2005 MERCEDES-BENZ SPRINTER Fluid
[x] Cancel search: FluidPage 317 of 1232
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
Page 393 of 1232
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
Page 467 of 1232
8W-35 ANTILOCK BRAKES
Component Page
Automatic Temperature Control Module . . 8W-35-2
Brake Fluid Level Switch.............. 8W-35-7
Brake Lamp Switch................ 8W-35-3, 4
Brake Wear Sensor- Left Front......... 8W-35-8
Brake Wear Sensor- Left Rear.......... 8W-35-8
Brake Wear Sensor- Right Front........ 8W-35-8
Brake Wear Sensor- Right Rear......... 8W-35-8
Center High Mounted Stop Lamp....... 8W-35-3
Controller Antilock Brake...... 8W-35-2, 3, 4, 5, 6
Data Link Connector................. 8W-35-5
Daytime Running Lamps Relay......... 8W-35-2
Fuse 2............................ 8W-35-5
Fuse 3............................ 8W-35-5
Fuse 5............................ 8W-35-3
Fuse 6............................ 8W-35-5
Fuse 7............................ 8W-35-5
Fuse 9............................ 8W-35-5
Fuse Block No. 1.................... 8W-35-3
Fuse/Relay Block.................... 8W-35-5
G100.............................. 8W-35-4Component Page
G200............................ 8W-35-7, 8
G202.............................. 8W-35-7
G203.............................. 8W-35-2
G300.............................. 8W-35-8
G302.............................. 8W-35-4
Instrument Cluster................. 8W-35-7, 8
Optional Equipment Relay............. 8W-35-5
Parking Brake Switch................ 8W-35-7
Power Distribution Center............. 8W-35-5
Relay Block........................ 8W-35-5
Shifter Assembly.................... 8W-35-3
Tail Lamp Assembly- Left.............. 8W-35-3
Tail Lamp Assembly- Right............ 8W-35-3
TCS Switch........................ 8W-35-2
Wheel Speed Sensor- Left Front......... 8W-35-6
Wheel Speed Sensor- Left Rear......... 8W-35-6
Wheel Speed Sensor- Right Front........ 8W-35-6
Wheel Speed Sensor- Right Rear........ 8W-35-6
VA8W-35 ANTILOCK BRAKES 8W - 35 - 1
Page 489 of 1232
8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-3
Ambient Temperature Sensor........... 8W-40-8
Automatic Temperature Control
Module........................ 8W-40-4, 8
Battery............................ 8W-40-2
Brake Fluid Level Switch.............. 8W-40-3
Brake Wear Sensor- Left Front......... 8W-40-5
Brake Wear Sensor- Left Rear.......... 8W-40-5
Brake Wear Sensor- Right Front........ 8W-40-5
Brake Wear Sensor- Right Rear......... 8W-40-5
Courtesy Lamp- Driver Door........... 8W-40-6
Courtesy Lamp- Passenger Door........ 8W-40-6
D+ Relay No. 1...................... 8W-40-8
Data Link Connector................. 8W-40-3
Dome Lamp........................ 8W-40-6
Door Jamb Switch- Driver............. 8W-40-6
Door Jamb Switch- Passenger.......... 8W-40-6
Engine Coolant Level Switch........... 8W-40-7
Fuel Level Sensor.................... 8W-40-3
Fuse 1............................ 8W-40-2
Fuse 3............................ 8W-40-6
Fuse 6............................ 8W-40-3
Fuse 18............................ 8W-40-2Component Page
Fuse Block No. 1.................... 8W-40-2
Fuse Block No. 2.................. 8W-40-3, 6
G100.............................. 8W-40-7
G200.......................... 8W-40-2, 3, 5
G202.......................... 8W-40-3, 7, 8
G203.............................. 8W-40-6
G300.............................. 8W-40-5
Generator.......................... 8W-40-2
Headlamp Assembly- Left.............. 8W-40-7
Headlamp Assembly- Right............ 8W-40-7
Ignition Lock Switch................. 8W-40-2
Instrument Cluster....... 8W-40-2, 3, 4, 5, 6, 7, 8
Instrument Panel Socket.............. 8W-40-6
Parking Brake Switch................ 8W-40-3
Power Distribution Center............. 8W-40-2
Radio............................. 8W-40-8
Seat Belt Switch..................... 8W-40-7
Security System Module............... 8W-40-6
Sentry Key Remote Entry Module....... 8W-40-4
Turn Signal/Anti-Theft Alarm Relay- Left . 8W-40-8
Turn Signal/Anti-Theft Alarm Relay-
Right........................... 8W-40-8
VA8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
Page 627 of 1232
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Control Module-Roof.............. 8W-80-4
A/C Fan Switch..................... 8W-80-4
A/C Switch-Roof..................... 8W-80-4
Accelerator Pedal Position Sensor....... 8W-80-5
Air Outlet Temperature Sensor......... 8W-80-5
Airbag Control Module................ 8W-80-5
Airbag Squib-Driver.................. 8W-80-5
Airbag Squib-Passenger............... 8W-80-6
Ambient Temperature Sensor........... 8W-80-6
Ash Receiver Lamp.................. 8W-80-6
Automatic Temperature Control
Module C1....................... 8W-80-6
Automatic Temperature Control
Module C2....................... 8W-80-7
Auxiliary Heater Relay (In Relay Block) . . 8W-80-9
Auxiliary Heater Switch............... 8W-80-9
Battery Relay-Auxiliary............... 8W-80-9
Blower Motor Resistor Block........... 8W-80-9
Blower Motor Resistor Block C1......... 8W-80-9
Blower Motor Resistor Block C2........ 8W-80-10
Blower Motor Resistor Block C3........ 8W-80-10
Blower Motor-Front................. 8W-80-10
Body Plug Connector................ 8W-80-10
Boost Pressure Sensor............... 8W-80-10
Boost Pressure Solenoid.............. 8W-80-11
Brake Fluid Level Switch............. 8W-80-11
Brake Lamp Switch C1............... 8W-80-11
Brake Lamp Switch C2............... 8W-80-11
Brake Wear Sensor-Left Front......... 8W-80-11
Brake Wear Sensor-Left Rear.......... 8W-80-12
Brake Wear Sensor-Right Front........ 8W-80-12
Brake Wear Sensor-Right Rear......... 8W-80-12
C100............................. 8W-80-12
C100............................. 8W-80-12
C101............................. 8W-80-13
C101............................. 8W-80-13
C200............................. 8W-80-13
C200............................. 8W-80-14
C201............................. 8W-80-14
C201............................. 8W-80-15
C202............................. 8W-80-15
C202............................. 8W-80-15
C203............................. 8W-80-16
C203............................. 8W-80-16
C204............................. 8W-80-16
C204............................. 8W-80-16
C205............................. 8W-80-17
C205............................. 8W-80-17
C206............................. 8W-80-17
C206............................. 8W-80-17
C207............................. 8W-80-18
C207............................. 8W-80-18Component Page
C208............................. 8W-80-18
C208............................. 8W-80-18
C209............................. 8W-80-18
C209............................. 8W-80-19
C210............................. 8W-80-19
C210............................. 8W-80-19
C211 ............................. 8W-80-19
C211 ............................. 8W-80-19
C214............................. 8W-80-20
C214............................. 8W-80-20
C215............................. 8W-80-20
C215............................. 8W-80-20
C216............................. 8W-80-20
C216............................. 8W-80-20
C217............................. 8W-80-21
C217............................. 8W-80-21
C218............................. 8W-80-21
C218............................. 8W-80-21
C219............................. 8W-80-22
C219............................. 8W-80-22
C220............................. 8W-80-22
C220............................. 8W-80-22
C221............................. 8W-80-23
C221............................. 8W-80-23
C224............................. 8W-80-23
C224............................. 8W-80-23
C225............................. 8W-80-23
C225............................. 8W-80-24
Cabin Heater Assembly C1............ 8W-80-24
Cabin Heater Assembly C2............ 8W-80-24
Camshaft Position Sensor............. 8W-80-24
Center High Mounted Stop Lamp....... 8W-80-24
Central Timer Module C1............. 8W-80-25
Central Timer Module C2............. 8W-80-25
Cigar Lighter...................... 8W-80-25
Cigar Lighter Lamp................. 8W-80-26
Circulation Pump (Cabin Heater
Module)........................ 8W-80-26
Circulation Pump (Rest System)........ 8W-80-26
Circulation Pump Diode.............. 8W-80-26
Clockspring C1..................... 8W-80-26
Clockspring C2..................... 8W-80-27
Controller Antilock Brake............. 8W-80-27
Courtesy Lamp-Driver Door........... 8W-80-27
Courtesy Lamp-Left Sliding Door....... 8W-80-27
Courtesy Lamp-Passenger Door........ 8W-80-28
Courtesy Lamp-Right Sliding Door...... 8W-80-28
Crankcase Heater................... 8W-80-28
Crankshaft Position Sensor........... 8W-80-28
Ctel Connector..................... 8W-80-28
Cylinder Lock Switch-Driver.......... 8W-80-29
Data Link Connector................ 8W-80-29
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
Page 637 of 1232
BOOST PRESSURE SOLENOID - BLACK
CAV CIRCUIT FUNCTION
1 20WT BOOST PRESSURE SOLENOID CONTROL
2 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY
BRAKE FLUID LEVEL SWITCH
CAV CIRCUIT FUNCTION
1 20BR/YL PARKING BRAKE SIGNAL
2 16BR GROUND
BRAKE LAMP SWITCH C1
CAV CIRCUIT FUNCTION
1 20WT BRAKE SWITCH OUTPUT
2 16RD/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 20BK/BL/RD BRAKE LAMP SWITCH
BRAKE LAMP SWITCH C2 - BLACK
CAV CIRCUIT FUNCTION
1 20BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 20BK/RD BRAKE LAMP SWITCH OUTPUT
BRAKE WEAR SENSOR-LEFT FRONT
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11
Page 696 of 1232
CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Blower Motor Resistor Block
C1Instrument Panel 15
Blower Motor Resistor Block
C2Instrument Panel 15
Blower Motor Resistor Block
C3Instrument Panel 15
Blower Motor-Front Underhood Right (To The
Instrument Panel)4
Body Plug Connector Under Driver Seat N/S
Boost Pressure Sensor Engine Compartment-Left 5
Brake Fluid Level Switch Engine Compartment 3
Brake Lamp Switch C1 Pedals Area (Brake) 14
Brake Lamp Switch C2 Pedals Area (Brake) 14
Brake Wear Sensor-Left
FrontOn Left Front Wheel N/S
Brake Wear Sensor-Left Rear On Left Rear Wheel N/S
Brake Wear Sensor-Right
FrontOn Right Front Wheel N/S
Brake Wear Sensor-Right
RearOn Right Rear Wheel N/S
C100 Under Driver Seat 18
C101 Under Instrument Panel-Left 14
C200 Under Instrument Panel-Left 11
C201 Under Instrument Panel-Left 11
C202 Under Instrument Panel-Left 11
C203 Instrument Panel N/S
C204 Upper Instrument Panel-Left 11
C205 Under Driver Seat N/S
C206 Instrument Panel N/S
C207 Near Interior Light Switch-Driver N/S
C208 Near A/C Fan Switch N/S
C209 Instrument Panel N/S
C210 Instrument Panel N/S
C211 Instrument Panel N/S
C212 Instrument Panel N/S
C213 Instrument Panel N/S
C214 Instrument Panel N/S
C215 Instrument Panel N/S
C216 Instrument Panel N/S
C217 Instrument Panel N/S
C218 Under Driver Seat 18
C219 Under Driver Seat 19
C220 Instrument Panel N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 742 of 1232
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
CYLINDER 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,
ADJACENT
CYLINDERS,
OR AIR
BUBBLES IN
COOLANT1. Sealing
SurfacesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace
Cylinder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing
Surfaces1. Remove
Cylinder Head
for Further
Inspection
2. Intake Valves
and Seats2. Replace
Valves, Guides
or Seats
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
EXHAUSTSealing
SurfacesRemove
Cylinder Head
for Further
Inspection
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing
SurfacesRemove Engine
for Further
Inspection
2. Pistons,
Piston Rings2. Replace
Pistons 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).
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.
CAUTION: STORE OR DISCARD ALL FLUIDS IN
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS.
(1) Disconnect the negative battery cable.
9 - 4 ENGINEVA
ENGINE (Continued)