check engine MERCEDES-BENZ SPRINTER 2005 Service Workshop Manual

(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOTOPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 47).
(4) Remove the oil cooler from the timing case
cover (Fig. 47).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 47).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 47).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
Fig. 46 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
Fig. 47 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
9 - 50 ENGINEVA
RIGHT MOUNT (Continued)

CATALYTIC CONVERTER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
rear clamp. (Fig. 1)
(3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front clamp.
(4) Remove the cataylic converter and muffler
assembly from the isolators.
(5) Seperat the cataylic converter and muffler
assembly from the tailpipe and the exhaust pipe.
(6) Remove the cataylic converter and muffler
assembly and isolators from the vehicle.
(7) Remove the bolt, nut and front isolator from
the cataylic converter and muffler assembly.
(8) Remove the rear isolator from the cataylic con-
verter and muffler assembly.
(9)
INSTALLATION
(1) Install bolt, front isolator and nut (Fig. 1).
(2) Install rear insulator onto the cataylic con-
verter and muffler assembly
(3) Position the cataylic conveter and muffler
assembly into the exhaust pipe and tailpipe until
alignment tab is inserted into the alignment slot.
(4) Install the front and rear insulators.
(5) Install the real clamp.
(6) Install the front clamp.
(7) Lower vehicle.
(8) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(9) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
EXHAUST PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front and rear clamp (Fig. 1).
(3) Remove the mounting bracket nuts.
(4) Remove the exhaust pipe.
INSTALLATION
(1) Position the exhaust pipe into the exhaust pipe
into the cataylic converter and muffler assembly
until alignment tab is inserted into the alignment
slot.
(2) Install mounting bracket and nuts (Fig. 1).(3) Install clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TAILPIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration (Fig. 1).
(3) Remove the clamp.
(4) Remove the tailpipe and insulator form the
vehicle
(5) Remove the insulator from the tailpipe.
INSTALLATION
(1) Position the tail pipe into the cataylic converter
and muffler assembly until alignment tab is inserted
into the alignment slot.
(2) Install the insulator.
(3) Install the clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The boost pressure
bracket is an integral part of the turbocharger. Tam-
pering with the boost pressure components can
reduce durability by increasing cylinder pressure
and thermal loading due to incorrect inlet and
exhaust manifold pressure. Poor fuel economy and
failure to meet regulatory emissions laws may
result. Increasing the turbocharger boost WILL NOT
increase engine power.
The turbocharger used on this vehicle is of the
variable turbine type. These turbochargers use the
entire exhaust energy to boost efficiency of the turbo-
charger and the engine.
The advantages of a turbocharger with variable
turbine geometry are:
²Higher charge pressure already in the lower and
in upper engine speed ranges.
VAEXHAUST SYSTEM 11 - 3

Low turbocharger boost pressure and low engine
performance can be caused by leaks in the charge air
cooler or it's plumbing. The following procedure out-
lines how to check for leaks in the charge air cooler
system.
(1) Loosen clamp and remove turbocharger to air
inlet duct rubber sleeve from turbocharger.
(2) Insert Special Tool 8442 Adapter into the rub-
ber sleeve. Tighten existing clamp to 8 N´m (72
in.lbs.).
CAUTION: Do not apply more than 138 kpa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect regulated air supply to air fitting on
Special Tool 8442 Adapter. Set air pressure to a Max-
imum of 138 kpa (20 psi).
(4) Using soapy water check the air inlet ducts,
rubber sleeves, charge air cooler and intake manifold
for leaks.
REMOVAL
(1) Remove front bumper.
(2) Remove headlamp assemblies.
(3) Remove front cross member together with front
grille.
(4) Remove left and right radiator trim (Fig. 3).
(5) Disconnect charge air hoses at charge air cooler
(Fig. 3).
(6) Disconnect power steering cooler loop from
charge air cooler (Fig. 3).
(7) Remove charge air cooler from radiator assem-
bly (Fig. 3).
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit.
INSTALLATION
(1) Install charge air cooler to radiator (Fig. 3).
(2) Connect power steering cooler loop to charge
air cooler (Fig. 3).
(3) Connect charge air hoses (Fig. 3).
(4) Install both radiator trim pieces (Fig. 3).
(5) Install front grille with front cross member.
(6) Install headlamp assemblies.
(7) Install front bumper.
Fig. 3 CHARGE AIR COOLER
1 - POWER STEERING COOLER LOOP
2 - CHARGE AIR HOSE
3 - CHARGE AIR COOLER HOSE
4 - CHARGE AIR COOLER
5 - LEFT RADIATOR TRIM PANEL
6 - RIGHT RADIATOR TRIM PANEL
VAEXHAUST SYSTEM 11 - 5
CHARGE AIR COOLER AND PLUMBING (Continued)

TURBOCHARGER
DESCRIPTION
The boost pressure vacuum solenoid is located
under the air filter housing and is responsible for
turbo-charger boost pressure. It generates a control
vacuum in response to a PWM signal from the ECM.
Vacuum is achieved by mixing the system vacuum
(from the vacuum pump) with atmospheric pressure
to a certain degree. The resulting vacuum is sent to
the vacuum unit at the turbocharger (Fig. 4).
OPERATION
The vacuum solenoid receives 12V from the ECM.
The ECM controls the solenoid through a PWM sig-
nal. When the solenoid receives a signal it closes the
passage to atmospheric pressure. The subchamber is
no longer under atmospheric pressure, it's spring can
push the diaphragm and valve downwards; this
releases the VAC duct. Vacuum can now go from here
through the throttle hole, filters and out the connec-
tion to the turbocharger vacuum unit (Fig. 5).
Fig. 4 CHARGE PRESSURE VACUUM TRANSDUCER
1 - CONNECTION TO TURBOCHARGER VACUUM UNIT
2 - VENT
3 - SUPPLY FROM VACUUM PUMP
Fig. 5 TURBOCHARGER VACUUM ROUTING
1 - ENGINE 5 - VACUUM SOLENOID
2 - BRAKE BOOSTER CHECK VALVE 6 - VACUUM RESERVOIR
3 - VACUUM PUMP 7 - ACCESSORY VACUUM JUNCTION
4 - TURBOCHARGER 8 - FILTER
11 - 6 EXHAUST SYSTEMVA

(3) Tighten steering gear bolts in three stages as
follows.
1. Tighten to 25 N´m (18 ft. lbs.)
2. Then tighten to 45 N´m (33 ft. lbs.)
3. Then tighten bolts an additional 90É.
(4) Install stabilizer bar. (Refer to 2 - SUSPEN-
SION/FRONT/STABILIZER BAR - INSTALLATION)
(5) Install heat shield and nuts.
(6) Install jounce bumpers and install nuts.
(7) Install support clips and brake lines.
(8) Raise engine cradle into place and install bolts.
(9) Tighten bolts to 125 N´m (92 ft. lbs.).
(10) Connect brake lines at couplings and tighten
to 14 N´m (10 ft. lbs.).
(11) Position power steering hose and install sup-
port bracket bolt.
(12) Install both power steering hoses at steering
gear. (Refer to 19 - STEERING/PUMP/HOSES -
INSTALLATION)
(13) Connect steering shaft to gear and install the
lower pinch bolt.
(14) Tighten lower pinch bolt to 24 N´m (18 ft.
lbs.).
(15) Install new tie straps holding transmission
harness to cradle.
(16) Install front spring. (Refer to 2 - SUSPEN-
SION/FRONT/SPRING - INSTALLATION)
(17) Install engine mount nuts and tighten to 45
N´m (33 ft. lbs.).
(18) Install calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION)
(19) Install new tie straps holding wheel speed
sensors and brake pad wear sensors wire harness to
cradle.
(20) Check and align vehicle to specifications.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
REAR CROSSMEMBER -
TRANSMISSION
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support transmission with a suitable lifting
device.
(3) Remove the bolts/nuts and remove transmis-
sion mount cover. (Fig. 14)
(4) Remove crossmember nuts and crossmember.
INSTALLATION
(1) Install crossmember and install nuts.
(2) Tighten crossmember nut to 45 N´m (33 ft.
lbs.).
(3) Remove transmission support.
(4) Install transmission mount bracket.
(5) Install transmission mount bolts/nuts and
tighten to 45 N´m (33 ft. lbs.).
TRAILER HITCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Disconnect electrical connector. (Fig. 15)
Fig. 14 TRANSMISSION CROSSMEMBER
1 - TRANSMISSION MOUNT BOLTS (2)
2 - TRANSMISSION MOUNT COVER
3 - TRANSMISSION CROSSMEMBER NUTS (4)
4 - TRANSMISSION MOUNT NUTS (2)
5 - TRANSMISSION SUPPORT
6 - CROSSMEMBER
7 - TRANSMISSION MOUNT
VAFRAME & BUMPERS 13 - 9
ENGINE CRADLE CROSSMEMBER (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM
PRESSURE...........................1
WARNING............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES.................1
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS............2STANDARD PROCEDURE -
DISCONNECTING AND CONNECTING
FUEL LINES..........................2
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER..............2
STANDARD PROCEDURE - LOW
PRESSURE FUEL PUMP TEST............3
FUEL DELIVERY..........................4
FUEL INJECTION........................17
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE INJECTORS. THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). 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
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
WARNING
WARNING: UNDER NO CIRCUMSTANCES SHOULD
GASOLINE BE MIXED WITH DIESEL FUEL (NOT
EVEN DURING WINTER). THE HIGH PRESSURE
PUMP IS LUBRICATED BY DIESEL FUEL. IMMEDI-
ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS-
ING REPLACEMENT AND FLUSHING OF THE
COMPLETE DIESEL FUEL SYSTEM. HIGH PRES-
SURE PUMP SEIZURE WILL CAUSE METAL PARTI-
CLES TO SPREAD THROUGH OUT THE FUEL
CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
BE EXCHANGED AND THE LINES FLUSHED.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
(Refer to 14 - FUEL SYSTEM - WARNING). High-
pressure fuel line leaks can cause starting problems
and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES,
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR
HAND NEAR A SUSPECTED LEAK. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 1). If a high-pressure line connec-
tion is leaking, tighten the connection and perform
the Fuel System Air Purge procedure (Refer to 14 -
FUEL SYSTEM - STANDARD PROCEDURE).
Replace damaged, restricted or leaking high-pressure
fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
VAFUEL SYSTEM 14 - 1

INSTALLATION
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Remov-
al/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines.
(6) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(7) Install and position both fuel tank support
straps to mounting studs.
(8) Install 2 fuel tank strap nuts. Refer to Torque
Specifications.
(9) Remove hydraulic jack.
(10) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump isnot usedin the fuel tank
module for diesel powered engines. Fuel is supplied
to the fuel injection pump by the fuel transfer (lift)
pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 9). The fuel tank module contains the
following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connection
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
(3) Disconnect both fuel lines from tank module
fittings.
Fig. 8 FUEL TANK ASSEMBLY
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
Fig. 9 FUEL TANK MODULE
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
VAFUEL DELIVERY 14 - 13
FUEL TANK (Continued)

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)

SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pump To
Timing Case Cover/
Support21 15 185
High Pressure Flexible
Hose To Power Steering
Pump38 28 336
Power Steering Pulley To
Pump30 22 265
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE
(1) Remove the cap from the fluid reservoir.
Check cap seal for damage and replace if
needed.
(2) Fill the power steering pump with Mopar
ATF+4 Automatic Transmission fluid or equivalent.
Do not fill fluid beyond the MAX mark.
(3) Raise the vehicles front wheels off the ground.
(4) With the engine off turn the steering wheel
from right to left.Perform this step until all the
bubble formations can no longer be seen in the
power steering reservoir.
(5) Start the engine and turn the steering wheel
with the engine at idle speed then shut the engine off
and check for correct oil level and no bubble in the
system.
(6) Reinstall power steering cap tightly.
(7) Test the system for leaks and proper operation.
FLUID COOLER TUBE
REMOVAL
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(3) Remove the left headlight assembly.
(4) Disconnect the return lines from the cooler
tube.
(5) Remove the radiator clips (2).
(6) Remove the heat shield bolt for the turbo at
the core support.
(7) Remove the right headlight assembly.(8) Remove the core support bolts (4) and discon-
nect the hood latch cable.
(9) Remove the fan bracket bolts (4) to the radiator
(Fig. 2).
(10) Remove the two upper screws for the con-
denser (Fig. 2).
(11) Remove the condenser air dam shield.
(12) Remove the mounting screws for the cooler
tube (Fig. 2).
(13) Remove the cooler tube from the vehicle.
INSTALLATION
(1) Install the cooler tube to the vehicle.
(2) Install the cooler tube mounting screws (Fig.
2).
(3) Install the condenser air dam shield.
(4) Install the condenser upper mounting screws
(Fig. 2).
Fig. 2 FLUID COOLER TUBE
1 - MOUNTING SCREWS (4)
2 - FLUID COOLER
3 - ELECTRIC COOLING FAN
4 - A/C CONDENSOR
19 - 14 PUMPVA
PUMP (Continued)