2005 MERCEDES-BENZ SPRINTER stop start

8W-02 COMPONENT INDEX
Component Page
A/C Auxiliary Fan Relay................ 8W-42
A/C Auxiliary Fan..................... 8W-42
A/C Compressor Clutch................. 8W-42
A/C Control Module-Roof................ 8W-42
A/C Fan Switch....................... 8W-42
A/C Switch-Roof...................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Air Outlet Temperature Sensor........... 8W-42
Airbag Control Module................. 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-42
Ash Receiver Lamp.................... 8W-44
Automatic Temperature Control Module.... 8W-42
Auxiliary Heater Relay................. 8W-42
Auxiliary Heater Switch................ 8W-42
Battery Relay-Auxiliary................ 8W-20
Batteries............................ 8W-20
Beam Select Switch.................... 8W-50
Blower Motors........................ 8W-42
Body Plug Connector................... 8W-11
Boost Pressure Sensor.................. 8W-30
Boost Pressure Solenoid................ 8W-30
Brake Fluid Level Switch............... 8W-35
Brake Lamp Switch.................... 8W-35
Brake Wear Sensors................... 8W-35
Cabin Heater Assembly................. 8W-42
Cabin Heater Control Module............ 8W-42
Camshaft Position Sensor............... 8W-30
Center High Mounted Stop Lamp......... 8W-51
Central Timer Module.................. 8W-45
Cigar Lighter Lamp................... 8W-44
Cigar Lighter......................... 8W-41
Circulation Pump Diode................ 8W-42
Circulation Pump Relay................ 8W-42
Circulation Pump..................... 8W-42
Clockspring....................... 8W-41, 43
Contact Switch Door-Tailgate............ 8W-44
Controller Antilock Brake............... 8W-35
Courtesy Lamps...................... 8W-44
Crankcase Heater..................... 8W-30
Crankshaft Position Sensor.............. 8W-30
Ctel Antenna Connector................ 8W-55
Ctel Connector..................... 8W-47, 55
Cylinder Lock Switch-Driver............. 8W-61
D+ Relay No. 1....................... 8W-10
D+ Relay No. 2....................... 8W-11
Data Link Connector................... 8W-18
Daytime Running Lamp Relays........... 8W-50
Differential Lock Solenoid Valve.......... 8W-31
Dome Lamp.......................... 8W-44
Door Jamb Switches................... 8W-44
Door Lock Motor/Ajar Switch Assemblies . . . 8W-61Component Page
Dosing Pump......................... 8W-42
EGR Valve........................... 8W-30
Engine Control Module................. 8W-30
Engine Control Relay.................. 8W-31
Engine Coolant Level Switch............. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Sensor..................... 8W-30
Evaporator Temperature Sensor.......... 8W-42
Fan Stage 1 Relay..................... 8W-42
Fog Lamp Relay...................... 8W-50
Fog Lamp Switch..................... 8W-50
Fuel Injectors........................ 8W-30
Fuel Level Sensor..................... 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Shutdown Solenoid................ 8W-30
Fuel Temperature Sensor............... 8W-30
Fuses............................ 8W-10, 11
Fuse Blocks.......................... 8W-10
Fuse/Relay Block...................... 8W-11
Fused Ignition Switch Run-Start Relay..... 8W-11
Grounds............................ 8W-70
Generator........................... 8W-20
Glow Plug Control Module.............. 8W-30
Glow Plugs.......................... 8W-30
Hazard Warning Switch................ 8W-52
Headlamp Adjust Switch................ 8W-50
Headlamp Assemblies............... 8W-50, 52
Headlamp Switch..................... 8W-50
Heat Exchanger Connector.............. 8W-42
Heat Exchanger Switch................. 8W-42
Heated Seat Modules.................. 8W-63
Heated Seat Switches.................. 8W-63
Heater Timer-Auxiliary................. 8W-42
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Horn............................... 8W-41
Ignition Lock Switch................... 8W-40
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Instrument Panel Socket................ 8W-40
Intake Air Temperature Sensor........... 8W-30
Interior Lamps....................... 8W-44
Interior Light Switches................. 8W-44
Interior Lighting Connector.............. 8W-44
Intrusion Sensors..................... 8W-39
Kickdown Switch...................... 8W-30
Lamp Relays......................... 8W-50
License Plate Lamps................... 8W-51
Locker Switches...................... 8W-31
Low Fuel Pressure Sensor............... 8W-30
VA8W-02 COMPONENT INDEX 8W - 02 - 1

8W-15 GROUND DISTRIBUTION
Component PageA/C Auxiliary Fan........................8W-15-4
A/C Auxiliary Fan Relay...................8W-15-12
A/C Control Module- Roof..................8W-15-28
A/C Fan Switch........................8W-15-21
A/C Switch- Roof.....................8W-15-24, 28
Airbag Control Module....................8W-15-11
Ash Receiver Lamp......................8W-15-22
Automatic Temperature Control Module.........8W-15-24
Auxiliary Heater Relay....................8W-15-12
Auxiliary Heater Switch...................8W-15-24
Battery..............................8W-15-8
Battery Relay- Auxiliary...................8W-15-11
Battery- Auxiliary.......................8W-15-11
Blower Motor- Front......................8W-15-9
Brake Fluid Level Switch...................8W-15-8
Brake Wear Sensor- Left Front................8W-15-8
Brake Wear Sensor- Left Rear...............8W-15-28
Brake Wear Sensor- Right Front...............8W-15-8
Brake Wear Sensor- Right Rear...............8W-15-28
Cabin Heater Assembly....................8W-15-3
Center High Mounted Stop Lamp..............8W-15-6
Central Timer Module....................8W-15-15
Cigar Lighter..........................8W-15-22
Cigar Lighter Lamp......................8W-15-22
Circulation Pump........................8W-15-9
Circulation Pump Relay...................8W-15-12
Clockspring...........................8W-15-10
Controller Antilock Brake.................8W-15-2, 28
CTEL Connector........................8W-15-21
Cylinder Lock Switch- Driver..............8W-15-7, 10
D+ Relay No. 1.........................8W-15-12
D+ Relay No. 2.........................8W-15-14
Data Link Connector.....................8W-15-10
Daytime Running Lamp Relay- Left Side.........8W-15-13
Daytime Running Lamp Relay- Right Side........8W-15-13
Daytime Running Lamps Relay...............8W-15-13
Differential Lock Solenoid Valve...............8W-15-2
Dome Lamp...........................8W-15-6
Dosing Pump...........................8W-15-2
Engine Control Module.....................8W-15-7
Engine Coolant Level Switch.................8W-15-2
Fan Stage 1 Relay.......................8W-15-11
Fog Lamp Relay........................8W-15-11
Fog Lamp Switch.......................8W-15-22
Fuse Block No. 1........................8W-15-7
Fused Ignition Switch Run-Start Relay..........8W-15-14
G100..............................8W-15-2, 3
G101................................8W-15-4
G102................................8W-15-4
G200.........................8W-15-6, 7, 8, 9, 10
G201...............................8W-15-11
G202.............8W-15-11, 12, 13, 14, 15, 16, 17, 18, 19
G203....................8W-15-20, 21, 22, 23, 24, 25
G300..........................8W-15-26, 27, 28
G301...............................8W-15-28
G302...............................8W-15-28
Glow Plug Control Module..................8W-15-2
Hazard Warning Switch....................8W-15-7
Headlamp Adjust Switch...................8W-15-22
Headlamp Assembly- Left...................8W-15-3
Headlamp Assembly- Right..................8W-15-4
Heat Exchanger Connector.................8W-15-12
Heat Exchanger Switch....................8W-15-24
Heated Seat Switch- Driver.................8W-15-25
Heated Seat Switch- Passenger...............8W-15-25
Heater Timer- Auxiliary...................8W-15-24
Hood Ajar Switch........................8W-15-4
Horn Relay...........................8W-15-11
Horn Switch..........................8W-15-10
Ignition Lock Switch.....................8W-15-10
Instrument Cluster......................8W-15-10
Instrument Panel Socket...................8W-15-20Component PageInterior Lamp No. 1......................8W-15-6
Interior Lamp No. 2......................8W-15-6
Interior Lamp No. 3......................8W-15-6
Interior Lamp No. 4......................8W-15-6
Interior Lamp No. 5......................8W-15-6
Interior Lamp- Middle Front................8W-15-5, 6
Interior Lamp- Middle Rear................8W-15-5, 6
Interior Lamp- Rear No. 2...................8W-15-5
Interior Lamp- Right Side.................8W-15-5, 6
Interior Light Switch.....................8W-15-21
Interior Lighting Connector..................8W-15-6
Intrusion Sensor No. 1.....................8W-15-6
Intrusion Sensor No. 2.....................8W-15-6
Intrusion Sensor No. 3.....................8W-15-6
Lamp Relay- Left.......................8W-15-13
Lamp Relay- Right......................8W-15-13
License Plate Lamp No. 1..................8W-15-27
License Plate Lamp No. 2..................8W-15-27
Locker Switch No. 1......................8W-15-20
Map/Reading Lamp Switch.................8W-15-21
Marker Lamp Connector...................8W-15-17
Marker Lamp No. 1- Left Front...............8W-15-16
Marker Lamp No. 1- Right Front..............8W-15-16
Marker Lamp No. 2- Left Front...............8W-15-16
Marker Lamp No. 2- Right Front..............8W-15-16
Marker Lamp- Left Center..................8W-15-17
Marker Lamp- Left Rear...................8W-15-27
Marker Lamp- Right Center.................8W-15-17
Marker Lamp- Right Rear..................8W-15-27
Master Door Lock Switch..................8W-15-25
Metering Pump.........................8W-15-18
Multi- Function Switch.....................8W-15-7
Optional Equipment Relay..................8W-15-19
Panic Alarm Switch......................8W-15-20
Parking Brake Switch....................8W-15-15
Power Mirror Motor- Driver.................8W-15-23
Power Mirror Motor- Passenger...............8W-15-23
Power Mirror Switch.....................8W-15-23
Power Window Switch- Driver...............8W-15-23
Power Window Switch- Master...............8W-15-23
Radio...............................8W-15-21
Reading Lamp Connector...................8W-15-6
Recirculated Air Solenoid Valve...............8W-15-9
Seat Belt Switch........................8W-15-15
Security System Module...................8W-15-15
Sentry Key Remote Entry Module..............8W-15-7
Shifter Assembly........................8W-15-20
Siren................................8W-15-9
Tail Lamp Assembly- Left..................8W-15-26
Tail Lamp Assembly- Right.................8W-15-26
TCS Switch...........................8W-15-25
Time Delay Relay.......................8W-15-17
Towing/Intrusion Sensor On/Off Switch..........8W-15-22
Trailer Tow Connector....................8W-15-28
Trailer Tow Control Module.................8W-15-19
Transmission Control Module................8W-15-19
Transmission Relay......................8W-15-19
Turn Signal No. 1- Left Front.................8W-15-3
Turn Signal No. 1- Right Front................8W-15-4
Turn Signal No. 2- Left Front.................8W-15-3
Warm Air Auxiliary Heater Assembly...........8W-15-18
Washer Pump Motor- Front..................8W-15-4
Water Cycle Valve........................8W-15-9
Window Defogger Module- Rear..............8W-15-15
Window Defogger Relay- Left Rear.............8W-15-14
Window Defogger Relay- Right Rear............8W-15-14
Window Defogger Switch- Rear...............8W-15-20
Window Defogger- Left Rear.................8W-15-26
Window Defogger- Right Rear................8W-15-26
Wiper Motor- Front.......................8W-15-9
Wiper/Turn Signal/Engine Start Control Module.....8W-15-7
VA8W-15 GROUND DISTRIBUTION 8W - 15 - 1

INSTALLATION
(1) Clean all sealing surfaces.
(2) Position driver on rear of pump and install vac-
uum pump with new seals. Tighten bolts to 14N´m
(124 lbs. in.). (Fig. 44)
(3) Install vacuum line to vacuum pump (Fig. 44).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(5) Start the engine and inspect for leaks.
LEFT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534±16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 45)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 45)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 45)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
45)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 45)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 45).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 45)
(7) Remove the engine support fixture and adap-
tors.
RIGHT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534-16 and raise the engine slightly.(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 46)
(4) Lower the vehicle.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 46)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 46)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
46)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 46)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 46).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 46)
Fig. 45 LEFT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - BRACKET
7 - GROUND CABLE
8 - WASHER
9 - BOLT
VAENGINE 9 - 49
VACUUM PUMP (Continued)

(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOTOPEN 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) Drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 47).
(4) Remove the oil cooler from the timing case
cover (Fig. 47).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 47).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 47).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
Fig. 46 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
Fig. 47 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
9 - 50 ENGINEVA
RIGHT MOUNT (Continued)

NOTE: Rivet pins of the riveted link individually.
(17) Position riveting tool exactly over middle of
pin (Fig. 60).
(18) Tighten riveting tool spindle until it stops.
(19) Remove riveting tool, inspect riveting, rerivet
if necessary (Fig. 61).(20) Repeat procedure for both rivets.
(21) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(22) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(23) Refill engine with proper oil to the correct
level.
(24) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR
THE PULLEYS, BELT OR FAN. DO NOT WEAR
LOOSE CLOTHES.
(25) Start engine and inspect for leaks.
OIL TEMPERATURE SENSOR
DESCRIPTION
Oil level, oil temperature and oil quality are
detected by means of an oil sensor located in the oil
pan. The sensor which operates on the capacitance
principle features an integrated electronic circuit
which analyzes the three signals. the signals are con-
stantly relayed to the ECM and over the CAN bus to
the instrument cluster by means of PWM signal.
OPERATION
Oil quality is detected for indicating the need-
based oil change interval. The oil quality is detected
on the basis of the capacitance of the engine oil
(dielectrics, does not conduct electricity), this being
as much as six times greater in case of poor quality.
Fig. 59 INSTALLING RIVETING INSERTS INTO
RIVETING TOOL
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #9310
Fig. 60 NEW LINK RIVETING
1 - SPECIAL TOOL #8947
2 - OIL PUMP CHAIN
Fig. 61 RIVET INSPECTION
9 - 56 ENGINEVA
OIL PUMP (Continued)

DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM
Air will enter the fuel system whenever fuel supply
lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start-
ing, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock.
Inspect the fuel system from the fuel tank to the
injectors for loose connections (Refer to 14 - FUEL
SYSTEM - WARNING). Leaking fuel is an indicator
of loose connections or defective seals. Air can also
enter the fuel system between the fuel tank and the
fuel pump. Inspect the fuel tank and fuel lines for
damage that might allow air into the system.
With the DRBIIItconnected to the vehicle, select
Engine and the select Sensor Display. Page down to
view Fuel Pressure Set Point and Actual Fuel Pres-
sure. Start the engine and observe the Fuel Pressure
Set Point and the Actual Fuel Pressure. If the Actual
Fuel Pressure Oscillates above and below the Fuel
Pressure Set Point in a regular cycle, perform the
Fuel System Air Purge procedure (Refer to 14 -
FUEL SYSTEM - STANDARD PROCEDURE).
If the Actual Fuel Pressure gradually drops below
the Fuel Pressure Set Point then spikes well above
the Fuel Pressure Set Point, replace the fuel pres-
sure solenoid (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL PRESSURE SOLENOID -
REMOVAL), then perform the Fuel System Air Purgeprocedure (Refer to 14 - FUEL SYSTEM - STAN-
DARD PROCEDURE).
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM COMPONENTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines, fuel rail, and fuel injection
pump. Very tight tolerances are used with these
parts. Dirt contamination could cause rapid part
wear and possible plugging of fuel injector nozzle
tip holes. This in turn could lead to possible engine
misfire. Always wash/clean any fuel system compo-
nent thoroughly before disassembly and then air
dry. DO NOT wire brush injector nozzles when
cleaning. Cap or cover any open part after disas-
sembly. Before assembly, examine each part for
dirt, grease or other contaminants and clean if nec-
essary. When installing new parts, lubricate them
with clean engine oil or clean diesel fuel only.
STANDARD PROCEDURE - DISCONNECTING
AND CONNECTING FUEL LINES
NOTE: Capture and store any fuel spillage in appro-
priately marked containers.
(1) Disconnect negative battery cable.
(2) Push release arm to release position A, as far
as the stop (arrow) (Fig. 2).
(3) Disconnect fuel line.
(4) Immediately return the release arm back to the
assembly position, as far as the stop (Fig. 2).
The release arm must not be left in the release
position for a long time. Connectors left in the
release position for lengthy periods may leak and
must be replaced.
(5) Insert connector into connection in assembly
position (B) (Fig. 2).
(6) Ensure that the connectors are firmly seated
and free of leaks (Fig. 2).
STANDARD PROCEDURES - DRAINING WATER
FROM FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL FILTER / WATER
SEPARATOR - REMOVAL).
Fig. 1 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14 - 2 FUEL SYSTEMVA
FUEL SYSTEM (Continued)

CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The crankshaft position sensor is located opposite
the teeth on the flywheel and uses a non contact
method to record the position of the crankshaft. The
leading edges of each tooth on the flywheel generate
a positive signal in the position sensor, while the
trailing edges generate a negative signal. When the
crankshaft is rotating, an alternating voltage is pro-
duced as a result.
The period of the signal is the time required by the
crankshaft to turn through the gap between two fly-
wheel teeth. The clearance between the crankshaft
position sensor and the teeth of the flywheel is fixed
by the installation.
Two teeth on the flywheel are missing. The result-
ing signal gap is used by the ECM to detect the TDC
position of cylinder number one.
OPERATION
The clearance between the crankshaft position sen-
sor and the flywheel are fixed by the installation
position. Two teeth on the flywheel are missing. The
resulting gap is used by the ECM to detect DTC of
cylinder number one. The crankshaft position is cal-
culated to an accuracy of a fraction of a degree so
that the start and end of injection can occur at
exactly the right moment. The engine speed signal is
also processed by the ECM from the crankshaft sen-
sor. This signal is then transferred to other control
modules over the CAN bus.
If the crankshaft position sensor fails, the signal
that provides reference rotation is missing. Injection
may occur at the wrong time and damage the engine.
In this case, the ECM will stop triggering the injec-
tors, the engine would cut out, the engine warning
light would illuminate and the engine will not
restart.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Unplug the crankshaft wiring harness connec-
tor.
(3) Remove the crankshaft sensor retaining bolt
and remove sensor (Fig. 6).
INSTALLATION
(1) Position the crankshaft position sensor into the
access hole and install retaining bolt.(2) Tighten the retaining bolt to 80 lbs. in. (9 N´m)
(Fig. 6).
(3) Connect crankshaft position sensor wiring har-
ness connector (Fig. 6).
(4) Connect negative battery cable.
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR
There are individual fuel injectors for all five cyl-
inders. These fuel injectors are used to spray fuel
into the combustion chamber (Fig. 7).
OPERATION
The injector operation can be subdivided into four
operating states with the engine running and the
high-pressure pump generating pressure:
²Injector closed (with high pressure applied)
²Injector opens (start of injection)
²Injector opened fully
²Injector closes (end of injection)
Fig. 6 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
14 - 20 FUEL INJECTIONVA

Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4)
Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4)
Remove the return hose from the pump (Fig. 1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5)
Fill the power steering fluid (Refer to 19 - STEER-
ING/PUMP/FLUID - STANDARD PROCEDURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
VAPUMP 19 - 13
PUMP (Continued)