MERCEDES-BENZ SPRINTER 2006 Service Manual

OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the fuseblock only when the ignition switch is
in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the heating element is
inserted in the receptacle shell, the heating element
resistor coil is grounded through its housing to the
receptacle shell. If the cigar lighter knob is pushed
inward, the heat shield slides up toward the knob
exposing the heating element.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up and glow.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For cigar lighter outlet diagnosis and testing pro-
cedures (Refer to 8 - ELECTRICAL/POWER DISTRI-
BUTION/POWER OUTLET - DIAGNOSIS AND
TESTING)
REMOVAL
For cigar lighter outlet removal procedure (Refer to
8 - ELECTRICAL/POWER DISTRIBUTION/POWER
OUTLET - REMOVAL).
CIRCUIT BREAKER
DESCRIPTION
Automatic resetting circuit breakers are used to
protect the power window voltage supply circuits.
These circuit breakers can protect the systems from a
short circuit, or from an overload condition caused byan obstructed or stuck power window regulator or
switch.
The circuit breaker cannot be repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The circuit breaker contains a bi-metal strip sand-
wiched between two contacts forming the connection
in the circuit. An overload condition causes the
bi-metal strip to heat and bend to the open position,
disconnecting current flow to the circuit. Then as the
system overload or short circuit is removed, the
bi-metal strip cools, re-establishing contact to allow
current flow to the circuit.
DIAGNOSIS AND TESTING - CIRCUIT BREAKER
For complete circuit descriptions and diagrams,
refer toWiring.
(1) Locate the correct circuit breaker in the fuse-
block. Pull out the circuit breaker slightly, but be cer-
tain that the circuit breaker terminals still contact
the terminals in the fuseblock cavities.
(2) Connect the negative lead of a 12-volt DC volt-
meter to a good ground.
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit
from the Power Distribution Center as required.
FUSE BLOCK #1
DESCRIPTION
An electrical fuse block is concealed under the
driver side steering column. The fuse block serves to
distribute electrical current to many of the electrical
systems in the vehicle. The fuse block contains blade-
type mini fuses, relays and micro processors that
enable automatic control of some of the power distri-
bution circuits throughout the vehicle.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the steering column. A finger recess is molded into
the cover for easy removal. A fuse layout map is
molded onto the back side of the cover to ensure
proper fuse identification.
The fuse block cannot be repaired, if the fuse block
is faulty or damaged or if any internal circuit is
faulty or damaged, the entire fuse block must be
replaced.
8W - 97 - 2 8W-97 POWER DISTRIBUTIONVA

OPERATION
All of the circuits entering and leaving the fuse
block do so through the instrument panel wire har-
ness. Internal connection of all of the fuse block cir-
cuits is accomplished by an intricate combination of
hard wiring and bus bars. Internal relays and micro
processors allow the vehicle electronics to control
some of the power distribution circuits throughout
the vehicle. Refer to the Wiring section for complete
circuit diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove fuse block cover by rotating locking
screw 90É.
(3) Remove the steering column cover. Refer to the
Body section for the procedure.
(4) Unscrew fuse block connections and disconnect
all electrical connectors from the fuse block.
(5) Remove the fuse block from the steering col-
umn.
INSTALLATION
(1) Position the fuse block in the steering column.
(2) Install fuse block connections and connect all
electrical connectors on the fuse block.
(3) Install the steering column cover. Refer to the
Body section for the procedure.
(4) Install fuse block cover by rotating locking
screw 90É.
(5) Connect the negative battery cable.
(6) Set time and radio stations.
FUSE BLOCK #2
DESCRIPTION
An electrical fuse block is concealed under the
driver side front seat. The fuse block serves to dis-
tribute electrical current to many of the electrical
systems in the vehicle. The fuse block houses blade-
type mini fuses, blade-type automatic resetting cir-
cuit breakers and International Standards
Organization relays. Additional provisions are avail-
able in the fuse block for additional fuses and ISO
relays.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the seat base. The driver side seat base also has a
snap-fit fuse access panel that can be removed for
service of the fuses and the relays. A finger recess is
molded into one end for easy removal. A fuse layout
map is molded onto the back side of the panel to
ensure proper fuse identification.
The fuse block is integral to the body wire harness.
If any internal circuit or the fuse block housing isfaulty or damaged, the entire fuse block and body
wire harness unit must be replaced.
OPERATION
All of the circuits entering and leaving the fuse
block do so through the body wire harness. Internal
connection of all of the fuse block circuits is accom-
plished by an intricate combination of hard wiring
and bus bars.
POWER DISTRIBUTION CEN-
TER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the Power Distribu-
tion Center (PDC). The molded plastic PDC housing
is located in the left front corner of the engine com-
partment, on the battery positive cable. The PDC
housing has a molded plastic cover that slides over
the PDC housing. The PDC cover is easily opened or
removed for service access.
The PDC unit cannot be repaired and is only ser-
viced as a unit with the headlamp and dash wire
harness. If the internal circuits or the PDC housing
are faulty or damaged, the headlamp and dash wire
harness unit must be replaced.
OPERATION
All of the current from the battery and the gener-
ator output enters the PDC through the positive bat-
tery cable. The PDC cover is removed to access the
battery and generator output connection B(+) termi-
nal studs. Internal connection of all of the PDC cir-
cuits is accomplished by an intricate combination of
hard wiring and bus bars. Refer to Wiring Diagrams
for the location of complete PDC circuit diagrams.
POWER OUTLET
DESCRIPTION
The power outlet is installed in the instrument
panel accessory switch plate, which is located near
the center of the instrument panel. The power outlet
base is secured by a snap fit within the instrument
panel. A plastic protective cap snaps over the power
outlet base when the power outlet is not being used.
While the power outlet is very similar to a cigar
lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the recepta-
cle shell that are used to secure the cigar lighter
heating element to the insulated contact.
The power outlet receptacle unit are available for
service. The power outlet receptacle cannot be
VA8W-97 POWER DISTRIBUTION 8W - 97 - 3

repaired and, if faulty or damaged, it must be
replaced.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the fuse block at all times.
DIAGNOSIS AND TESTING - POWER OUTLET
(1) Check for battery voltage at the fused B(+) fuse
in the fuse block. If OK, go to Step 2. If not OK,
repair the open fused B(+) circuit to the battery as
required.
(2) Check for continuity between the inside cir-
cumference of the power outlet receptacle and a good
ground. There should be continuity. If OK, go to Step
3. If not OK, go to Step 4.
(3) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 4.
(4) Disconnect and isolate the battery negative
cable. Check for continuity between the ground cir-
cuit cavity of the power outlet wire harness connector
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open ground
circuit to ground as required.
(5) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the fuse in the fuse
block as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of
the cigar lighter receptacle base, or unsnap the pro-
tective cap from the power outlet receptacle base.
(3) Look inside the cigar lighter or power outlet
receptacle base and note the position of the rectangu-
lar retaining bosses of the mount that secures the
receptacle base to the instrument panel.
(4) Insert a pair of external snap ring pliers into
the cigar lighter or power outlet receptacle base and
engage the tips of the pliers with the retaining
bosses of the mount.
(5) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of the mount.
(6) Disconnect the instrument panel wire harness
connector from the connector receptacle of the cigar
lighter or the power outlet receptacle base.(7) Remove the cigar lighter or power outlet mount
from the instrument panel.
INSTALLATION
(1) Install the cigar lighter or power outlet mount
into the instrument panel.
(2) Reconnect the instrument panel wire harness
connector to the connector receptacle of the cigar
lighter or the power outlet receptacle base.
(3) Align the splines on the outside of the cigar
lighter or power outlet receptacle base connector
receptacle with the grooves on the inside of the
mount.
(4) Press firmly on the cigar lighter or power out-
let receptacle base until the retaining bosses of the
mount are fully engaged in their receptacles.
(5) Install the cigar lighter knob and element into
the cigar lighter receptacle base.
(6) Reconnect the battery negative cable.
RELAY
DESCRIPTION
A relay (Fig. 1) is an electromechanical device that
switches fused battery current to a electrical compo-
nent when the ignition switch is turned to the Acces-
sory or Run positions, or when controlled by a
electronic module. The relays are located in the fuse
block.
The relay is a International Standards Organiza-
tion (ISO) relay. Relays conforming to the ISO speci-
fications have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
Fig. 1 ISO RELAY
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8W - 97 - 4 8W-97 POWER DISTRIBUTIONVA

A relay cannot be repaired or adjusted and, if
faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
DIAGNOSIS AND TESTING - RELAY
(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 60.7 - 80.3 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the fuse block is connected to battery voltage and
should be hot at all times. Check for battery voltage
at the fused B(+) circuit cavity in the fuse block
receptacle for the relay. If OK, go to Step 2. If not
OK, repair the fused B(+) circuit to the fuse block
fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the fuse block that feeds the
accessory when the relay is energized by the ignition
switch. There should be continuity between the fuse
block cavity for relay terminal 87 and the fused B(+)
fuse in the fuse block at all times. If OK, go to Step
4. If not OK, repair the open fused B(+) circuit to the
fuse block fuse as required.(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the relay when the ignition switch is
in the Accessory or Run positions. Turn the ignition
switch to the On position. Check for battery voltage
at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the fuse block recep-
tacle for the relay. If OK, go to Step 5. If not OK,
repair the open fused ignition switch output (acc/run)
circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The fuse block cavity
for this terminal should have continuity to ground at
all times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle. A slight
back and fourth rocking motion may help the
removal process.
INSTALLATION
(1) Position the relay to the proper receptacle.
(2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
(4) Connect the negative battery cable.
VA8W-97 POWER DISTRIBUTION 8W - 97 - 5

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................5
INSTALLATION
INSTALLATION - ENGINE COVER..........9
INSTALLATION........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS.....................11
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
AIR CLEANER HOUSING
REMOVAL.............................21
INSTALLATION.........................22
CYLINDER HEAD
DESCRIPTION.........................22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............22
REMOVAL
REMOVAL - CYLINDER HEAD............23
REMOVAL - CYLINDER HEAD FRONT
COVER.............................25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD........26
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE..................30
REMOVAL.............................30
INSTALLATION.........................32CYLINDER HEAD COVER(S)
REMOVAL.............................33
INSTALLATION.........................34
VALVE STEM SEALS
DESCRIPTION.........................34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............35
REMOVAL - VALVES...................36
INSTALLATION
INSTALLATION - VALVE SPRINGS........36
INSTALLATION - VALVES...............37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................38
CRANKSHAFT
DESCRIPTION.........................39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....39
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
FLYWHEEL
REMOVAL.............................43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - CRANKSHAFT LOCK.....44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................47
REMOVAL.............................47
INSTALLATION.........................49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................53
INSTALLATION.........................54
VAENGINE 9 - 1

VACUUM PUMP
DESCRIPTION.........................54
OPERATION...........................54
REMOVAL.............................55
INSTALLATION.........................55
LEFT MOUNT
REMOVAL.............................55
INSTALLATION.........................55
RIGHT MOUNT
REMOVAL.............................56
INSTALLATION.........................56
OIL
REMOVAL - OIL SEPARATOR..............56
INSTALLATION - OIL SEPARATOR..........56
OIL COOLER & LINES
REMOVAL.............................56
INSTALLATION.........................57
OIL FILTER
REMOVAL.............................57
INSTALLATION.........................57
OIL JET
DESCRIPTION.........................57
REMOVAL.............................58
INSTALLATION.........................58
OIL PAN
REMOVAL.............................58
INSTALLATION.........................60
OIL PUMP
REMOVAL
REMOVAL...........................61
REMOVAL- OIL PUMP CHAIN............61
INSTALLATION
INSTALLATION.......................62INSTALLATION - OIL PUMP CHAIN........62
OIL SENSOR
DESCRIPTION.........................64
OPERATION...........................64
REMOVAL.............................65
INSTALLATION.........................65
INTAKE MANIFOLD
REMOVAL.............................65
INSTALLATION.........................68
EXHAUST MANIFOLD
REMOVAL.............................68
INSTALLATION.........................69
TIMING CHAIN COVER
REMOVAL.............................70
INSTALLATION.........................71
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE RAILS . 72
REMOVAL - INTERMEDIATE GEAR........73
REMOVAL - TIMING CHAIN TENSIONING
RAIL...............................74
REMOVAL - TIMING CHAIN..............74
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE
RAIL...............................76
INSTALLATION - INTERMEDIATE GEAR....77
INSTALLATION - TIMING CHAIN
TENSIONING RAIL....................77
ADJUSTMENTS
INSTALLATION - TIMING CHAIN..........77
TIMING CHAIN TENSIONER
REMOVAL.............................81
INSTALLATION.........................81
ENGINE
DESCRIPTION
This 2.7 Liter five-cylinder Common Rail Diesel
Injection (CDI) engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has for valve per cylinder and dual overhead
camshafts (Fig. 1).
Fig. 1 2.7L CDI ENGINE
9 - 2 ENGINEVA

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System 2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194ÉF). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING COOLANT. OPEN CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
VAENGINE 9 - 3

NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
CYLINDER LEAK DOWN VALUES
CYLINDER LEAK
DOWN PERMISSIBLE
TOTAL LOSS  25%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT VALVES AND
CYLINDER HEAD  10%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT PISTON AND
RINGS  20%
STANDARD PROCEDURE - DETERMINING CYL-
INDER PRESSURE LOSS
If an increased pressure loss was found with the
cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.
Possible causes for the pressure loss are:
POSSIBLE CAUSE FOR PRESSURE LOSS
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR, AD-
JACENT CYL-
INDERS, OR
AIR BUBBLES
IN COOLANT1. Sealing Sur-
facesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace Cyl-
inder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing Sur-
faces1. Remove Cyl-
inder Head for
Further Inspec-
tion
CONDITION POSSIBLE
CAUSESCORRECTION
2. Intake
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH EX-
HAUSTSealing Surfac-
esRemove Cylin-
der Head for
Further Inspec-
tion
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing Sur-
facesRemove Engine
for Further In-
spection
2. Pistons, Pis-
ton Rings2. Replace Pis-
tons or Piston
Rings
It is possible to pin point the pressure loss of the
relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.
Determining the cause can be falsified by the posi-
tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
REMOVAL
REMOVAL - ENGINE COVER
(1) Remove the retaining screws and remove cover
(Fig. 2).
9 - 4 ENGINEVA

REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES, AND EYE WEAR.
(1) Disconnect the negative battery cable.
NOTE: REPLACE THE AIR CONDITIONING DRIER
WHEN EVER THE AIR CONDITIONING SYSTEM IS
OPENED.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Evacuate and recover air conditioning system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(4) Remove the front grille and fascia assembly.(5) Disconnect the engine wiring harness at the
cabin side and carefully guide though the cowl into
the engine area.
Fig. 2 ENGINE COVER
1 - ENGINE COVER
2 - FASTENERS
VAENGINE 9 - 5