2005 MERCEDES-BENZ SPRINTER transmission fluid

COOLING
TABLE OF CONTENTS
page page
COOLING
OPERATIONÐCOOLING SYSTEM...........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS.............................1DIAGNOSIS AND TESTING - COOLING
SYSTEM.............................2
ACCESSORY DRIVE.......................5
ENGINE................................9
COOLING
OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
VACOOLING 7 - 1

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)

The TCM continuously checks for electrical prob-
lems, mechanical problems, and some hydraulic prob-
lems. When a problem is sensed, the TCM stores a
diagnostic trouble code (DTC). Some of these codes
cause the transmission to go into9Limp-In9or
9default9mode. Some DTCs cause permanent
Limp-In and others cause temporary Limp-In. The
NAG1 defaults in the current gear position if a DTC
is detected, then after a key cycle the transmission
will go into Limp-in, which is mechanical 2nd gear.
Some DTCs may allow the transmission to resume
normal operation (recover) if the detected problem
goes away. A permanent Limp-In DTC will recover
when the key is cycled, but if the same DTC is
detected for three key cycles the system will not
recover and the DTC must be cleared from the TCM
with the DRBIIItscan tool.
TCM SIGNALS
The TCM registers one part of the input signals by
direct inputs, the other part by CAN C bus. In addi-
tion to the direct control of the actuators, the TCM
sends various output signals by CAN C bus to other
control modules.
Selector Lever Position
The TCM monitors the SLA for all shift lever posi-
tions via the CAN bus.
ATF Temperature Sensor
The ATF temperature sensor is a positive temper-
ature co-efficient (PTC) thermistor. It measures the
temperature of the transmission fluid and is a direct
input signal for the TCM. The temperature of the
ATF has an influence on the shifttime and resulting
shift quality. As the temperature rises, resistance
rises, and therefore, the probing voltage is decreas-
ing. Because of its registration, the shifting process
can be optimized in all temperature ranges.
The ATF temperature sensor is wired in series
with the park/neutral contact. The temperature sig-
nal is transmitted to the TCM only when the reed
contact of the park/neutral contact is closed because
the TCM only reads ATF temperature while in any
forward gear, or REVERSE. When the transmission
is in PARK or NEUTRAL, the TCM will substitute
the engine temperature for the ATF temperature.
Starter Interlock
The TCM monitors a contact switch wired in series
with the transmission temperature sensor to deter-
mine PARK and NEUTRAL positions. The contact
switch is open in PARK and NEUTRAL. The TCM
senses transmission temperature as high (switch
supply voltage), confirming switch status as open.
The TCM then broadcasts a message over CAN bus
to confirm switch status. The PCM receives thisinformation and allows operation of the starter cir-
cuit.
N2 and N3 Speed Sensors
The N2 and N3 Input Speed Sensors are two Hall-
effect speed sensors that are mounted internally in
the transmission and are used by the TCM to calcu-
late the transmission's input speed. Since the input
speed cannot be measured directly, two of the drive
elements are measured. Two input speed sensors
were required because both drive elements are not
active in all gears.
CAN C Bus Indirect Input Signals
A 2.5-volt bias (operating voltage) is present on the
CAN C bus any time the ignition switch is in the
RUN position. Both the TCM and the ABS apply this
bias. On this vehicle, the CAN C bus is used for mod-
ule data exchange only. The indirect inputs used on
the NAG1 electronic control system are:
²Wheel Speed Sensors.
²Brake Switch.
²Engine RPM.
²Engine Temperature.
²Cruise Control Status.
²Gear Limit Request.
²Throttle Position - 0% at idle, 100% at WOT. If
open, TCM assumes idle (0% throttle opening).
²Odometer Mileage
²Maximum Effective Torque.
²Engine in Limp-In Mode/Mileage Where DTC
Was Set.
BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)
The BTSI solenoid prevents shifting out of the
PARK position until the ignition key is in the RUN
position and the brake pedal is pressed. The TCM
controls the ground while the ignition switch supplies
power to the BTSI solenoid. The PCM monitors the
brake switch and broadcasts brake switch status
messages over the CAN C bus. If the park brake is
depressed and there is power (Run/Start) to SLA, the
BTSI solenoid deactivates.
SHIFT SCHEDULES
The basic shift schedule includes up and down-
shifts for all five gears. The TCM adapts the shift
program according to driving style, accelerator pedal
position and deviation of vehicle speed. Influencing
factors are:
²Road Conditions.
²Incline, Decline and Altitude.
²Trailer Operation, Loading.
²Engine Coolant Temperature.
²Cruise Control Operation.
²Sporty Driving Style.
8E - 6 ELECTRONIC CONTROL MODULESVA
TRANSMISSION CONTROL MODULE (Continued)

INDICATORS
Indicators are located in various positions within
the EMIC and are all connected to the EMIC elec-
tronic circuit board. The ambient temperature indica-
tor (optional), brake indicator, brake wear indicator,
charging indicator, coolant low indicator, high beam
indicator, low fuel indicator, seatbelt indicator, turn
signal indicators, and washer fluid indicator operate
based upon hard wired inputs to the EMIC. The air-
bag (SRS) indicator is normally controlled by a hard
wired input from the Airbag Control Module (ACM);
however, if the EMIC sees an abnormal or no input
from the ACM, it will automatically turn the airbag
indicator On until the hard wired input from the
ACM has been restored. The Malfunction Indicator
Lamp (MIL) is normally controlled by CAN data bus
messages from the Engine Control Module (ECM);
however, if the EMIC loses CAN data bus communi-
cation, the EMIC circuitry will automatically turn
the MIL on until CAN data bus communication is
restored. The EMIC uses CAN data bus messages
from the ECM, the ACM, and the Controller Antilock
Brake to control all of the remaining indicators.
The various EMIC indicators are controlled by dif-
ferent strategies; some receive battery feed from the
EMIC circuitry and have a switched ground, while
others are grounded through the EMIC circuitry and
have a switched battery feed. However, all indicators
are completely controlled by the EMIC microproces-
sor based upon various hard wired and electronic
message inputs. Except for the indications provided
by the multi-function indicator Liquid Crystal Dis-
play (LCD) unit, all indicators are illuminated at a
fixed intensity, which is not affected by the selected
illumination intensity of the EMIC general illumina-
tion lamps.
The hard wired indicator inputs may be diagnosed
using conventional diagnostic methods. However,
proper testing of the EMIC circuitry and the CAN
bus message controlled indicators requires the use of
a DRBIIItscan tool. Refer to the appropriate diag-
nostic information. Specific details of the operation
for each indicator may be found elsewhere in this
service information.
CLUSTER ILLUMINATION
The EMIC has several general illumination lamps
that are illuminated when the exterior lighting is
turned on with the multi-function switch. The illumi-
nation intensity of these lamps is adjusted by a dim-
ming level input received from the multi-function
indicator ª+º (plus) and ª±º (minus) switch push but-
tons that extend through the lower edge of the clus-
ter lens below the right end of the multi-function
indicator. When the exterior lighting is turned Off,
the display is illuminated at maximum brightness.When the exterior lighting is turned On and the
transmission gear selector is in the Park position,
depressing the plus switch push button brightens the
display lighting, and depressing the minus switch
push button dims the display lighting. The EMIC
also provides a Pulse-Width Modulated (PWM) panel
lamps dimmer output that can be used to synchro-
nize the illumination lighting levels of external illu-
mination lamps (up to about 23 to 30 watts) with
that of the EMIC.
The hard wired multi-function switch input and
the EMIC panel lamps dimmer output may be diag-
nosed using conventional diagnostic methods. How-
ever, proper testing of the PWM control of the EMIC
and the electronic dimming level inputs from the
multi-function indicator push buttons requires the
use of a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
INPUT AND OUTPUT CIRCUITS
HARD WIRED INPUTS
The hard wired inputs to the EMIC include the fol-
lowing:
NOTE: Final approved circuit names were not yet
available at the time this information was compiled.
²Airbag Indicator Driver
²Ambient Temperature Sensor Signal
(Optional)
²Brake Wear Indicator Sense
²Charging Indicator Driver
²Coolant Level Switch Sense
²Front Door Jamb Switch Sense
²Fuel Level Sensor Signal
²Fused B(+)
²Fused Ignition Switch Output
²High Beam Indicator Driver
²Key-In Ignition Switch Sense
²Left Turn Signal
²Park Brake Switch Sense
²Right Turn Signal
²Seat Belt Switch Sense
²Washer Fluid Switch Sense (Optional)
Refer to the appropriate wiring information for
additional details.
HARD WIRED OUTPUTS
The hard wired outputs of the EMIC include the
following:
NOTE: Final approved circuit names were not yet
available at the time this information was compiled.
²Engine Running Relay Control
²Panel Lamps Driver
8J - 6 INSTRUMENT CLUSTERVA
INSTRUMENT CLUSTER (Continued)

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

(11) Install the transmission cooler lines to trans-
mission.(Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(12) Install transmission electrical connector and
shifter hardware.Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(13) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(14) Install the crank sensor.
(15) Install the starter.
(16) Connect the ground strap (left side).
(17) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(18) Lower the vehicle.
(19) Install the air inlet hose at the turbocharger
(Fig. 3).
(20) Connect the vacuum hose at the turbocharger
(Fig. 3).
(21) Connect the coolant supply and return hoses
(Fig. 3).(22) Connect the brake booster vacuum hose at the
vacuum pump (Fig. 3).
(23) Connect the refrigerant lines (Fig. 3).
(24) Connect the fuel lines at the filter assembly
(Fig. 3).
(25) Connect the power steering hoses (Fig. 3).
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser.
(28) Install air cleaner housing, sensors, and hoses
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).
(29) Route the engine wiring harness inside the
vehicle and connect.
(30) Install the front grill assembly.
(31) Install and align the hood.
(32) Connect the negative battery cable.
(33) Check and fill engine oil.
(34) Fill cooling system to proper level with the
appropriate coolant.
(35) Evacuate and recharge air conditioning.
(36) Check and refill all ancillary system fluid lev-
els.
(37) Start engine and inspect for leaks.
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge
Distribution Pipe to Air
Charge Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to
Cylinder Head14 - 124
12m-Bolt-Cylinder Head to
Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44 -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque
angle)55, 90É 40 -
Bolt-End Cover to
Crankcase9-80
9 - 8 ENGINEVA
ENGINE (Continued)

(5) Remove calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) (Fig. 7)
(6) Cut tie straps holding wheel speed sensor and
brake pad wear sensor wire harness to the cradle.
(7) Cut tie straps holding transmission harness to
the cradle.
(8) Remove lower pinch bolt from steering shaft
and disconnect shaft. (Fig. 8)
(9) Siphon the power steering fluid out of the res-
ervoir.
(10) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 8).
(11) Remove bolt and remove power steering hose
support bracket from the cradle. (Fig. 9)
Fig. 7 FRONT DISC BRAKE CALIPER
1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS
Fig. 8 STEERING GEAR
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
Fig. 9 POWER STEERING HOSE BRACKET
1 - POWER STEERING LINE
2 - SUPPORT BRACKET BOLT
VAFRAME & BUMPERS 13 - 7
ENGINE CRADLE CROSSMEMBER (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................2COLUMN...............................5
GEAR..................................8
LINKAGE..............................10
PUMP.................................12
STEERING
DESCRIPTION
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
VASTEERING 19 - 1