y
Doors 22 ro
b
p
po
i
r
I o
h
p
Heater 22
o
C
e
o
C
r
r
Identifcation lights 135
Locks 23
r
p
d
e
Inspection 22
Positive
pressure
system
147
t
n
s
ze door 23
o
i
i
Rear
a
r
t
J
oSeat 22
c
h
u
lim
t
i
d
t
Jump seat
u Seat belt 22, 154U
d
o
a
r
e
Replacement 159 p
Matting (cab floor)2 139
n
U
0 charts 28, 29, 111 erv
Seat belt 156
Metric conversion
re
0
s
2 22, 26, 140
d
Mirrors 11, t18,
e
e
r
K
h 30
MONOBOLT
iz
g
r
ts
i
r
h
Kazoo draino64
Mud flaps
18
y
h
ig
t
p
Keys 132
r
u
o
a
ll
C
n
A
U
F
189
S
l
a Safety
aw
l
u
an Belt. See Seat belt
by
M
Cable latch 11,d 42
e
te 17, 19
Considerations
20, 132 ic
i
Sealant 33ib
rv
e
Seals, door
oh 24, 55, 56
S
r
l
y
Seat p
a
d
18, 158
nu
on
it Pedestal
Bo
a
O
Replacement 158
cSeat
M
—
u
e
belt 152
e
Oil. See Lubricants l
d Buckle 155
c 141
ic
i
o
Overhead shelf cover
v
r
r
p
eh
Buckle latch plate 155
e
e
V
P
r
S
D-Loop 154
r
y
d
e
d
Height adjuster 155
Paint 142.stSee also Decals
ze
o
i
a
Jump
seat
156
r
B
Parts
o
m 18
i
Maintenance
22,
154
—
l
h
Guide
i
t
e
t
u
Pedestal 155 cl
Numbers
13
U
a
i
n Retractor 154
n
h
Ordering 14
o
e
i
U
t
Sending unitVaccess, fuel 71
Parts manuals 10
a
r
Serial number
er 12
Pedestal, seat 152
o
t
Shelf cover
Pedestal, seat belt 155
rp
as 160141
o
w
Shelving
Phone numbers 14, 16, 17, 18,C20, 132
m
a
i
l
l
Sun
Pin-and-collar fastener 31
ti visors 18, 164
er
t
U
by
Switches 22, 161
Pop rivet 31
s
a
d
Positive pressure systemm11, 146
e
T
t
Primer, paint 142
ili
bi
t
i
Tape 26, 32
Pull strap 11, 23 U
oh
2
r
Thread
adhesive
31
w
0
R
la switch 22, 161n p
0
Toggle,
2
n
y 27
t
io
Refrigerant-134a.
See Air conditioning
o
bTools
i
t
h
t
d Torque seal 32 uc
Retractor,
a
igseat belt. See Seat belt
e
r
r
d 29, 111
it Torque value charts
y control 3
o
Revision
o
b
p
p
i
r
r
Towing
20
RIMo(Reaction Injected Molding). See Hood
h
o
C 148
ep132
o
Transponder
C
Roof
r
r
p
Transport
Security, Inc. 132 er
d
Rub rail 67
t
e
n
s
ir z
it o
a
o
c
m
i
u
th
il
d
t
u
U
a
ro
ed
n
p
2
v
U
re
er
00
s
2
d
t
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h
ir z
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ig
r
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h
y
h
ig
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p
r
u
o
a
ll
C
n
A
U
N
d
e
Numbers
rv 12
Body serial number
e
s
Parts 13 re
Phone 14,
ts 16, 17, 18,
h
VIN 12
igorder 12
Work
r
l
Nutsert
Al 30
190
l
w
d
a
a
e
l
u
Utilimaster body serial
n
rv number 12
y
a
e
b
Utilimaster customer
service.
See
Customer
s
M
d
service re
e
e
t
c
UtilimastertsGlossary of Terms 18 vi
bi
i
h
r
Utilimaster
h
eGuide 18
ig Quick Reference Parts
o
S
r
r
l
y
V ll
p
a
d
A
u
n
VACS 11, 18, 42, 43, 132
it o
Bo
an
c
M
Vent
—
u
e
e
l
Fan 70
d
c
c
i
i
o
v
r
Parts ordering 18
h
r
p
e
e
e
Positive pressure
system
146
r
S
rV
Two-way hingeless
11, 162
y
d
e
t
d
e
VIN 12 s
o
ir z
a
B
Visorsm18, 164
o
i
—
l
h
i
le
WUt
ut
c
a
i
n
n
h
Warranty claims 16 U
e
io
t
V
a
Web site 3, 14, 16, 18
r
r
o
Windows 18, 23, 56, 57, 165
te
p
s
r
a
Wipers 18, 22, 179
o
w
m
a
C
Arm replacement 186
i
l
l
r
ti
y
Blade replacement 185 te
U
b
Linkage replacement 185
as
d
e
Motor replacement 183
m
t
ili
bi
Pivot replacement t187
i
h
Troubleshooting U
180
o
2
r
0 179
Washer assembly
p
aw
l
0
n
2
Wiring schematics
18
n
tnumber 12
io
o
by
Work order
i
t
h
t
c
d
a
ig transponder 132
Wristband,
u
e
r
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it
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o
o
b
p
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Co
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rv
U
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C
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191
193
Vehicles
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Number
:
03102102-VY00EN
p
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a Cor poration, 65906 State Road 19, P.O. CBox 585, Wakar usa, Indiana,
ll 465730585, USA
Utilimaster
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