oil MERCEDES-BENZ SPRINTER 2006 Owners Manual

SENTRY KEY REMOTE ENTRY MODULE (SKREEM)
CAV CIRCUIT FUNCTION
1 18YL RKE ANTENNA
2 16BR GROUND
3 16RD/YL FUSED B(+)
4 16BK/WT LEFT TURN SIGNAL
5 20DG/WT CAN C BUS (+)
6 20DG CAN C BUS (-)
7 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20WT/DG K-SKREEM
9 16WT/BL/RD (EXCEPT VTSS) RKE INTERFACE
9 16WT/BL/RD (VTSS) SECURITY SYSTEM INTERFACE
10 18DG/YL TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT/
RIGHT CONTROL
11 20BR TRANSPONDER COIL (+)
12 - TRANSPONDER COIL (-)
SHIFTER ASSEMBLY - BLACK
CAV CIRCUIT FUNCTION
1- -
2 20GY/DG/RD LAMP DRIVER
3 20BL/DG K-ABS/SHIFTER ASSEMBLY
4 18BR GROUND
5 20BK/BL/RD BRAKE LAMP SWITCH
6 20DG/WT CAN C BUS (+)
7 20DG CAN C BUS (-)
8 18BK/DG TRANSMISSION RELAY OUTPUT
9 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 16WT/RD BACK-UP LAMP
SIREN - BLACK
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSVA

SKREEM TRANSPONDER
CAV CIRCUIT FUNCTION
1 20BR TRANSPONDER COIL (+)
2 - TRANSPONDER COIL (-)
SPEAKER-LEFT FRONT DOOR ASSEMBLY C1
CAV CIRCUIT FUNCTION
1 18BL/YL SPEAKER-LEFT FRONT (+) CTEL
2 18BL/DG SPEAKER-LEFT FRONT (-) CTEL
SPEAKER-LEFT FRONT DOOR ASSEMBLY C2
CAV CIRCUIT FUNCTION
1 18BR/DG SPEAKER-LEFT FRONT (+)
2 18BR SPEAKER-LEFT FRONT (-)
SPEAKER-LEFT REAR
CAV CIRCUIT FUNCTION
1 16BR/BL SPEAKER-LEFT REAR
2 16WT/BL SPEAKER-LEFT REAR
SPEAKER-RIGHT FRONT DOOR
CAV CIRCUIT FUNCTION
1 18BR/RD SPEAKER-RIGHT FRONT (+)
2 18BK SPEAKER-RIGHT FRONT (-)
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Daytime Running Lamps Relay (Relay
Block)BK Under Driver Seat N/S
Differential Lock Solenoid Valve BK Underbody 51
Dome Lamp BK Dome Area 42
Door Jamb Switch-Driver Driver Door 43
Door Jamb Switch-Left Sliding Left Sliding Door N/S
Door Jamb Switch-Passenger Passenger Door 43
Door Jamb Switch-Right Sliding Right Sliding Door 30
Door Jamb Switch-Tailgate Tailgate N/S
Door Lock Motor/Ajar Switch Assembly -
Driver C1Driver Door 43
Door Lock Motor/Ajar Switch Assembly -
Driver C2Driver Door 43
Door Lock Motor/Ajar Switch Assembly - Left
Sliding C1Left Sliding Door 46
Door Lock Motor/Ajar Switch Assembly - Left
Sliding C2Left Sliding Door 46
Door Lock Motor/Ajar Switch Assembly -
Passenger C1Passenger Door 46
Door Lock Motor/Ajar Switch Assembly -
Passenger C2Passenger Door 46
Door Lock Motor/Ajar Switch Assembly -
Rear C1Right Sliding Door 52
Door Lock Motor/Ajar Switch Assembly -
Rear C2Right Sliding Door 52
Door Lock Motor/Ajar Switch Assembly-Right
Sliding C1Cargo Door 45
Door Lock Motor/Ajar Switch Assembly-Right
Sliding C2Cargo Door 45
Dosing Pump Engine Compartment N/S
EGR Valve Engine Compartment 14
Engine Control Module C1 (Except OBD) BK Instrument Panel 22
Engine Control Module C1 (OBD) BK NS
Engine Control Module C2 (Except OBD) BK Instrument Panel 22
Engine Control Module C2 (OBD) BK NS
Engine Control Module C3 (Except OBD) BK Instrument Panel 22
Engine Control Module C4 (Except OBD) BK Instrument Panel 22
Engine Control Module C5 (Except OBD) GY Instrument Panel 22
Engine Control Relay (Fuse Block No.1 NS
Engine Coolant Level Switch BK Engine Compartment 2, 8
Engine Coolant Temperature Sensor BK Engine Compartment 13
Engine Oil Sensor BK Engine Compartment 14
Evaporator Temperature Sensor WT Instrument Panel-Right 33
Fan Stage 1 Relay (Relay Block) BK Under Driver Seat N/S
Fog Lamp Relay (Relay Block) BK Under Driver Seat N/S
Fog Lamp Switch BK Instrument Panel 25
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the fuseblock only when the ignition switch is
in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the heating element is
inserted in the receptacle shell, the heating element
resistor coil is grounded through its housing to the
receptacle shell. If the cigar lighter knob is pushed
inward, the heat shield slides up toward the knob
exposing the heating element.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up and glow.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For cigar lighter outlet diagnosis and testing pro-
cedures (Refer to 8 - ELECTRICAL/POWER DISTRI-
BUTION/POWER OUTLET - DIAGNOSIS AND
TESTING)
REMOVAL
For cigar lighter outlet removal procedure (Refer to
8 - ELECTRICAL/POWER DISTRIBUTION/POWER
OUTLET - REMOVAL).
CIRCUIT BREAKER
DESCRIPTION
Automatic resetting circuit breakers are used to
protect the power window voltage supply circuits.
These circuit breakers can protect the systems from a
short circuit, or from an overload condition caused byan obstructed or stuck power window regulator or
switch.
The circuit breaker cannot be repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The circuit breaker contains a bi-metal strip sand-
wiched between two contacts forming the connection
in the circuit. An overload condition causes the
bi-metal strip to heat and bend to the open position,
disconnecting current flow to the circuit. Then as the
system overload or short circuit is removed, the
bi-metal strip cools, re-establishing contact to allow
current flow to the circuit.
DIAGNOSIS AND TESTING - CIRCUIT BREAKER
For complete circuit descriptions and diagrams,
refer toWiring.
(1) Locate the correct circuit breaker in the fuse-
block. Pull out the circuit breaker slightly, but be cer-
tain that the circuit breaker terminals still contact
the terminals in the fuseblock cavities.
(2) Connect the negative lead of a 12-volt DC volt-
meter to a good ground.
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit
from the Power Distribution Center as required.
FUSE BLOCK #1
DESCRIPTION
An electrical fuse block is concealed under the
driver side steering column. The fuse block serves to
distribute electrical current to many of the electrical
systems in the vehicle. The fuse block contains blade-
type mini fuses, relays and micro processors that
enable automatic control of some of the power distri-
bution circuits throughout the vehicle.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the steering column. A finger recess is molded into
the cover for easy removal. A fuse layout map is
molded onto the back side of the cover to ensure
proper fuse identification.
The fuse block cannot be repaired, if the fuse block
is faulty or damaged or if any internal circuit is
faulty or damaged, the entire fuse block must be
replaced.
8W - 97 - 2 8W-97 POWER DISTRIBUTIONVA

repaired and, if faulty or damaged, it must be
replaced.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the fuse block at all times.
DIAGNOSIS AND TESTING - POWER OUTLET
(1) Check for battery voltage at the fused B(+) fuse
in the fuse block. If OK, go to Step 2. If not OK,
repair the open fused B(+) circuit to the battery as
required.
(2) Check for continuity between the inside cir-
cumference of the power outlet receptacle and a good
ground. There should be continuity. If OK, go to Step
3. If not OK, go to Step 4.
(3) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 4.
(4) Disconnect and isolate the battery negative
cable. Check for continuity between the ground cir-
cuit cavity of the power outlet wire harness connector
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open ground
circuit to ground as required.
(5) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the fuse in the fuse
block as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of
the cigar lighter receptacle base, or unsnap the pro-
tective cap from the power outlet receptacle base.
(3) Look inside the cigar lighter or power outlet
receptacle base and note the position of the rectangu-
lar retaining bosses of the mount that secures the
receptacle base to the instrument panel.
(4) Insert a pair of external snap ring pliers into
the cigar lighter or power outlet receptacle base and
engage the tips of the pliers with the retaining
bosses of the mount.
(5) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of the mount.
(6) Disconnect the instrument panel wire harness
connector from the connector receptacle of the cigar
lighter or the power outlet receptacle base.(7) Remove the cigar lighter or power outlet mount
from the instrument panel.
INSTALLATION
(1) Install the cigar lighter or power outlet mount
into the instrument panel.
(2) Reconnect the instrument panel wire harness
connector to the connector receptacle of the cigar
lighter or the power outlet receptacle base.
(3) Align the splines on the outside of the cigar
lighter or power outlet receptacle base connector
receptacle with the grooves on the inside of the
mount.
(4) Press firmly on the cigar lighter or power out-
let receptacle base until the retaining bosses of the
mount are fully engaged in their receptacles.
(5) Install the cigar lighter knob and element into
the cigar lighter receptacle base.
(6) Reconnect the battery negative cable.
RELAY
DESCRIPTION
A relay (Fig. 1) is an electromechanical device that
switches fused battery current to a electrical compo-
nent when the ignition switch is turned to the Acces-
sory or Run positions, or when controlled by a
electronic module. The relays are located in the fuse
block.
The relay is a International Standards Organiza-
tion (ISO) relay. Relays conforming to the ISO speci-
fications have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
Fig. 1 ISO RELAY
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8W - 97 - 4 8W-97 POWER DISTRIBUTIONVA

A 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 and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay con-
tact 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-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
DIAGNOSIS AND TESTING - RELAY
(1) Remove the relay from its mounting location.
(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 60.7 - 80.3 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, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the fuse block is connected to battery voltage and
should be hot at all times. Check for battery voltage
at the fused B(+) circuit cavity in the fuse block
receptacle for the relay. If OK, go to Step 2. If not
OK, repair the fused B(+) circuit to the fuse block
fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the fuse block that feeds the
accessory when the relay is energized by the ignition
switch. There should be continuity between the fuse
block cavity for relay terminal 87 and the fused B(+)
fuse in the fuse block at all times. If OK, go to Step
4. If not OK, repair the open fused B(+) circuit to the
fuse block fuse as required.(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the relay when the ignition switch is
in the Accessory or Run positions. Turn the ignition
switch to the On position. Check for battery voltage
at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the fuse block recep-
tacle for the relay. If OK, go to Step 5. If not OK,
repair the open fused ignition switch output (acc/run)
circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The fuse block cavity
for this terminal should have continuity to ground at
all times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle. A slight
back and fourth rocking motion may help the
removal process.
INSTALLATION
(1) Position the relay to the proper receptacle.
(2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
(4) Connect the negative battery cable.
VA8W-97 POWER DISTRIBUTION 8W - 97 - 5

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................5
INSTALLATION
INSTALLATION - ENGINE COVER..........9
INSTALLATION........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS.....................11
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
AIR CLEANER HOUSING
REMOVAL.............................21
INSTALLATION.........................22
CYLINDER HEAD
DESCRIPTION.........................22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............22
REMOVAL
REMOVAL - CYLINDER HEAD............23
REMOVAL - CYLINDER HEAD FRONT
COVER.............................25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD........26
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE..................30
REMOVAL.............................30
INSTALLATION.........................32CYLINDER HEAD COVER(S)
REMOVAL.............................33
INSTALLATION.........................34
VALVE STEM SEALS
DESCRIPTION.........................34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............35
REMOVAL - VALVES...................36
INSTALLATION
INSTALLATION - VALVE SPRINGS........36
INSTALLATION - VALVES...............37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................38
CRANKSHAFT
DESCRIPTION.........................39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....39
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
FLYWHEEL
REMOVAL.............................43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - CRANKSHAFT LOCK.....44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................47
REMOVAL.............................47
INSTALLATION.........................49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................53
INSTALLATION.........................54
VAENGINE 9 - 1

VACUUM PUMP
DESCRIPTION.........................54
OPERATION...........................54
REMOVAL.............................55
INSTALLATION.........................55
LEFT MOUNT
REMOVAL.............................55
INSTALLATION.........................55
RIGHT MOUNT
REMOVAL.............................56
INSTALLATION.........................56
OIL
REMOVAL - OIL SEPARATOR..............56
INSTALLATION - OIL SEPARATOR..........56
OIL COOLER & LINES
REMOVAL.............................56
INSTALLATION.........................57
OIL FILTER
REMOVAL.............................57
INSTALLATION.........................57
OIL JET
DESCRIPTION.........................57
REMOVAL.............................58
INSTALLATION.........................58
OIL PAN
REMOVAL.............................58
INSTALLATION.........................60
OIL PUMP
REMOVAL
REMOVAL...........................61
REMOVAL- OIL PUMP CHAIN............61
INSTALLATION
INSTALLATION.......................62INSTALLATION - OIL PUMP CHAIN........62
OIL SENSOR
DESCRIPTION.........................64
OPERATION...........................64
REMOVAL.............................65
INSTALLATION.........................65
INTAKE MANIFOLD
REMOVAL.............................65
INSTALLATION.........................68
EXHAUST MANIFOLD
REMOVAL.............................68
INSTALLATION.........................69
TIMING CHAIN COVER
REMOVAL.............................70
INSTALLATION.........................71
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE RAILS . 72
REMOVAL - INTERMEDIATE GEAR........73
REMOVAL - TIMING CHAIN TENSIONING
RAIL...............................74
REMOVAL - TIMING CHAIN..............74
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE
RAIL...............................76
INSTALLATION - INTERMEDIATE GEAR....77
INSTALLATION - TIMING CHAIN
TENSIONING RAIL....................77
ADJUSTMENTS
INSTALLATION - TIMING CHAIN..........77
TIMING CHAIN TENSIONER
REMOVAL.............................81
INSTALLATION.........................81
ENGINE
DESCRIPTION
This 2.7 Liter five-cylinder Common Rail Diesel
Injection (CDI) engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has for valve per cylinder and dual overhead
camshafts (Fig. 1).
Fig. 1 2.7L CDI ENGINE
9 - 2 ENGINEVA

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System 2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194ÉF). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING COOLANT. OPEN CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
VAENGINE 9 - 3

NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
CYLINDER LEAK DOWN VALUES
CYLINDER LEAK
DOWN PERMISSIBLE
TOTAL LOSS  25%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT VALVES AND
CYLINDER HEAD  10%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT PISTON AND
RINGS  20%
STANDARD PROCEDURE - DETERMINING CYL-
INDER PRESSURE LOSS
If an increased pressure loss was found with the
cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.
Possible causes for the pressure loss are:
POSSIBLE CAUSE FOR PRESSURE LOSS
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR, AD-
JACENT CYL-
INDERS, OR
AIR BUBBLES
IN COOLANT1. Sealing Sur-
facesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace Cyl-
inder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing Sur-
faces1. Remove Cyl-
inder Head for
Further Inspec-
tion
CONDITION POSSIBLE
CAUSESCORRECTION
2. Intake
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH EX-
HAUSTSealing Surfac-
esRemove Cylin-
der Head for
Further Inspec-
tion
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing Sur-
facesRemove Engine
for Further In-
spection
2. Pistons, Pis-
ton Rings2. Replace Pis-
tons or Piston
Rings
It is possible to pin point the pressure loss of the
relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.
Determining the cause can be falsified by the posi-
tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
REMOVAL
REMOVAL - ENGINE COVER
(1) Remove the retaining screws and remove cover
(Fig. 2).
9 - 4 ENGINEVA