coolant MERCEDES-BENZ SPRINTER 2006 Manual Online

Component Page
Cigar Lighter...................... 8W-80-30
Cigar Lighter Lamp................. 8W-80-30
Circulation Pump (Cabin Heater
Module)........................ 8W-80-31
Circulation Pump (Rest System)........ 8W-80-31
Circulation Pump Diode.............. 8W-80-31
Clockspring C1..................... 8W-80-31
Clockspring C2..................... 8W-80-31
Controller Antilock Brake............. 8W-80-32
Courtesy Lamp-Driver Door........... 8W-80-33
Courtesy Lamp-Left Sliding Door....... 8W-80-33
Courtesy Lamp-Passenger Door........ 8W-80-33
Courtesy Lamp-Right Sliding Door...... 8W-80-33
Crankcase Heater................... 8W-80-34
Crankshaft Position Sensor........... 8W-80-34
CTEL Antenna Connector............. 8W-80-34
CTEL Connector.................... 8W-80-34
Cylinder Lock Switch-Driver.......... 8W-80-35
Data Link Connector................ 8W-80-35
Differential Lock Solenoid Valve........ 8W-80-35
Dome Lamp....................... 8W-80-35
Door Lock Motor/Ajar Switch
Assembly-Driver C1............... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Driver C2............... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C1........... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C2........... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Passenger C1............ 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Passenger C2............ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Rear C1................ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Rear C2................ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C1.......... 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C2.......... 8W-80-37
Dosing Pump...................... 8W-80-38
EGR Valve........................ 8W-80-38
Electrohydraulic Control Unit......... 8W-80-38
Engine Control Module C1 (Except
OBD).......................... 8W-80-38
Engine Control Module C1 (OBD)...... 8W-80-39
Engine Control Module C2 (Except
OBD).......................... 8W-80-40
Engine Control Module C2 (OBD)...... 8W-80-41
Engine Control Module C3 (Except
OBD).......................... 8W-80-42
Engine Control Module C4 (Except
OBD).......................... 8W-80-43Component Page
Engine Control Module C5 (Except
OBD).......................... 8W-80-44
Engine Coolant Level Switch.......... 8W-80-44
Engine Coolant Temperature Sensor.... 8W-80-44
Engine Oil Sensor................... 8W-80-44
Evaporator Temperature Sensor........ 8W-80-45
Fog Lamp Switch................... 8W-80-45
Fuel Injector No. 1.................. 8W-80-45
Fuel Injector No. 2.................. 8W-80-45
Fuel Injector No. 3.................. 8W-80-46
Fuel Injector No. 4.................. 8W-80-46
Fuel Injector No. 5.................. 8W-80-46
Fuel Level Sensor................... 8W-80-46
Fuel Pressure Sensor................ 8W-80-47
Fuel Pressure Solenoid............... 8W-80-47
Fuel Pump (OBD)................... 8W-80-47
Fuel Pump Relay (OBD).............. 8W-80-47
Fuel Quantity Control Valve (OBD)..... 8W-80-47
Fuel Shutdown Solenoid.............. 8W-80-48
Fuel Temperature Sensor............. 8W-80-48
Fuse Block No. 1 C1................. 8W-80-48
Fuse Block No. 1 C2................. 8W-80-49
Fuse Block No. 1 C3................. 8W-80-49
Fuse Block No. 1 C4................. 8W-80-49
Fuse Block No. 1 C5................. 8W-80-49
Glow Plug Control Module C1......... 8W-80-50
Glow Plug Control Module C2......... 8W-80-50
Headlamp Adjust Switch............. 8W-80-50
Headlamp Assembly-Left............. 8W-80-51
Headlamp Assembly-Right............ 8W-80-51
Heated Seat Module-Driver........... 8W-80-51
Heated Seat Module-Passenger........ 8W-80-52
Heated Seat Switch-Driver............ 8W-80-52
Heated Seat Switch-Passenger......... 8W-80-52
Heater Timer-auxiliary............... 8W-80-53
High Idle Switch.................... 8W-80-53
Hood Ajar Switch................... 8W-80-53
Horn............................. 8W-80-54
Horn (VTSS)....................... 8W-80-54
Ignition Lock Switch................. 8W-80-54
Instrument Cluster C1............... 8W-80-54
Instrument Cluster C2............... 8W-80-55
Instrument Panel Socket............. 8W-80-55
Intake Air Pressure Sensor (OBD)...... 8W-80-55
Intake Air Temperature Sensor........ 8W-80-56
Interior Lamp No. 1................. 8W-80-56
Interior Lamp No. 2................. 8W-80-56
Interior Lamp No. 3................. 8W-80-56
Interior Lamp No. 4................. 8W-80-56
Interior Lamp No. 5................. 8W-80-57
Interior Lamp-Left.................. 8W-80-57
Interior Lamp-middle Front........... 8W-80-57
Interior Lamp-middle Rear............ 8W-80-57
Interior Lamp-Rear No. 1............. 8W-80-58
Interior Lamp-Rear No. 2............. 8W-80-58
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSVA

ENGINE CONTROL MODULE C1 (OBD)
CAV CIRCUIT FUNCTION
1 16BL FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
2 16BL/WT FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL
3 16DG FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
4 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
8 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
10 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
11 20GY/BL ENGINE OIL SENSOR SIGNAL
12 20BR/RD INTAKE PRESSURE SENSOR GROUND
13 20VT/DG INTAKE PRESSURE SENSOR SIGNAL
14 20BR/DG CAMSHAFT POSITION SENSOR GROUND
15 20DG/BK O2 1/1 PUMP CELL SIGNAL
20 18BK/YL WATER IN FUEL SENSOR SIGNAL
21 18BK/RD CRANKCASE HEATER SIGNAL
25 16BK FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
26 16BK/WT FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL
28 18RD/BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY
31 20YL/BL MASS AIR FLOW SENSOR GROUND
32 18DG/BK FUEL TEMPERATURE SENSOR GROUND
35 20BR/BK SENSOR GROUND
36 20VT/RD INTAKE PRESSURE SENSOR 5 VOLT SUPPLY
37 20RD/BL CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
38 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
39 20GY O2 1/1 SENSOR CELL SIGNAL
40 20GY/WT O2 1/1 VIRTUAL GROUND
49 16BK/VT FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
50 16BK/DG FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
51 16BK/YL FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
52 20BK/WT FUEL PRESSURE SOLENOID CONTROL
55 18BR WATER IN FUEL SENSOR GROUND
56 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
57 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
59 20DG/VT FUEL PRESSURE SENSOR SIGNAL
61 20BR/VT MASS AIR FLOW SENSOR 5 VOLT SUPPLY
62 20DG/YL O2 1/1 PUMP CELL CONTROL
72 20GY/BL O2 1/1 HEATER CONTROL
73 16BK/RD FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
74 16BK/BL FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
76 18BR/YL FUEL QUANTITY SOLENOID CONTROL
79 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
84 20BR/GY FUEL PRESSURE SENSOR GROUND
85 20YL/DG MASS AIR FLOW SENSOR SIGNAL
86 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
87 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
88 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
90 20DG/WT EGR VALVE CONTROL
91 18BK/BR CRANKCASE HEATER GROUND
93 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39

ENGINE CONTROL MODULE C4 (EXCEPT OBD) - BLACK
CAV CIRCUIT FUNCTION
1- -
2 20BR/DG CAMSHAFT POSITION SENSOR GROUND
3 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
4 20BR/GY FUEL PRESSURE SENSOR GROUND
5- -
6- -
7 18GY/YL LOW FUEL PRESSURE SENSOR GROUND
8 18GY/DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY
9- -
10 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
11 18BK/YL WATER IN FUEL SENSOR GROUND
12 18RD/BL CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
13 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
14 20DG/VT FUEL PRESSURE SENSOR SIGNAL
15 20GY/BL ENGINE OIL SENSOR SIGNAL
16 - -
17 20BR/BK SENSOR GROUND
18 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
19 - -
20 - -
21 20BK/WT FUEL PRESSURE SOLENOID CONTROL
22 18RD/BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY
23 - -
24 - -
25 - -
26 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
27 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
28 - -
29 - -
30 18DG/BK FUEL TEMPERATURE SENSOR GROUND
31 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
32 20BR/YL FUEL SHUTDOWN SOLENOID CONTROL
33 - -
34 18BR WATER IN FUEL SENSOR SIGNAL
35 - -
36 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
37 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
38 18GY/RD LOW FUEL PRESSURE SENSOR SIGNAL
39 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
40 20RD/YL EGR VALVE CONTROL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43

ENGINE CONTROL MODULE C5 (EXCEPT OBD) - GRAY
CAV CIRCUIT FUNCTION
1- -
2 14BK COMMON INJECTOR DRIVER NO. 1
3 14BK/YL FUEL INJECTOR NO. 4 CONTROL
4 14BL COMMON INJECTOR DRIVER NO. 2
5 14BK/VT FUEL INJECTOR NO. 2 CONTROL
6- -
7 14BK/DG FUEL INJECTOR NO. 5 CONTROL
8 14BK/RD FUEL INJECTOR NO. 3 CONTROL
9 14BK/BL FUEL INJECTOR NO. 1 CONTROL
ENGINE COOLANT LEVEL SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
2 16BR GROUND
ENGINE COOLANT TEMPERATURE SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20GY/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTSVA

HORN
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
HORN (VTSS)
CAV CIRCUIT FUNCTION
1 16BK/BR HORN RELAY OUTPUT
2 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
IGNITION LOCK SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
INSTRUMENT CLUSTER C1
CAV CIRCUIT FUNCTION
1 20BR FUEL LEVEL SENSOR SIGNAL RETURN
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN
4 20WT/GY K-IC/ATC/HBM/CHM
5 20BR/BK PARK BRAKE INDICATOR SIGNAL
7 20BK/DG RIGHT TURN SIGNAL
10 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
11 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
14 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
15 20BR/WT FRONT COURTESY LAMPS CONTROL
16 20YL/RD SEAT BELT SWITCH SIGNAL
17 20DG CAN C BUS (-)
18 20DG/WT CAN C BUS (+)
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTSVA

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

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

REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
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) Disconnect the negative battery cable.
NOTE: REPLACE THE AIR CONDITIONING DRIER
WHEN EVER THE AIR CONDITIONING SYSTEM IS
OPENED.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Evacuate and recover air conditioning system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(4) Remove the front grille and fascia assembly.(5) Disconnect the engine wiring harness at the
cabin side and carefully guide though the cowl into
the engine area.
Fig. 2 ENGINE COVER
1 - ENGINE COVER
2 - FASTENERS
VAENGINE 9 - 5

(6) Remove the turbocharger heat shield (Fig. 3).
(7) Remove the engine cover (Fig. 3).
(8) Remove the air cleaner and hose at the turbo-
charger and air cleaner assembly.
(9) Disconnect the transmission lines at the radia-
tor.
(10) Disconnect the upper and lower radiator
hoses.
(11) Disconnect the A/C lines at the condenser.
(12) Disconnect the condenser fan harness connec-
tor.
(13) Disconnect the power steering cooler lines at
the cooler.
(14) Disconnect the charge air cooler hose at the
intake manifold (Fig. 3).
(15) Remove charge air hose fasteners at the radi-
ator closure panel.
(16) Remove the fasteners retaining the radiator to
the front crossmember.(17) Remove the change air cooler, A/C conderser
and fan as an assembly.
(18) Disconnect the charge air hose at the intake
manifold (Fig. 3).
(19) Remove the radiator assembly.
(20) Disconnect the high pressure and return
hoses at the power steering pump.
(21) Disconnect the fuel lines at the fuel filter.
(22) Disconnect the refrigerant line at the A/C
compressor.
(23) Disconnect the vacuum line for the brake
booster at the vacuum pump (Fig. 3).
(24) Disconnect the coolant hose of heating return
flow at the water pump.
(25) Disconnect the coolant hose of the heater sup-
ply at the coolant pipe at the side of the cylinder
head.
Fig. 3 ENGINE COVER
1 - ENGINE COVER 6 - HIGH PRESSURE FUEL PUMP
2 - FUEL RAIL 7 - VACUUM PUMP
3 - INTAKE MANIFOLD 8 - OIL LEVEL INDICATOR
4 - EGR VALVE 9 - HEAT SHIELD
5 - AIR INLET TUBE 10 - TRANSMISSION OIL LEVEL INDICATOR
9 - 6 ENGINEVA