battery MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 1) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greaterthe bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
2 INTRODUCTIONVA

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNING: Do not tow the vehicle if the key cannot
be turned in the ignition lock. If the key cannot be
turned, the ignition lock remains locked and the
vehicle cannot be steered. With the engine not run-
ning there is no power assistance for the braking
and steering systems. In this case, it is important to
keep in mind that a considerably higher degree of
effort is necessary to brake and steer the vehicle.
The vehicle must not be towed with the front axle
raised and the key in position 2 in the ignition lock
as the drive wheels could then lock due to the
acceleration skid control (ASR)
0 - 6 LUBRICATION & MAINTENANCEVA

MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
NOTE: The engine manufacturer strongly recom-
mends the use of synthetic engine oils, such as
TMobil 1 SAE 0W-40.
When the next maintenance service is due, this
will be indicated in the multi-function display with
the wrench icon symbol displayed in km/miles or
days.
²One wrench icon showing indicates Oil Service
is necessary.
²Two wrench icons showing indicates Mainte-
nance Service is necessary ± displayed in km/miles or
days.
If the display shows the number of days, a clock
symbol will also appear in the multi-function display.
You should have the maintenance performed
within the stated period/distance.
The service indicator should be reset after an oil
service and/or maintenance service has been per-
formed.
REGULAR CHECK-UPS
To maintain the safe operation of the vehicle, it is
recommended that the following tasks be performed
on a regular basis (i.e. weekly or whenever the vehi-
cle is refueled). Check:
²Engine oil level
²Brake system, clutch mechanism ± fluid level
²Battery ± acid level
²Windshield washer system and headlamp clean-
ing system ± fluid level
²Mechanical assemblies (e. g. engine, transmis-
sion, etc.) ± check for leaks
²Condition of tires and tires pressures
²All exterior lights
SPECIAL MAINTENANCE REQUIREMENTS
If bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehi-
cle, the maintenance requirements and lubrication
intervals specified by the body manufacturer must be
adhered to, in addition to all standard maintenance
requirements.
Brake Fluid
Only use brake fluids approved by the manufac-
turer (DOT 4 plus).
Coolant
Corrosion inhibitor/antifreeze concentration in the
coolant should be checked before the onset of winter
(once year in countries with high prevailing temper-
atures).Replace the coolant every five years or 100,000
miles.
Dust Filter for Heating/Ventilation Replace-
ment
The dust filter and the tailgate interior filter are to
be renewed during routine maintenance service. If
operating conditions are dusty, these filters should be
renewed more frequently.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
At the minimum, change the engine oil and oil fil-
ter once a year ± even if the vehicle mileage per year
is extremely low. For standard oil service schedules
refer to the chapter oil service and maintenance ser-
vice.
Once a Year
Select the viscosity of the engine oil (SAE classes)
according to the outside air temperature.
Only use engine oil approved by DaimlerChrysler
Corporation if following the ASSYST system guide-
lines.
If the fuel used has a sulphur content exceeding
0.05% by weight, the service intervals should be split
in half.
SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
²Engine:
Oil change and filter replacement
Check fluid levels of the following system,
refill as necessary.
²If fluid is lost, trace and eliminate cause ± as a
separate order.
²Power-assisted steering
Lubrication work:
²Trailer tow hitch (original equipment)
Maintenance
²ASSYST maintenance computer reset
Function check
²Signalling system, warning and indicator lamps
²Headlamps, exterior lighting
²Windshield wipers, windshield washer system
Check for leaks and damage.
²Check for abrasion points and ensure that lines
are correctly routed!
²All lines and hoses, sensor cables
²Rubber boots on front axle drive shafts, rubber
boots on front axle suspension ball joints, shock
absorbers
Check fluid levels for the following systems,
correct as necessary.
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
0 - 8 LUBRICATION & MAINTENANCEVA
MAINTENANCE SCHEDULES (Continued)

²Engine cooling system. Check corrosion inhibi-
tor/antifreeze, refill as necessary.
²Hydraulic brake system
²Battery
²Windshield washer system
Engine
²Fuel filter renewal
²Air cleaner with maintenance indicator:
²Check degree of contamination.
²Air cleaner filter element renewed as necessary.
Chassis and body
²Trailer coupling:
Check operation, play and retaining fixtures
²Secondary rubber springs:
Visual check
²Tire pressures:
Correct as necessary, including spare tire
²Check thickness of brake pads
²Brake test
²Check condition of steering mechanism
²Heating/ventilation dust filter renewal
ADDITIONAL MAINTENANCE WORK
Automatic transmission once only at 80,000
miles/128000 km
Oil and filter change
During every second maintenance service
Air cleaner without maintenance indicator:
Air cleaner filter element renewal
Check poly-V-belt for wear and signs of damage
During every 6th maintenance service
Rear axle
ADDITIONAL MAINTENANCE WORK AFTER YEARS
Every 3 years
Air cleaner filter element renewal (note installa-
tion date)
Every 5 years or 100,000 miles
Coolant renewal
Note coolant composition
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).
Fig. 3 INTERNATIONAL SYMBOLS
VALUBRICATION & MAINTENANCE 0 - 9
MAINTENANCE SCHEDULES (Continued)

INSTALLATION
(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig.
3).Only due this step if replacing the sensor.
(2) Install the wheel speed sensor all the way into
the axle tube, the wheel speed sensor will self adjust
when the vehicle is moved (Fig. 3).
(3) Install the rear wheels.
(4) Lower the vehicle.
TONE WHEEL
REMOVAL
(1) Remove the hub/bearing assembly (DRW)
(Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR
AXLE/AXLE BEARINGS - REMOVAL).
(2) Insert a hooked prybar between the hub/bear-
ing and the inside of the tone wheel and pry upwards
slightly and work your way around the tone wheel
until the wheel is loose (Fig. 4).
(3) Remove the tone wheel.
INSTALLATION
(1) Install the tone wheel to the hub/bearing with
a thin bead of silicone around the tone wheel.
(2) Tap the tone wheel down with a soft hammer
until seated.
(3) Install the hub/bearing (DRW) (Refer to 3 -
DIFFERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - INSTALLATION).
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor, low
pressure accumulators, inlet valves, outlet valves and
noise attenuators.
REMOVAL
NOTE: Store the Hydraulic Control Unit in an
upright position only.
(1) Disconnect the ground cable at the battery.
The ignition switch must be switched to the off
position when disconnecting the battery cable.
(2) Disconnect the multiplug from the control mod-
ule (Fig. 5).
(3) Disconnect the brake lines from the hydraulic
control unit (Fig. 5).Mark the brake lines for
reinstallation, also seal off the connections and
lines to prevent contamination.
(4) Remove the hydraulic control unit from the
bracket (Fig. 5).
(5) Check the rubber mounts on the bracket.
(Replace if necessary) (Fig. 5).
Fig. 4 TONE WHEEL REMOVAL
1 - HOOKED PRYBAR
2 - TONE WHEEL
3 - HUB/BEARING ASSEMBLY
Fig. 5 HYDRAULIC CONTROL UNIT (ABS)
1 - BRAKE LINES
2 - HCU WITH CONTROL MODULE
3 - ABS/ABD CONTROL MODULE MULTIPLUG
4 - RUBBER SUPPORT
VABRAKES - ABS 5 - 31
REAR WHEEL SPEED SENSOR (Continued)

INSTALLATION
(1) Install the hydraulic control unit into the rub-
ber mounts (Fig. 5).
(2) Reconnect the brake lines to the hydraulic con-
trol unit (Fig. 5).Do not mix up the brake lines.
Tighten the lines to 16 N´m (142 in. lbs.)
(3) Reconnect the multiplug to the control module
(Fig. 5).(4) Reconnect the ground cable on the battery.
(5) Bleed the brake system.
(6) Check the fluid in the reservoir and correct if
necessary.
(7) Perform function test.
5 - 32 BRAKES - ABSVA
HCU (HYDRAULIC CONTROL UNIT) (Continued)

COOLANT LEVEL SENSOR
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN 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.
NOTE: Drain coolant from radiator drain plug only.
(1) Drain coolant until the coolant reservoir is
emptied.
(2) Disconnect the wiring harness electrical con-
nector.
(3) Turn the level sensor 90 degrees clockwises, lift
up and out of the container.
INSTALLATION
(1) Align coolant level sensor with coolant
reservior access whole, press down while turning
counterclockwise 90 degrees to seat sensor (Fig. 4).
(2) Connect coolant level sensor electrical connec-
tor (Fig. 4).
(3) Refill cooling system to proper level.
(4) Inspect for leaks.
RADIATOR FAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the front end cross member.
(3) Push complete radiator assembly forward and
unclip the fan shroud at the radiator.
(4) Detach coolant line from lower radiator shroud.
(5) Retain accessory drive belt pulley of water
pump with a counterholder (Fig. 5).
(6) Unscrew the central bolt of the viscous fan
clutch and lift fan and shroud up and out (Fig. 5).
NOTE: Store the viscous fan clutch in the upright
position. DO NOT place down flat.
(7) Remove radiator fan from viscous fan clutch
(Fig. 5).
INSTALLATION
(1) Install fan blade to viscous clutch. Tighten
bolts to 80 lbs. in. (9 N´m) (Fig. 5).
(2) Install fan and clutch along with fan shroud in
to engine bay area (Fig. 5).
(3) Install the center bolt of the viscous clutch.
Tighten bolt to 33 lbs. ft. (45 N´m) (Fig. 5)
(4) Attach coolant line to lower radiator shroud.
(5)
Properly align and clip the fan shroud into place.
Fig. 4 COOLANT LEVEL SENSOR
1 - COOLANT LEVEL SENSOR
2 - COOLANT RESERVIOR
3 - ELECTRICAL CONNECTOR
Fig. 5 RADIATOR FAN
1 - VISCOUS CLUTCH
2 - COUNTERHOLDER
3 - CLUTCH BOLT
4 - FAN BOLT
5-FAN
VAENGINE 7 - 13

(6) Properly align the radiator assembly and
install the front end cross member.
(7) Connect negative battery cable.
ENGINE BLOCK HEATER
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN 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) Disconnect the negative battery cable.
(2) Drain the cooling system.
(3) Record the location and snip the wire ties.
(4) Unscrew the engine block heater from the core
plug hole and remove (Fig. 6).
INSTALLATION
(1) Screw the block heater into the appropriate
core hole (Fig. 6).
(2) Route the heater wiring harness away from
and interference and secure with wiring tie straps.
(3) Refill the cooling system.
(4) Connect the negative battery cable.
(5) Start the engine and inspect for leaks.
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The ECM determines the operating temperature of
the engine by using the signal from the coolant tem-
perature sensor. The coolant temperature sensor has
a negative temperature coefficient (NTC) resistor
contained in the plastic housing. NTC means; the
higher the temperature, then the lower the resis-
tance. The ECM also uses the coolant temperature
sensor signal to calculate glow plug relay triggering.
If the coolant temperature sensor fails during opera-
tion, the ECM will switch on the cooling fan to pre-
vent engine overheating (A/C models only).
REMOVAL
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. OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES AND EYE WEAR.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partailly drain coolant system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Unplug coolant temperature sensor electrical
connector.
Fig. 6 ENGINE BLOCK HEATER
1 - ENGINE BLOCK HEATER
2 - CORE PLUG
3 - ENGINE MOUNT
4 - WIRING TIE STRAPS
7 - 14 ENGINEVA
RADIATOR FAN (Continued)

NOTE: Capture any residual coolant that may flow.
(5) Remove coolant temperature sensor (Fig. 7).
INSTALLATION
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) Position and install coolant temperature sensor
(Fig. 7).
(2) Connect coolant temperature sensor electrical
connector (Fig. 7).
(3) Refill coolant system to proper level with
proper mixture of coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).(4) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(5) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(6) Start engine and inspect for leaks.
ENGINE COOLANT
THERMOSTAT
REMOVAL
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.
NOTE: Inspect condition of all clamps and hoses,
replace as necessary.
(1) Disconnect negative battery cable.
(2) Drain engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Unplug connector, pull off locking element and
pull out coolant temperature sensor.
(4) Detach air intake hose at charge air distribu-
tion pipe.
(5) Detach coolant hoses at thermostat housing.
(6) Remove bracket for fuel line.
(7) Unscrew cap at oil filter housing.
(8) Remove thermostat housing (Fig. 8).
(9) Clean all sealing surfaces.
Fig. 7 ENGINE COOLANT TEMPERATURE SENSOR
1 - RETAINING CLAMP
2 - ENGINE COOLANT TEMPERATURE SENSOR
VAENGINE 7 - 15
ENGINE COOLANT TEMP SENSOR (Continued)

INSTALLATION
(1) Clean all sealing surfaces.
(2) Position and install thermostat housing with
new gasket (Fig. 8). Tighten bolts to 9N´m (80
lbs.in.).
NOTE: Inspect condition of all clamps and hoses,
replace as necessary.
(3) Install cap at oil filter housing.
(4) Connect coolant hoses and vent hose (Fig. 8).
(5) Install bracket for fuel line (Fig. 8).
(6) Attach air intake hose at charge air distribu-
tion pipe.
(7) Close coolant drain.
(8) Connect negative battery cable.
(9) Fill coolant system to proper level with appro-
priate coolant mixture (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE).
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(10) Start engine and inspect for leaks.
FAN DRIVE VISCOUS CLUTCH
REMOVAL
(1) For fan drive viscous clutch removal refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
INSTALLATION
(1) For fan drive viscous clutch installation refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
RADIATOR
REMOVAL
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.
NOTE: Capture all residual fluid spillage and store
in suitably marked containers. Inspect condition of
all clamps and hoses, replace as necessary.
(1) Drain coolant from radiator only(Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(2) Remove headlamp.
(3) Remove front cross member together with front
grille.
(4) Remove front bumper.
(5) Evacuate air conditioning.
(6) Remove A/C condenser.
(7) Detach charge air hose at turbocharger (Fig. 9).
(8) Detach charge air hose at air intake pipe (Fig.
9).
(9) Detach air intake pipe at the body (Fig. 9).
(10) Detach coolant hoses at the coolant reservoir
(Fig. 9).
(11) Unplug wiring connector at coolant level sen-
sor (Fig. 9).
(12) Drain steering gear oil from reservoir of
power steering pump.
(13) Detach the hydraulic oil hose at reservoir of
power steering pump.
(14) Detach the hydraulic oil hose at hydraulic oil
line.
Fig. 8 THERMOSTAT HOUSING ASSEMBLY
1 - O-RING
2 - CLAMP
3 - COOLANT TEMPERATURE SENSOR
4 - FUEL LINE W/BRACKET
5 - THERMOSTAT HOUSING ASSEMBLY
6 - COOLANT HOSE
7 - CLAMP
8 - COOLANT HOSE
9 - GASKET
7 - 16 ENGINEVA
ENGINE COOLANT THERMOSTAT (Continued)