2006 MERCEDES-BENZ SPRINTER radiator

REFILLING COOLING SYSTEM
(1) Tighten the radiator drain and the cylinder
block drain plug(s) (if removed). Tighten the engine
drain plug to 30 N´m (22 lbs. ft.).
(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 raisecontainer level to the COLD MINIMUM mark after
each cool down period.
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 temperature is below 194Éf
(90Éc). Wear protective 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.
Fig. 3 DRAINING COOLANT SYSTEM
1 - DRAIN HOSE 3 - RADIATOR DRAIN PLUG
2 - ENGINE DRAIN PLUG 4 - DRAIN HOSE
VAENGINE 7 - 13

(3) Turn the level sensor 90 degrees clockwise, lift
up and out of the container (Fig. 4).
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 (Refer to 7
- COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Inspect for leaks.
RADIATOR FAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Detach coolant line from lower radiator shroud.
(3) The radiator fan assembly is attached
(threaded) to the water pump hub shaft (Fig. 5).
Remove the fan blade/viscous fan drive assembly
from the water pump by turning the mounting nut
counterclockwise as viewed from the front. Threads
on the radiator fan drive areRIGHT-HAND.A36
MM Fan Wrench should be used to prevent pulley
from rotating (Fig. 5).(4) Remove radiator fan shroud and radiator fan.
(Fig. 5).
NOTE: Store the viscous fan clutch in the upright
position. DO NOT place down flat.
INSTALLATION
(1) Install fan blade to viscous clutch. Tighten
bolts to 9 N´m (80 lbs. in.). (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 45 N´m (33 lbs. ft.). (Fig. 5)
(4) Attach coolant line to lower radiator shroud.
(5) Properly align and clip the fan shroud into
place.
(6) 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 temperature is below 90ÉC
(194ÉF). Wear protective clothing and eye wear. Risk
of poisoning if coolant is swallowed. Store coolant
in proper and appropriately marked containers.
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
7 - 14 ENGINEVA

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 headlamps.
(3) Remove front cross member together with front
grille.
(4) Remove front bumper.
(5) Remove bolts holding air charge hose to sheet
metal and intercooler.
(6) Detach air intake pipe at the body (Fig. 9).
(7) Detach both coolant hoses at the coolant reser-
voir (Fig. 9).
VAENGINE 7 - 17

(8) Unplug wiring connector at coolant level sensor
(Fig. 9).
(9) Detach coolant hose at bottom right of radiator
(Fig. 9).
(10) Detach transmission cooler lines at radiator
(Fig. 9).
(11) Remove the radiator trim from the left and
right (Fig. 9).
(12) Remove radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(13) Remove bolts securing intercooler to radiator.
(14) Remove screws and upper radiator trim from
radiator.
(15) Move condenser/intercooler/power steering
cooler assembly forward.
(16) Lift the radiator assembly up and out of the
rubber grommets (Fig. 9).
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
7 - 18 ENGINEVA

(17) Take off charge air cooler together with cool-
ing loop of the steering at the radiator (Fig. 10).
(18) Remove bottom radiator trim (Fig. 10).
(19) Detach coolant hose at radiator.
(20) Detach coolant pipe together with coolant
hose at the fan shroud.
(21) 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.
(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 (Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(22) Recharge air conditioning (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(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 124-145 kPa (18-21 psi). The pressure
relief point (in pounds) is engraved on top of the cap
The 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 124-145
kPa (18-21 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.
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
VAENGINE 7 - 19

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.
DIAGNOSIS AND TESTING - RADIATOR PRES-
SURE 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 124-145 kPa (18-21 psi). The cap is satis-
factory when the pressure holds steady. It is also
good if it holds pressure within the 124-145 kPa
(18-21 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 coolant
in suitable and appropriately marked container.
Wear protective gloves, clothes and eye wear.
Fig. 11 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
Fig. 12 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
7 - 20 ENGINEVA

(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 14 N´m (124 lbs.
in)., M8 (20 N´m (177 lbs. in.) (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 35
N´m (26 lbs. ft.) (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 (Refer to 7
- COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE). 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 - 22 ENGINEVA

NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
CYLINDER LEAK DOWN VALUES
CYLINDER LEAK
DOWN PERMISSIBLE
TOTAL LOSS  25%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT VALVES AND
CYLINDER HEAD  10%
CYLINDER LEAK
DOWN PERMISSIBLE
LOSS AT PISTON AND
RINGS  20%
STANDARD PROCEDURE - DETERMINING CYL-
INDER PRESSURE LOSS
If an increased pressure loss was found with the
cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.
Possible causes for the pressure loss are:
POSSIBLE CAUSE FOR PRESSURE LOSS
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR, AD-
JACENT CYL-
INDERS, OR
AIR BUBBLES
IN COOLANT1. Sealing Sur-
facesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace Cyl-
inder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing Sur-
faces1. Remove Cyl-
inder Head for
Further Inspec-
tion
CONDITION POSSIBLE
CAUSESCORRECTION
2. Intake
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH EX-
HAUSTSealing Surfac-
esRemove Cylin-
der Head for
Further Inspec-
tion
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing Sur-
facesRemove Engine
for Further In-
spection
2. Pistons, Pis-
ton Rings2. Replace Pis-
tons or Piston
Rings
It is possible to pin point the pressure loss of the
relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.
Determining the cause can be falsified by the posi-
tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
REMOVAL
REMOVAL - ENGINE COVER
(1) Remove the retaining screws and remove cover
(Fig. 2).
9 - 4 ENGINEVA