low oil pressure MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

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)

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)

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION..........................9
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS......................10
STANDARD PROCEDURE
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................11
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM....................12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM....................12
COOLANT LEVEL SENSOR
REMOVAL.............................13
INSTALLATION.........................13
RADIATOR FAN
REMOVAL.............................13
INSTALLATION.........................13
ENGINE BLOCK HEATER
REMOVAL.............................14
INSTALLATION.........................14
ENGINE COOLANT TEMP SENSOR
DESCRIPTION.........................14REMOVAL.............................14
INSTALLATION.........................15
ENGINE COOLANT THERMOSTAT
REMOVAL.............................15
INSTALLATION.........................16
FAN DRIVE VISCOUS CLUTCH
REMOVAL.............................16
INSTALLATION.........................16
RADIATOR
REMOVAL.............................16
INSTALLATION.........................17
RADIATOR PRESSURE CAP
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP......................19
WATER PUMP
REMOVAL.............................19
INSTALLATION.........................20
COOLANT
DESCRIPTION
Coolant flows through the engine water jackets and
cylinder heads absorbing heat produced by the engine
during operation. The coolant carries heat to the radia-
tor and heater core. Here it is transferred to ambient
air passing through the radiator and heater core fins.
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 -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, 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 -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause forma-
tion of additive deposits in the system, as the corrosion
inhibitive additives in ethylene-glycol require the pres-
ence of water to dissolve. The deposits act as insulation,
causing temperatures to rise to as high as 149 deg. C
(300 deg. F). This temperature is hot enough to melt
plastic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22 deg. C (-8 deg. F ).
Propylene-glycol FormulationsÐShould Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.
It's overall effec-
tive temperature range is smaller than that of ethylene-
glycol. The freeze point of 50/50 propylene-glycol and
water is -32 deg. C (-26 deg. F). 5 deg. C higher than
ethylene-glycol's freeze point. The boiling point (protec-
tion against summer boil-over) of propylene-glycol is 125
deg. C (257 deg.F)at96.5 kPa (14 psi), compared to
128 deg. C (263 deg. F) for ethylene-glycol. Use of pro-
pylene-glycol can result in boil-over or freeze-up in
Chrysler vehicles, which are designed for ethylene-gly-
col. Propylene glycol also has poorer heat transfer char-
VAENGINE 7 - 9

Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on coolant
container until thermostat opens. Attach a Pressure
Tester to container. If pressure builds up quickly it
indicates a combustion leak exists. This is usually
the result of a cylinder head gasket leak or crack in
engine. Repair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean and suitably marked
container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN
WITH SYSTEM HOT AND UNDER PRESSURE. SERI-
OUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat removal.
Remove accessory drive belt.
Add coolant to pressure container to bring level to
within 6.3 mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
STANDARD PROCEDURE
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
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 (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
VAENGINE 7 - 11
COOLANT (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)

(16) Install A/C condenser.
(17) Install front bumper.
(18) Install front end cross member.
(19) Refill power steering to proper level.
(20) Refill transmission to proper level.
(21) Close radiator drain plug and refill the cooling
system to the correct level with the appropriate cool-
ant mixture.
(22) Recharge air conditioning.
(23) Run engine until warm and check for leaks.
RADIATOR PRESSURE CAP
DESCRIPTION
All vehicles are equipped with a pressure cap (Fig.
11). This cap releases pressure at some point within
a range of 124-to-145 kPa (18-to-21 psi). The pres-
sure relief point (in pounds) is engraved on top of the
capThe cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap contains a spring-
loaded pressure relief valve. This valve opens when
system pressure reaches the release range of 124-to-
145 kPa (18-to-21 psi).
A rubber gasket seals the radiator filler neck. This
is done to maintain vacuum during coolant cool-down
and to prevent leakage when system is under pres-
sure.OPERATION
A vent valve in the center of the cap will remain
shut as long as the cooling system is pressurized. As
the coolant cools, it contracts and creates a vacuum
in cooling system. This causes the vacuum valve to
open and coolant in reserve/overflow tank to be
drawn through connecting hose into radiator. If the
vacuum valve is stuck shut, or overflow hose is
kinked, radiator hoses will collapse on cool-down.
Fig. 10 RADIATOR AND FAN SHROUD
1 - CLIP
2 - SHROUD
3 - RADIATOR
4 - BOTTOM RADIATOR TRIM PANEL
5 - CHARGE AIR COOLER
6 - TOP RADIATOR TRIM PANEL
7 - POWER STEERING COOLER LOOP
Fig. 11 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
7 - 18 ENGINEVA
RADIATOR (Continued)

REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the ECM harness connectors (5)
(Fig. 3).
(3) Grasp ECM and pull down firmly to release
ECM from the retaining bracket tensioning springs
(Fig. 3).
INSTALLATION
NOTE: THE ECM MUST BE PROGRAMMED TO SUP-
PORT THE VEHICLE OPTIONS PACKAGE.
(1) Position the ECM into the guide of the retain-
ing bracket (Fig. 3).
(2) Carefully push the ECM in to the bracket until
the bracket tensioning springs engage (Fig. 3).
(3) Connect the ECM wiring harness connectors
(5) (Fig. 3).
(4) Connect negative battery cable.
Fig. 2 ECM
1 - A/C PUSH BUTTON CONTROL 12 - MASS AIR FLOW SENSOR
2 - ECM 13 - CRANKSHAFT POSITION SENSOR
3 - INSTRUMENT CLUSTER 14 - OIL LEVEL, OIL TEMPERATURE AND OIL QUALITY SENSOR
4 - ABS/ASR CONTROLLER 15 - LOW FUEL PRESSURE SENSOR
5 - ANTI-THEFT CONTROLLER 16 - COOLANT TEMPERATURE SENSOR
6 - AIR BAG CONTROLLER 17 - FUEL RAIL PRESSURE SENSOR
7 - IGNITION CYLINDER TRANSCEIVER RING 18 - CAMSHAFT POSITION SENSOR
8 - GLOW PLUG RELAY 19 - CHARGE AIR PRESSURE SENSOR
9 - INTAKE AIR TEMPERATURE SENSOR 20 - FUEL TEMPERATURE SENSOR
10 - KICK DOWN SWITCH 21 - WATER IN FUEL SENSOR
11 - ACCELERATOR PEDAL SENSOR
8E - 4 ELECTRONIC CONTROL MODULESVA
ENGINE CONTROL MODULE (Continued)

HEATED SEAT RELAY
DESCRIPTION
The heated seat relay is an electromechanical
device that switches 12v battery current to the
heated seat elements when the relay control coil is
energized. The heated seat relay is located in the
Fuse Block, under the drivers seat. The heated seat
relay is a International Standards Organization
(ISO) relay. Relays conforming to the ISO specifica-
tions have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
The heated seat relay cannot be repaired or
adjusted and, if faulty or damaged, it must be
replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact. When the electromagnetic coil is de-ener-
gized, spring pressure returns the movable contact to
the normally closed position. The resistor or diode is
connected in parallel with the electromagnetic coil in
the relay, and helps to dissipate voltage spikes that
are produced when the coil is de-energized.
DIAGNOSIS AND TESTING - HEATED SEAT
RELAY
The heated seat relay is located in the Fuse Block,
under the drivers seat. Refer toWiringfor the loca-
tion of complete heated seat system wiring diagrams.
(1) Remove the heated seat relay from the fuse
block.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, check the relay supply circuits. If not
OK, replace the faulty relay.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) The heated seat relay is located in the fuse
block, under the drivers seat. Refer to wiring for
detailed location.
(3) Grasp the heated seat relay firmly and pull it
straight out from the fuse block. A slight rocking
motion will aid in removal.
INSTALLATION
(1) Grasp the heated seat relay firmly and push it
straight in the fuse block.
(2) Reconnect the battery negative cable.
HEATED SEAT SENSOR
DESCRIPTION
The heated seat temperature sensor is a Negative
Temperature Coefficient (NTC) thermistor. One tem-
perature sensor is used for each seat. The sensor is
located in the seat cushion heating element for all
models.
The heated seat sensor cannot be adjusted or
repaired and if it is found to be faulty, the complete
heated seat element must be replaced.
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring.
NOTE: Any resistance values (ohmsV) given in the
following text are supplied using the automatic
range generated by a FLUKETautomotive meter. If
another type of measuring device is used the val-
ues generated may not be the same as the results
shown here, or may have to be converted to the
range used here.
(1) Backprobe the heated seat relay wire harness
connector, do not disconnect. Using an voltmeter,
check the voltage of the seat temperature sensor
input cavity of the heated seat relay wire harness
connector. The seat sensor input voltage should be
between 1.7 volts and 3.0 volts with the system ON.
If OK, sensor is OK at this time. If not OK, replace
the faulty seat cushion heating element and sensor
assembly.
8G - 4 HEATED SYSTEMSVA

²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.
²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
The wiper relay cannot be adjusted or repaired. If
the relay is damaged or faulty, it must be replaced.
OPERATION
The wiper relay (or intermittent wipe relay) is an
electromechanical switch that uses a low current
input from the intermittent wipe logic circuitry
within the fuse block underneath the steering column
to control a high current output to the low speed
brush of the wiper motor. The movable common feed
contact point is held against the fixed normally
closed contact point by spring pressure. When the
relay coil is energized, an electromagnetic field is
produced by the coil windings. This electromagnetic
field draws the movable relay contact point away
from the fixed normally closed contact point, and
holds it against the fixed normally open contact
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back
against the fixed normally closed contact point. A
resistor or diode is connected in parallel with the
relay coil in the relay, and helps to dissipate voltage
spikes and electromagnetic interference that can be
generated as the electromagnetic field of the relay
coil collapses.The wiper relay terminals are connected to the
vehicle electrical system through a connector recepta-
cle in the fuse block. The inputs and outputs of the
wiper relay include:
²The common feed terminal (30) provides an out-
put to the wiper motor low speed brush through the
wiper control circuitry of the multi-function switch on
the steering column. When the wiper relay is de-en-
ergized, the common feed terminal is connected to
the input of the relay normally closed terminal (87).
When the wiper relay is energized, the common feed
terminal is connected to the input of the relay nor-
mally open terminal (87A).
²The coil ground terminal (85) is connected to
battery current through a fused ignition switch out-
put circuit whenever the ignition switch is in the On
position.
²The coil battery terminal (86) is connected to the
relay control output of the wiper, turn signals and
engine start control module within the fuse block
through the wiper relay control circuit. This elec-
tronic circuitry controls the ground path for this cir-
cuit internally to energize or de-energize the wiper
relay control coil based upon its programming and
inputs from the wiper and washer control circuitry of
the multi-function switch, the wiper motor park
switch, and the ignition switch.
²The normally open terminal (87) is connected to
the output of the wiper motor park switch through
the wiper motor park switch sense circuit. This cir-
cuit can carry either battery current (wipers are not
in park position) or ground (wipers are in park posi-
tion), depending upon the status of the wiper park
switch.
²The normally closed terminal (87A) is connected
to battery current through a fused ignition switch
output circuit whenever the ignition switch is in the
On position.
The wiper relay can be diagnosed using conven-
tional diagnostic tools and methods.
Fig. 25 Wiper Relay
1 - HOUSING
2 - TERMINAL (5)
3 - BASE
VAWIPERS/WASHERS 8R - 21
WIPER RELAY (Continued)