2005 MERCEDES-BENZ SPRINTER radiator

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

COOLANT LEVEL SENSOR
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
NOTE: Drain coolant from radiator drain plug only.
(1) Drain coolant until the coolant reservoir is
emptied.
(2) Disconnect the wiring harness electrical con-
nector.
(3) Turn the level sensor 90 degrees clockwises, lift
up and out of the container.
INSTALLATION
(1) Align coolant level sensor with coolant
reservior access whole, press down while turning
counterclockwise 90 degrees to seat sensor (Fig. 4).
(2) Connect coolant level sensor electrical connec-
tor (Fig. 4).
(3) Refill cooling system to proper level.
(4) Inspect for leaks.
RADIATOR FAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the front end cross member.
(3) Push complete radiator assembly forward and
unclip the fan shroud at the radiator.
(4) Detach coolant line from lower radiator shroud.
(5) Retain accessory drive belt pulley of water
pump with a counterholder (Fig. 5).
(6) Unscrew the central bolt of the viscous fan
clutch and lift fan and shroud up and out (Fig. 5).
NOTE: Store the viscous fan clutch in the upright
position. DO NOT place down flat.
(7) Remove radiator fan from viscous fan clutch
(Fig. 5).
INSTALLATION
(1) Install fan blade to viscous clutch. Tighten
bolts to 80 lbs. in. (9 N´m) (Fig. 5).
(2) Install fan and clutch along with fan shroud in
to engine bay area (Fig. 5).
(3) Install the center bolt of the viscous clutch.
Tighten bolt to 33 lbs. ft. (45 N´m) (Fig. 5)
(4) Attach coolant line to lower radiator shroud.
(5)
Properly align and clip the fan shroud into place.
Fig. 4 COOLANT LEVEL SENSOR
1 - COOLANT LEVEL SENSOR
2 - COOLANT RESERVIOR
3 - ELECTRICAL CONNECTOR
Fig. 5 RADIATOR FAN
1 - VISCOUS CLUTCH
2 - COUNTERHOLDER
3 - CLUTCH BOLT
4 - FAN BOLT
5-FAN
VAENGINE 7 - 13

(6) Properly align the radiator assembly and
install the front end cross member.
(7) Connect negative battery cable.
ENGINE BLOCK HEATER
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system.
(3) Record the location and snip the wire ties.
(4) Unscrew the engine block heater from the core
plug hole and remove (Fig. 6).
INSTALLATION
(1) Screw the block heater into the appropriate
core hole (Fig. 6).
(2) Route the heater wiring harness away from
and interference and secure with wiring tie straps.
(3) Refill the cooling system.
(4) Connect the negative battery cable.
(5) Start the engine and inspect for leaks.
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The ECM determines the operating temperature of
the engine by using the signal from the coolant tem-
perature sensor. The coolant temperature sensor has
a negative temperature coefficient (NTC) resistor
contained in the plastic housing. NTC means; the
higher the temperature, then the lower the resis-
tance. The ECM also uses the coolant temperature
sensor signal to calculate glow plug relay triggering.
If the coolant temperature sensor fails during opera-
tion, the ECM will switch on the cooling fan to pre-
vent engine overheating (A/C models only).
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. OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES AND EYE WEAR.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partailly drain coolant system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Unplug coolant temperature sensor electrical
connector.
Fig. 6 ENGINE BLOCK HEATER
1 - ENGINE BLOCK HEATER
2 - CORE PLUG
3 - ENGINE MOUNT
4 - WIRING TIE STRAPS
7 - 14 ENGINEVA
RADIATOR FAN (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)

(15) Detach coolant hose at bottom right of radia-
tor (Fig. 9).
(16) Detach transmission cooler lines (Fig. 9).
(17) Remove the radiator trim from the left and
right (Fig. 9).
(18) Lift the radiator assembly up and out of the
rubber grommets (Fig. 9).
(19) Remove top radiator trim.
(20) Take off charge air cooler together with cool-
ing loop of the steering at the radiator (Fig. 10).
(21) Remove bottom radiator trim (Fig. 10).
(22) Detach coolant hose at radiator.
(23) Detach coolant pipe together with coolant
hose at the fan shroud.
(24) Remove radiator fan shroud (Fig. 10).
INSTALLATION
(1) Install fan shroud to radiator (Fig. 10).
(2) Attach coolant pipe with hoses to fan shroud
(Fig. 10).(3) Attach coolant hose at radiator (Fig. 10).
(4) Install bottom radiator trim (Fig. 10).
(5) Install charge air cooler along with cooling loop
of the power steering, to radiator (Fig. 10).
(6) Install radiator assembly into the rubber grom-
mets (Fig. 9).
(7) Install both right and left side radiator trim
panels (Fig. 9).
(8) Attach the transmission cooler lines (Fig. 9).
(9) Attach coolant hose to the bottom right of the
radiator (Fig. 9).
(10) Attach both power steering hydraulic lines
(Fig. 9).
(11) Connect coolant level sensor electrical connec-
tor (Fig. 9).
(12) Connect coolant hoses to the coolant reservoir,
radiator and water pump (Fig. 9).
(13) Attach air intake pipe at the body.
(14) Attach charge air hose at air intake.
(15) Attach charge air hose at turbocharger.
Fig. 9 RADIATOR ASSEMBLY
1 - COOLANT HOSE 8 - ATF LINE
2 - SENSOR HARNESS CONNECTOR 9 - LEFT RADIATOR TRIM PANEL
3 - HYDRAULIC HOSE 10 - RIGHT RADIATOR TRIM PANEL
4 - CHARGE AIR HOSE 11 - RADIATOR
5 - HYDRAULIC HOSE 12 - ATF LINE
6 - RUBBER GROMMET 13 - COOLANT HOSE
7 - COOLANT HOSE 14 - COOLANT RESERVOIR
VAENGINE 7 - 17
RADIATOR (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)

DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester (tool 7700 or
an equivalent) (Fig. 12).
Operate the tester pump and observe the gauge
pointer at its highest point. The cap release pressure
should be 124 to 145 kPa (18 to 21 psi). The cap is
satisfactory when the pressure holds steady. It is also
good if it holds pressure within the 124 to 145 kPa
(18 to 21 psi) range for 30 seconds or more. If the
pointer drops quickly, replace the cap.CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
WATER PUMP
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 the negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove viscous fan clutch.
(4) Detach fuel lines from the brackets at the
water pump.
(5) Detach the coolant hoses at the water pump
(Fig. 13).
Fig. 12 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
VAENGINE 7 - 19
RADIATOR PRESSURE CAP (Continued)

(6) Press off cap at belt guide pulleys.
(7) Remove belt guide pulleys.
(8) Remove water pump retaining bolts and
remove water pump.
INSTALLATION
NOTE: Clean all mating surfaces.
(1) Fit existing accessory drive belt pulley onto the
water pump.
(2) Properly position water pump with new gasket
to the engine and tighten bolts to 124 lbs. in. (14
N´m), M8 177 lbs. in. (20 N´m) (Fig. 13).
NOTE: Be sure to install the washer behind the
guide pulley to assure proper alignment.(3) Install belt guide pulleys. Tighten bolts to 26
lbs. ft. (35 N´m) (Fig. 13).
(4) Attach the coolant hoses to the water pump
and tighten clamps (Fig. 13).
(5) Attach fuel lines to the brackets at the water
pump.
(6) Install accessory drive belt.
(7) Install viscous fan clutch.
(8) Close radiator and or engine drain plug.
(9) Refill cooling system to proper level with the
correct coolant and mixture. Check for leaks.
Fig. 13 WATER PUMP
1 - GASKET 5 - CAP
2 - WASHER 6 - WATER PUMP
3 - GUIDE PULLEY 7 - COOLANT HOSE
4 - BOLT 8 - COOLANT HOSE
7 - 20 ENGINEVA
WATER PUMP (Continued)