engine MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

Injector opens fully
The control plunger reaches its upper stop where it
remains supported by a cushion of fuel which is gen-
erated by the flow of fuel between the bleed and feed
orifices. The injector nozzle has now opened fully,
and the fuel is injected into the combustion chamber
at a pressure almost equal to that in the fuel rail
(Fig. 8).
Injector closes (end of injection)
As soon as the solenoid valve is no longer trig-
gered, the valve spring forces the armature down-
wards and the ball closes the bleed orifice. The
armature is a 2±piece design. Here, although the
armature plate is guided by a driver shoulder in its
downward movement, it can ªoverspringº with the
return spring so that it exerts no downwards-acting
forces on the armature and the ball. The closing of
the bleed orifice lead to pressure build up in the con-
trol chamber via the input from the feed orifice. This
pressure is the same as that in the rail and exerts an
increased force on the control plunger through its
end face. This force, together with that of the spring,
now exceeds the force exerted by the chamber volume
and the nozzle needle closes. Injection ceases as soon
as the nozzle needle comes up against its bottom stop
again (Fig. 8).
STANDARD PROCEDURE
STANDARD PROCEDURE - INJECTOR
CLASSIFICATION
The classification of injectors into 3 classes
describes the quantity characteristic of the injector.
This will make it possible in the future to match the
engine software to the tolerances of the injector
within a more narrowly graduated range. Classifica-
tion can be clearly recognized, and assigned only by
means of a DRBIIIt.
Classified injectors can be recognized by the part
number and identification on the magnetic head (cir-
cle with a number between 1 and 3 inside) (Fig. 9).
The number corresponds to the classification stage.
These general conditions equally apply if, as a
result of replacing an engine, carrying out repairs to
the cylinder head etc., the cylinder selective assign-
ment of the injectors or the engine control module
assignment may have changed. If proper attention is
not paid to the classification on these vehicles drive-
ability and smoking concerns could result.
If an injector is replaced, it is then necessary to
assign the classification number to the corresponding
cylinder with theDRBIIItin the control module.
INJECTOR CLASSIFICATION PROCEDURE
(1) Turn ignition switch ªONº.
(2) Using a DRB IIItand select ENGINE then
MISCELLANEOUS.
(3) Select LEARN INJECTORS.
(4) Using the up and down arrows, scroll to the
appropriate injector.
(5) Using the right and left arrows, set injector to
proper classification.
(6) Once injectors are classified, cycle ignition to
complete.
STANDARD PROCEDURE - CLEANING FUEL
INJECTORS
NOTE: Before cleaning the injector recesses, seal
the injector holes in the injector recesses with the
appropriate pin to prevent debris from falling into
the recesses and entering the motor.
(1) Seal the injector holes inside the cylinder head
recesses.
(2) Wipe out injector recesses with a non-woven
cloth, then clean with a cylinder brush.
(3) Clean the bottom of the cylinder recess with a
round brush.
(4) Blow out the recess and clean again with a
non-woven cloth and cover over.
(5) Perform these steps for each injector recess.
NOTE: DO NOT clean the tip of the injector with a
wire brush. Use a non - woven cloth.
(6) Clean injector body with a wire brush.
(7) Clean injector tips with a non-woven cloth.
NOTE: Do Not apply antiseize lubricant to the injec-
tor nozzle area.
(8) Grease injector body with anti seize lubricant.
Fig. 9 INJECTOR CLASSIFICATION MARKINGS
14 - 22 FUEL INJECTIONVA
FUEL INJECTOR (Continued)

NOTE: Always replace the seals that seal off the
injectors at the cylinder head to the combustion
chamber and replace the retaining screws.
REMOVAL
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
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.
NOTE: The engine must be lowered in the vehicle to
remove the fourth and fifth cylinders fuel injectors.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Raise and suitably support the vehicle.
(4) Remove lower radiator deflector plate.
(5) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(6) Remove turbocharger down pipe assembly.
(7) Remove oil dipstick tube retaining bolt and pull
tube from oil pan.
(8) Lower vehicle.
(9) Remove upper radiator hose.
(10) Remove air cleaner box assembly and hoses.
(11) Remove charge air cooler inlet hose.
(12) Remove charge air cooler to turbocharger inlet
adaptor.
(13) Remove turbocharger to right engine mount
bracket.
(14) Disconnect steering coupler at gear box (RHD
Only).
(15) Remove battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - REMOVAL).
(16) Unclip PDC from battery tray and set aside.(17) Remove battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - REMOVAL).
(18) Remove power steering reservoir (Refer to 19 -
STEERING/PUMP/RESERVOIR - REMOVAL).
(19) Remove charger air cooler outlet hose.
(20) Remove intake manifold to left engine mount
bracket.
(21) Evacuate air conditioning system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(22) Disconnect air conditioning suction / discharge
lines at A/C compressor.
(23) Disconnect pedal position sensor electrical
connector.
(24) Unplug injector electrical connectors.
(25) Remove fuel / water separator to intake man-
ifold retaining bolts.
(26) Support engine with hoist.
(27) Remove engine mount through bolts.
(28) Remove right engine mount sill plate.
NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
(29) Disconnect fuel injector high pressure line.
(30) Remove fuel injector retaining bolt and ten-
sion claw.
(31) Suitably lower engine to gain fuel injector
access and remove injector.
NOTE: If injectors are tight, remove with extraction
claw in place of tensioning claw. If extraction claw
contacts cylinder head cover, remove cylinder head
cover. If necessary, remove injectors with threaded
adaptor and discard injector.
(32) Remove injectors (Fig. 10).
(33) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
INSTALLATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
VAFUEL INJECTION 14 - 23
FUEL INJECTOR (Continued)

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.
(1) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(2) Coat injector body with anti seize lubricant
then install injectors with new seals.
(3) Install tensioning claws with new screws at
injectors. Tighten screws in two stages, 7 N´m (62
lbs. in.) then 90É.
NOTE: If locking clamp has been pulled off at injec-
tor, the locking clamp must be replaced.
(4) Position fuel return line at injectors and secure
locking clamps.NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
(5) Install high pressure injection lines (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).
(6) Reconnect injector electrical connectors.
(7) Raise engine and install right sill plate.
(8) Install engine mount through bolts and tighten
to 40N´m (30 lbs. ft.).
(9) Install fuel / water separator to intake mani-
fold retaining bolts.
(10) Connect pedal position sensor electrical con-
nector.
(11) Connect air conditioning lines to A/C compres-
sor.
(12) Install intake manifold to left engine mount
bracket.
(13) Install charge air cooler outlet hose.
(14) Install power steering reservoir(Refer to 19 -
STEERING/PUMP/RESERVOIR - INSTALLATION).
Fig. 10 FUEL INJECTOR REMOVAL / INSTALLATION
1 - FUEL INJECTOR RETURN LINE
2 - RETAINING CLIP
3 - INJECTOR HIGH PRESSURE LINE
4 - INJECTOR SEAL5 - FUEL INJECTOR
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND # 8937
14 - 24 FUEL INJECTIONVA
FUEL INJECTOR (Continued)

(15) Install battery tray(Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(16) Connect PDC to battery tray.
(17) Install battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(18) Connect steering coupler at gear box (RHD
Only).
(19) Install turbocharger to right engine mount
bracket (Refer to 11 - EXHAUST SYSTEM/TURBO-
CHARGER SYSTEM - INSTALLATION).
(20) Install charge air cooler to turbocharger inlet
adaptor (Refer to 11 - EXHAUST SYSTEM/CHARGE
AIR COOLER AND PLUMBING - INSTALLATION) .
(21) Install charger air cooler inlet hose (Refer to
11 - EXHAUST SYSTEM/CHARGE AIR COOLER
AND PLUMBING - INSTALLATION).
(22) Install air cleaner box assembly and hoses.
(23) Install upper radiator hose.
(24) Raise vehicle.
(25) Install dipstick tube into oil pan and tighten
retaining bolt.
(26) Install turbocharger down pipe assembly.
(27) Close cooling system drain.
(28) Install lower radiator deflector plate.
(29) Lower vehicle.
(30) Connect negative battery cable.
(31) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION)..
(32) Fill cooling system with the correct mixture to
the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT
WEAR LOOSE CLOTHING.
(33) Start engine and inspect for leaks.
(34) Recharge air conditioning system.
FUEL PRESSURE SENSOR
DESCRIPTION
DESCRIPTION
The fuel pressure sensor provides the current low
pressure (the pressure that exist at the inlet of the
high pressure injection pump) fuel pressure to the
ECM (Fig. 11).
The fuel pressure when the engine is idling is
approximately 36 psi (2.5 Bar). The fuel pressure
while driving is 50±58 psi (3.5 - 4.0Bar).
DESCRIPTION
The fuel rail pressure sensor provides the current
fuel rail pressure to the ECM.
OPERATION
OPERATION
A diaphragm and an electric resistance meter are
integrated in the fuel pressure sensor. The non-con-
stant fuel system pressure from the low pressure fuel
pump influences the position of the diaphragm which
in turn alters it's electrical resistance. This resis-
tance is analyzed by the ECM. The ECM then actu-
ates the fuel rail pressure control valve until the
desired rail pressure value is obtained (Fig. 11).
OPERATION
The fuel rail pressure sensor measures the current
fuel rail pressure and sends a voltage signal to the
ECM. The ECM then actuates the fuel rail pressure
control valve solenoid until the desired rail pressure
is achieved.
Fig. 11 FUEL PRESSURE SENSOR
VAFUEL INJECTION 14 - 25
FUEL INJECTOR (Continued)

INSTALLATION
(1) (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION - WARNING) Install the sealing ring on to the
sensor (Fig. 13).
(2) Screw the sensor in to the fuel rail. Counter-
hold the threaded connection and tighten the sensor
to 18 lbs. ft. (25 N´m.) (Fig. 13).
(3) Connect the wiring harness to the sensor.
(4) Install the mixing housing.
(5) Connect negative battery cable.
FUEL PRESSURE SOLENOID
DESCRIPTION
The fuel pressure solenoid is attached to the rear
of the fuel rail. The solenoid controls and maintains
the rail pressure constant along with a control cur-
rent transmitted by the engine control module (ECM)
(Fig. 14).
OPERATION
High pressure which is present in the fuel rail
flows to the ball seat of the solenoid (Fig. 15). The
specified pressure required by the system is built up
in the rail by the fuel pressure solenoid building up a
magnetic force which corresponds to this specific
pressure by means of a control current from the elec-
tronic control module (ECM) (Fig. 15). This magnetic
force equals a certain outlet cross section at the ball
seat of the solenoid. The rail pressure is altered as a
result of the quantity of fuel which flows off (Fig. 15).
The current fuel pressure is signaled by the fuel
pressure sensor to the engine control module (ECM).
The controlled fuel flows back along the return fuel
line, into the tank.
In a de-energized state, the fuel pressure solenoid
is closed as the spring force presses the ball into the
ball seat (Fig. 15). When driving, the fuel pressure
solenoid is constantly open (Fig. 15). When engine is
started, the fuel pressure solenoid is held closed by
magnetic force (Fig. 15). When driving, the pressure
of the fluid counteracts the magnetic force of the coil
and the slight spring force (Fig. 15).
Fig. 14 FUEL PRESSURE SOLENOID - TYPICAL
1 - INJECTION LINES
2 - FUEL RAIL
3 - FUEL RETURN LINE
4 - FUEL PRESSURE SOLENOID
5 - OIL LINE
6 - SEALS
7 - FUEL RETURN LINE AT COOLER
8 - HIGH PRESSURE FUEL LINE TO FUEL RAIL
9 - FUEL LINE BRACKET
10 - FUEL PRESSURE SENSOR
Fig. 15 FUEL PRESSURE SOLENOID OPERATION
1 - BALL SEAT
2 - SPRING FORCE
3 - MAGNETIC FORCE
4 - COIL
5 - FUEL PRESSURE SOLENOID
6 - HIGH PRESSURE FEED
VAFUEL INJECTION 14 - 27
FUEL PRESSURE SENSOR (Continued)

WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT PUT YOUR HANDS NEAR
PULLEYS, BELTS, OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(4) Start engine and inspect for leaks (Refer to 14 -
FUEL SYSTEM - DIAGNOSIS AND TESTING).
FUEL TEMPERATURE SENSOR
DESCRIPTION
The fuel temperature sensor is located in the fuel
return line directly down stream of the fuel rail pres-
sure control valve. The sensor measures the temper-
ature of the fuel in the return pipe between the rail
and the pre-heating valve. The sensor ranges from -
40ÉF (- 40C) to 284ÉF (140ÉC). If the engine is cold,
the actual value sent will read ambient temperature.
The value rises after the engine has been started.
OPERATION
An negative temperature coefficient (NTC) resistor
integrated in the fuel temperature sensor alters it's
electrical resistance in line with the fuel temperature
(the resistance drops as the temperature rises). If
fuel temperature has reached 248ÉF and engine
speed is above 2000 rpm, a pumping element of the
high pressure fuel injection pump is switched off and
engine output is reduced.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor wiring harness connector
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION -
WARNING).
(3) Remove the fuel temperature sensor from the
fuel rail (Fig. 17).
INSTALLATION
(1) Clean sealing surfaces.
(2) Install new seal on sensor (Fig. 17).
(3) Screw the sensor into the fuel rail and tighten
to 18 lbs.ft. (25 N´m)(Refer to 14 - FUEL SYSTEM/
FUEL INJECTION - WARNING) . (Fig. 17)
(4) Connect negative battery cable.
INLET AIR TEMPERATURE
SENSOR
DESCRIPTION
The inlet air temperature sensor is located
between the charge air pipe and the charge air dis-
tribution of the cylinders. The inlet air temperature
sensor measures the temperature of the air as it is
supplied to the cylinders and transmits the value to
the ECM. This is required in order to determine the
density of the air being supplied for the combustion
process. The value range is from minus 40ÉF up to
302ÉF (minus 40ÉC to 150ÉC).
OPERATION
The Negative Temperature Coefficient (NTC)
resister located within the inlet air temperature sen-
sor alters it's resistance in line with the charge air
temperature. If the engine is cold, the value equals
ambient temperature. For a temperature of 68ÉF
(20ÉC) the resistance is approximately 6000 ohms.
For a temperature of 104ÉF (40ÉC) the resistance is
approximately 2600 ohms (Fig. 18).
Fig. 17 FUEL TEMPERATURE SENSOR
1 - FUEL RAIL
2 - FUEL TEMPERATURE SENSOR
3 - HARNESS CONNECTOR
4 - SEAL
VAFUEL INJECTION 14 - 29
FUEL PRESSURE SOLENOID (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................2COLUMN...............................5
GEAR..................................8
LINKAGE..............................10
PUMP.................................12
STEERING
DESCRIPTION
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
VASTEERING 19 - 1

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION..........................8
REMOVAL.............................8INSTALLATION..........................8
SPECIFICATIONS - TORQUE CHART.........9
GEAR
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part
of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa-
rate the tie rods from the steering knuckles (Fig. 2)
using special tool C-3894±A.
(6) Remove the left outer tie rod end from the
steering gear.(7) Remove both spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).
(8) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from
the steering gear (Fig. 2).
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.
INSTALLATION
(1) Install the gear to the vehicle.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR REMOVAL / INSTALL
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
19 - 8 GEARVA

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 12
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....12
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............13
REMOVAL.............................13
INSTALLATION.........................13
SPECIFICATIONS - TORQUE CHART........14
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE........................14FLUID COOLER TUBE
REMOVAL.............................14
INSTALLATION.........................14
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE...........15
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE.......................15
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE....................15
INSTALLATION
INSTALLATION - PRESSURE HOSE.......15
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE...............15
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE...............15
PUMP
DESCRIPTION
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
19 - 12 PUMPVA

Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4)
Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4)
Remove the return hose from the pump (Fig. 1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5)
Fill the power steering fluid (Refer to 19 - STEER-
ING/PUMP/FLUID - STANDARD PROCEDURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
VAPUMP 19 - 13
PUMP (Continued)