cold minimum MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................1
DESCRIPTION - ENGINE COOLANT........1
DESCRIPTION - HOAT COOLANT..........2
DESCRIPTION - AXLE...................3
DESCRIPTION - BRAKE FLUID............3
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................3
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID - NAG1............4
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................4
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......4FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................4
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS.........5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........6
MAINTENANCE SCHEDULES
DESCRIPTION..........................7
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use good quality diesel fuel from a reputable sup-
plier in your Dodge truck. For most year-round ser-
vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If
the vehicle is exposed to extreme cold (below 0ÉF/-
18ÉC), or is required to operate at colder-than-normal
conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50%
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol-low the cold-weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm-up perfor-
mance.
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37É C (-34É F). The antifreeze
concentrationmust alwaysbe a minimum of 44 per-
cent, year-round in all climates.If percentage is
lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7É C (-90É F). A higher
percentage will freeze at a warmer temperature.
Also, a higher percentage of antifreeze can cause the
VALUBRICATION & MAINTENANCE 0 - 1

CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUG OR LOOSEN THE RADIATOR
DRAIN PLUG WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT remove coolant recovery pressure con-
tainer cap first. With engine cold, raise vehicle on a
hoist and locate radiator draincock.
NOTE: Radiator draincock is located on the left/
lower side of radiator.
(2)
Attach one end of a hose to the draincock (Fig. 3).
Put the other end into a clean and appropriately
marked container. Open draincock and drain coolant
from radiator. This will empty the coolant recovery pres-
sure container first. The coolant does not have to be
removed from the container unless the system is being
refilled with a fresh mixture. When container is empty,
remove cap and continue draining cooling system.
To drain the engine of coolant, loosen the cylinder
block drain plug located on the side of cylinder block
(Fig. 3).
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM
(1) Tighten the radiator drain and the cylinder
block drain plug(s) (if removed). Tighten the engine
drain plug to 22 lbs. ft. (30 N´m)
(2) Fill system using a 50/50 mixture of ethylene-
glycol antifreeze and low mineral content water. Fill
radiator to top and add sufficient coolant to the cool-
ant recovery pressure container to raise level to
COLD MINIMUM mark.
(3) With heater control unit in the HEAT position,
operate engine with container cap in place.
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the pressure container.
(5) Add coolant to pressure container as necessary.
Only add coolant to the container when the
engine is cold. Coolant level in a warm engine
will be higher due to thermal expansion.To
purge the cooling system of all air, this heat up/cool
down cycle (adding coolant to cold engine) must be
performed three times. Add necessary coolant to raise
container level to the COLD MINIMUM mark after
each cool down period.
Fig. 3 DRAINING COOLANT SYSTEM
1 - DRAIN HOSE 3 - RADIATOR DRAIN PLUG
2 - ENGINE DRAIN PLUG 4 - DRAIN HOSE
7 - 12 ENGINEVA
COOLANT (Continued)

SPECIFICATIONS
TORQUE - STARTER - DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Battery Cable Nut at
Starter Solenoid (larger
nut)14 - 124
Starter Mounting Bolts 40 30 -
Starter Solenoid (smaller
nut)6-52
SPECIFICATIONS - STARTER MOTOR - DIESEL
ITEM SPECIFICATION
ENGINE 2.7L TURBO DIESEL
RATED VOLTAGE 12 VOLTS
NUMBER OF FIELDS 4
NUMBER OF POLES 4
NUMBER OF BRUSHES 4
DRIVE TYPE GEAR REDUCTION
FREE RUNNING TEST VOLTAGE 11.5 VOLTS
FREE RUNNING TEST MAXIMUM
AMPERAGE DRAW160 AMPS
FREE RUNNING TEST MINIMUM SPEED 5500 RPM
SOLENOID CLOSING MAXIMUM VOLTAGE 7.8 VOLTS
MAXIMUM CRANKING AMPERAGE DRAW * 500 AMPS
* A COLD OR NEW ENGINE WILL INCREASE STARTER AMPERAGE DRAW. THE USE OF HEAVY
WEIGHT ENGINE OIL WILL ALSO INCREASE STARTER AMPERAGE DRAW.
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with starter motor
removed from vehicle. Refer to Starter Specifications
for specifications.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on the
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect a suitable volt-ampere tester and a
12-volt battery to starter motor in series, and set
ammeter to 100 ampere scale. See instructions pro-vided by manufacturer of volt-ampere tester being
used.
(4) Install jumper wire from solenoid terminal to
solenoid battery terminal. The starter motor should
operate. If starter motor fails to operate, replace
faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to Specifications for
starter motor free running test voltage specifications.
(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to Specifications for starter motor free running test
maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
VASTARTING SYSTEM 8F - 29
STARTING SYSTEM (Continued)

shown on the tire placard. For continuous speeds in
excess of 120 km/h (75 mph), tires must be inflated
to the maximum pressure specified on the tire side-
wall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.
DESCRIPTION - REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DESCRIPTION - TIRE INFLATION PRESSURES
Under inflation will cause rapid shoulder wear, tire
flexing, and possible tire failure (Fig. 12).
Over inflation will cause rapid center wear and
loss of the tire's ability to cushion shocks (Fig. 13).
Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²Vehicle drift
For proper tire pressure specification refer to the
Tire Inflation Pressure Chart provided with the vehi-
cles Owners Manual. A Certification Label on the
drivers side door pillar provides the minimum tire
and rim size for the vehicle. The label also list the
cold inflation pressure for these tires at full load
operationTire pressures have been chosen to provide safe
operation, vehicle stability, and a smooth ride. Tire
pressure should be checked cold once a month. Tire
pressure decreases as the ambient temperature
drops. Check tire pressure frequently when ambient
temperature varies widely.
Tire inflation pressures are cold inflation pressure.
The vehicle must sit for at least 3 hours to obtain the
correct cold inflation pressure reading. Or be driven
less than one mile after sitting for 3 hours. Tire
inflation pressures may increase from 2 to 6 pounds
per square inch (psi) during operation. Do not reduce
this normal pressure build-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
Fig. 12 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREA
VATIRES/WHEELS 22 - 7
TIRES (Continued)

To maintain minimum evaporator temperature and
prevent evaporator freezing, an evaporator tempera-
ture sensor is used.
Vehicles equipped with the available rear A/C sys-
tem have an individual temperature control and
blower motor speed switches. When the rear A/C sys-
tem is turned on, a solenoid valve opens the rear
refrigerant circuit and activates the blower motor for
the rear evaporator. The circulated internal air tem-
perature is measured by a temperature sensor and
the temperature value is compared within the rear
A/C control module to an adjusted value at the tem-
perature control switch. To prevent icing of the rear
evaporator, the temperature switch cuts off the flow
of refrigerant through the rear A/C circuit by de-en-
ergizing the solenoid valve.
The front and rear A/C systems are designed for
the use of non-CFC, R-134a refrigerant only. Both
the front and rear systems use an expansion valve to
meter refrigerant flow to the evaporator.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUNCTION TEST
The ATC system can perform an self-test, which
can be activated by the DRBIIItscan tool to confirm
that the air conditioning system is performing satis-
factorily. This test provides a quick confirmation of
heater - air conditioning system performance to the
service technician. Refer to Body Diagnostic Proce-
dures for the appropriate diagnostic information.
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
The air conditioning system is designed to provide
the passenger compartment with low temperature
and low specific humidity air. The evaporator, located
in the heater housing on the dash panel below the
instrument panel, is cooled to temperatures near the
freezing point. As warm damp air passes through the
cooled evaporator, the air transfers its heat to the
refrigerant in the evaporator and the moisture in the
air condenses on the evaporator fins. During periods
of high heat and humidity, an air conditioning sys-
tem will be more effective in the Recirculation Mode.
With the system in the Recirculation Mode, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, the air conditioning system performance
levels improve.
Humidity has an important bearing on the temper-
ature of the air delivered to the interior of the vehi-
cle. It is important to understand the effect that
humidity has on the performance of the air condition-
ing system. When humidity is high, the evaporatorhas to perform a double duty. It must lower the air
temperature, and it must lower the temperature of
the moisture in the air that condenses on the evapo-
rator fins. Condensing the moisture in the air trans-
fers heat energy into the evaporator fins and tubing.
This reduces the amount of heat the evaporator can
absorb from the air. High humidity greatly reduces
the ability of the evaporator to lower the temperature
of the air.
However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Remov-
ing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from their
air conditioning system on humid days. A perfor-
mance test is the best way to determine whether the
system is performing up to standard. This test also
provides valuable clues as to the possible cause of
trouble with the air conditioning system.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
NOTE: Very specific instructions and conditions
pertain to this procedure which are significantly dif-
ferent than procedures used in other vehicle appli-
cations. Follow each step in the order they are
presented. Do not skip steps or change conditions
from those stated or results will be adversely
affected and invalid.
The compressor clutch is de-energized under any of
the following conditions:
²Blocked compressor (thermal fuse in the pulley)
²Low pressure in the system
²Low evaporator temperature
²Hard acceleration (WOT)
²High coolant temperatures
(1) Place the vehicle in the shade with all widows
open.
(2) Turn the temperature control to cold.
(3) Select Fresh Air, not Recirculate and open all
air conditioning duct louvers.
(4) Start the vehicle and allow it to idle.
(5) Turn the blower switch to the maximum blower
speed setting and allow to operate for a short period
of time before proceeding.
(6) Perform an outlet temperature test as follows:
a. Turn the blower switch to the lowest blower
speed setting.
b. Insert a thermometer into a center duct for at
least five minutes.
VAHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)