engine coolant 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

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

engine to overheat because the specific heat of anti-
freeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at -22É C (-8É F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32É C (-26É F), 10É C
higher than ethylene-glycol's freeze point. The boiling
point (protection against summer boil-over) of propy-
lene-glycol is 125É C (257ÉF)at96.5 kPa (14 psi),
compared to 128É C (263É F) for ethylene-glycol. Pro-
pylene glycol also has slightly poorer heat transfer
characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain
conditions.
Propylene-glycol/ethylene-glycol mixtures can cause
the destabilization of various corrosion inhibitors,
causing damage to the various cooling system compo-
nents. Also, once ethylene-glycol and propylene-glycol
based coolants are mixed in the vehicle, conventional
methods of determining freeze point will not be accu-
rate. Both the refractive index and specific gravity
differ between ethylene glycol and propylene glycol.
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.CAUTION: Use of Propylene-Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene-glycol base coolant with organic corro-
sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% ethylene-glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-34ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT), may
result in engine damage that may not be covered
under the new vehicle warranty, and decreased cor-
rosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise. The increased tempera-
ture can result in engine detonation. In addition, 100
percent ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
0 - 2 LUBRICATION & MAINTENANCEVA
FLUID TYPES (Continued)

down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-34ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends MoparTlubri-
cant or lubricant conforming to MS-8985.
REAR AXLE
²Synthetic Gear & Axle Lubricant SAE 75W-140
DESCRIPTION - BRAKE FLUID
NOTE: DaimlerChrysler recommends using DOT- 4
or equivalent brake fluid.
BRAKE FLUID
²DOT-4 or equivalent brake fluid.
DESCRIPTION - POWER STEERING FLUID
NOTE: DaimlerChrysler recommends using Mopar
ATF+4 Automatic Transmission fluid or equivalent.
POWER STEERING FLUID
²Mopar ATF+4 Automatic Transmission fluid or
equivalent.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality.
The engine manufacturer strongly recommends the
use of synthetic engine oils, such as Mobilt1 SAE
0W-40.
We strongly recommend engine oils that meet the
requirements of the API Service Category CI-4 and
meet the requirements of Material Standard
MS-6395. Use Mopar or an equivalent oil meeting
the specification MS-6395.
Do not add any materials (other than leak detec-
tion dyes) to the engine oil. Engine oil is an engi-
neered product and it's performance may be impaired
by supplemental additives.
When topping off engine oil, only use oil of the
same quality grade and SAE classification.
The SAE class(viscosity)should be selected in
accordance with the average air temperature for the
season of the year.
The temperature limits given for the different SAE
classes should be regarded as guidelines which may
be exceeded temporarily to avoid excessively frequent
engine oil changes.
OIL VISCOSITY CHART
VALUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)

Full synthetic oils, such as Mobilt1 0W-40, is
required if the ASSYST Oil Service Reminder is fol-
lowed. Use of a lower quality oil on this service
schedule may cause severe engine damage.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Shellt3403 Automatic Transmission Fluid is the
recommended fluid for the NAG1 DaimlerChrysler
automatic transmission.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF+4, Automatic Transmission Fluid, or
other fluids meeting MS-9602, may be used if Shellt
3403 Automatic Transmission Fluid is not available.
Shellt3403 Automatic Transmission Fluid when
new is red in color. The ATF is dyed red so it can be
identified from other fluids used in the vehicle such
as engine oil or antifreeze. The red color is not per-
manent and is not an indicator of fluid condition. As
the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L with Filter
Replacement9.5 Quarts with Filter
Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to appropriate 21 - TRANSMISSION/
AUTOMATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE   .03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
FLUID FILL/CHECK
LOCATIONS
INSPECTION - FLUID FILL/CHECK LOCATIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
0 - 4 LUBRICATION & MAINTENANCEVA
FLUID TYPES (Continued)

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)

COOLING
TABLE OF CONTENTS
page page
COOLING
OPERATIONÐCOOLING SYSTEM...........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS.............................1DIAGNOSIS AND TESTING - COOLING
SYSTEM.............................2
ACCESSORY DRIVE.......................5
ENGINE................................9
COOLING
OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
VACOOLING 7 - 1

DIAGNOSIS AND TESTING - COOLING SYSTEM
COOLING SYSTEM DIAGNOSISÐDIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATUREGAUGE READS
LOW1. Vehicle is equipped with a heavy
duty cooling system.1. None. System operating normaly.
2. Temperature gauge not
connected2. Connect gauge.
3. Temperature gauge connected
but not operating.3. Check gauge. Refer (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
4. Coolant level low. 4. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
TEMPERATURE GAUGE READS
HIGH. COOLANT MAY OR MAY
NOT BE LEAKING FROM SYSTEM1. Vehicle overloaded, high ambient
(outside) temperatures with A/C
turned on, stop and go driving or
prolonged operation at idle speeds.1. Temporary condition, repair not
required. Notify customer of vehicle
operation instructions located in
Owners Manual.
2. Temperature gauge not
functioning correctly.2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Air traped in cooling 3. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD
PROCEDURE)
4. Radiator cap faulty. 4. Replace radiator cap.
5. Plugged A/C or radiator cooling
fins.5. Clean all debre away from A/C
and radiator cooling fins.
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) refill with correct
mixture (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Thermostat stuck shut. 7. Replace thermostat.
8. Bug screen or winter front being
used.8. Remove bug screen or winter
front.
9. Viscous fan drive not operating
properly.9. Check viscous fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
11. Heater core leaking. 11. Replace heater core.
12. cooling system hoses leaking. 12. Tighten clamps or Replace
hoses.
7 - 2 COOLINGVA
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)
TEMPERATURE GAUGE READING
INCONSISTENT ( ERRATIC,
CYCLES OR FLUCTUATES)1. Heavy duty cooling system,
extream cold ambient (outside)
temperature or heater blower motor
in high position.1. None. System operating normaly.
2. Temperature gauge or gauge
sensor defective.2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water
pump.6. Check for leak. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM
AND /OR COOLANT INTO
RESERVOIR BOTTLE.
(TEMPERATURE GAUGE MAY
READ HIGH)1. Radiator cap defective. 1. Replace radiator cap.
2. Radiator neck surface damaged. 2. Replace radiator.
HOSE OR HOSES COLLAPSE
WHEN ENGINE IS COOLING.1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reservior/overflow system.1. Replace radiator cap, check vent
hose between radiator and reservoir
bottle for blockage also check
reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
2. Thermal viscous fan drive. 2. None. Normal condition.
3. Fan blades striking surrounding
objects.3. Locate contact point and repair
as necessary.
4. Thermal viscous fan drive
bearing.4. Replace viscous fan drive
assembly.
5. Obstructed air flow through
radiator.5. Remove obstruction.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)1. Radiator and/or A/C condenser
air flow obstructed.1. Remove obstruction and/or clean.
VACOOLING 7 - 3
COOLING (Continued)