2006 MERCEDES-BENZ SPRINTER sensor

(6) Remove the metal cover over the sensor.
(7) Disconnect the electrical connector (Fig. 16).
(8) Remove the Yaw rate/lateral Acceleration Sen-
sor.
INSTALLATION
(1) Reconnect the yaw rate/lateral acceleration
sensor electrical connector (Fig. 16).
(2) Install the yaw rate/lateral acceleration sensor.
(3) Install the metal cover over top of the sensor.
(4) Install the screws securing the yaw rate/lateral
acceleration sensor (Fig. 15). Tighten to 6 N´m (53
in.lbs).(5) Install the bracket with the control modules
(Fig. 14).
(6) Install the cover for the drivers seat (Fig. 13).
(7) Return the drivers seat to normal position.
(8) Reconnect the battery.
(9) Perform diagnosis quick check and road test
the vehicle.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor, low
pressure accumulators, inlet valves, outlet valves and
noise attenuators.
REMOVAL
NOTE: Store the Hydraulic Control Unit in an
upright position only.
(1) Disconnect the ground cable at the battery.
The ignition switch must be switched to the off
position when disconnecting the battery cable.
(2) Disconnect the multiplug from the control mod-
ule (Fig. 17).
(3) Disconnect the brake lines from the hydraulic
control unit (Fig. 17).Mark the brake lines for
reinstallation, also seal off the connections and
lines to prevent contamination.
(4) Remove the hydraulic control unit from the
bracket (Fig. 17).
(5) Check the rubber mounts on the bracket.
(Replace if necessary) (Fig. 17).
Fig. 15 SENSOR REMOVE/INSTALL
1 - SCREWS
2 - YAW RATE/LATERAL ACCELERATION SENSOR
Fig. 16 ELECTRICAL CONNECTOR
1 - YAW RATE/ATERAL ACCELERATION SENSOR
2 - ELECTRICAL CONNECTOR
Fig. 17 HYDRAULIC CONTROL UNIT (ABS)
1 - BRAKE LINES
2 - HCU WITH CONTROL MODULE
3 - ABS/ABD CONTROL MODULE MULTIPLUG
4 - RUBBER SUPPORT
5 - 36 BRAKES - ABSVA

CONDITION POSSIBLE CAUSES CORRECTION
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANI-
CAL - DIAGNOSIS AND TESTING)
TEMPERATURE GAUGE READ-
ING INCONSISTENT ( ERRATIC,
CYCLES OR FLUCTUATES)1. Heavy duty cooling system, ex-
tream cold ambient (outside) tem-
perature or heater blower motor in
high position.1. None. System operating norma-
ly.
2. Temperature gauge or gauge
sensor defective.2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD PROCE-
DURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water
pump.6. Check for leak. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM
AND /OR COOLANT INTO RES-
ERVOIR BOTTLE. (TEMPERA-
TURE GAUGE MAY READ HIGH)1. Radiator cap defective. 1. Replace radiator cap.
2. Radiator neck surface damaged. 2. Replace radiator.
HOSE OR HOSES COLLAPSE
WHEN ENGINE IS COOLING.1. Vacuum created in cooling sys-
tem on engine cool-down is not
being relieved through coolant re-
servior/overflow system.1. Replace radiator cap, check vent
hose between radiator and reser-
voir bottle for blockage also check
reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
2. Thermal viscous fan drive. 2. None. Normal condition.
3. Fan blades striking surrounding
objects.3. Locate contact point and repair
as necessary.
4. Thermal viscous fan drive bear-
ing.4. Replace viscous fan drive as-
sembly.
5. Obstructed air flow through radi-
ator.5. Remove obstruction.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING SYS-
TEM SUSPECTED)1. Radiator and/or A/C condenser
air flow obstructed.1. Remove obstruction and/or
clean.
2. Thermal viscous fan drive not
working.2. Check fan drive. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
3. Air seals around radiator dam-
aged or missing.3. Inspect air seals, repair or re-
place as necessary.
VACOOLING 7 - 3

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION..........................9
DIAGNOSIS AND TESTING
COOLING SYSTEM LEAKS..............10
STANDARD PROCEDURE
ADDING ADDITIONAL COOLANT.........12
DRAINING COOLING SYSTEM...........12
REFILLING COOLING SYSTEM...........13
COOLANT LEVEL SENSOR
REMOVAL.............................13
INSTALLATION.........................14
RADIATOR FAN
REMOVAL.............................14
INSTALLATION.........................14
ENGINE BLOCK HEATER
REMOVAL.............................14
INSTALLATION.........................15
ENGINE COOLANT TEMP SENSOR
DESCRIPTION.........................15REMOVAL.............................15
INSTALLATION.........................15
ENGINE COOLANT THERMOSTAT
REMOVAL.............................16
INSTALLATION.........................16
FAN DRIVE VISCOUS CLUTCH
REMOVAL.............................17
INSTALLATION.........................17
RADIATOR
REMOVAL.............................17
INSTALLATION.........................19
RADIATOR PRESSURE CAP
DESCRIPTION.........................19
OPERATION...........................20
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP......................20
WATER PUMP
REMOVAL.............................20
INSTALLATION.........................22
COOLANT
DESCRIPTION
Coolant flows through the engine water jackets
and cylinder heads absorbing heat produced by the
engine during operation. The coolant carries heat to
the radiator and heater core. Here it is transferred to
ambient air passing through the radiator and heater
core fins.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37É C (-35É F). The antifreeze
concentrationmust alwaysbe a minimum of 44 per-
cent, year-round in all climates.If percentage is
lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7É C (-90É F). A higher
percentage will freeze at a warmer temperature.
Also, a higher percentage of antifreeze can cause the
engine to overheat because the specific heat of anti-
freeze is lower than that of water.100 Percent Ethylene - Glycol - Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149É C (300É F). This temperature is hot enough to
melt plastic and soften solder. The increased temper-
ature can result in engine detonation. In addition,
100 percent ethylene-glycol freezes at -22É C (-8É F ).
Propylene - glycol Formulations - Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.It's overall effec-
tive temperature range is smaller than that of ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32É C (-26É F). 5É C higher than ethyl-
ene-glycol's freeze point. The boiling point (protection
against summer boil-over) of propylene-glycol is 125É
C (257ÉF)at96.5 kPa (14 psi), compared to 128É C
(263É F) for ethylene-glycol. Use of propylene-glycol
can result in boil-over or freeze-up in Chrysler vehi-
cles, which are designed for ethylene-glycol. Propy-
lene glycol also has poorer heat transfer
characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain
conditions.
VAENGINE 7 - 9

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

(1) Disconnect the negative battery cable.
(2) Drain the cooling system.
(3) Record the location and snip the wire ties.
(4) Unscrew the engine block heater from the core
plug hole and remove (Fig. 6).
INSTALLATION
(1) Screw the block heater into the core hole (Fig.
6).
(2) Route the heater wiring harness away from
and interference and secure with wiring tie straps.
(3) Refill the cooling system.
(4) Connect the negative battery cable.
(5) Start the engine and inspect for leaks.
ENGINE COOLANT TEMP SEN-
SOR
DESCRIPTION
The ECM determines the operating temperature of
the engine by using the signal from the coolant tem-
perature sensor. The coolant temperature sensor has
a negative temperature coefficient (NTC) resistor
contained in the plastic housing. NTC means; the
higher the temperature, then the lower the resis-
tance. The ECM also uses the coolant temperature
sensor signal to calculate glow plug relay triggering.
If the coolant temperature sensor fails during opera-
tion, the ECM will switch on the cooling fan to pre-
vent engine overheating (A/C models only).
REMOVAL
WARNING: Risk of injury to skin and eyes from
scalding with hot coolant. Risk of poisoning from
swallowing coolant. Do not open cooling system
unless coolant temperature is below 90ÉC. Open
cap slowly to release pressure. Store coolant in
suitable and appropriately marked container. Wear
protective gloves, clothes and eye wear.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partailly drain coolant system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Unplug coolant temperature sensor electrical
connector.
NOTE: Capture any residual coolant that may flow.
(5) Remove coolant temperature sensor (Fig. 7).
INSTALLATION
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.
(1) Position and install coolant temperature sensor
(Fig. 7).
(2) Connect coolant temperature sensor electrical
connector (Fig. 7).
Fig. 6 ENGINE BLOCK HEATER
1 - ENGINE BLOCK HEATER
2 - CORE PLUG
3 - ENGINE MOUNT
4 - WIRING TIE STRAPS
Fig. 7 ENGINE COOLANT TEMPERATURE SENSOR
1 - RETAINING CLAMP
2 - ENGINE COOLANT TEMPERATURE SENSOR
VAENGINE 7 - 15

(3) Refill coolant system to proper level with
proper mixture of coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(5) Connect negative battery cable.
WARNING: Use extreme caution when engine is
operating. Do not stand in a direct line with fan. do
not put your hands near pulleys, belts or fan. Do
not wear loose clothes.
(6) Start engine and inspect for leaks.
ENGINE COOLANT THERMO-
STAT
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES AND EYE WEAR.
NOTE: Inspect condition of all clamps and hoses,
replace as necessary.
(1) Disconnect negative battery cable.
(2) Partially drain engine coolant (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(3) Unplug connector, pull off locking element and
pull out coolant temperature sensor.
(4) Detach air intake hose at charge air distribu-
tion pipe.
(5) Detach coolant hoses at thermostat housing.
(6) Unscrew cap at oil filter housing.
(7) Remove thermostat housing (Fig. 8).(8) Clean all sealing surfaces.
INSTALLATION
(1) Clean all sealing surfaces.
(2) Position and install thermostat housing with
new gasket (Fig. 8). Tighten bolts to 9N´m (80
lbs.in.).
NOTE: Inspect condition of all clamps and hoses,
replace as necessary.
(3) Install cap at oil filter housing.
(4) Connect coolant hoses and vent hose (Fig. 8).
(5) Attach air intake hose at charge air distribu-
tion pipe.
(6) Close coolant drain.
(7) Connect negative battery cable.
(8) Fill coolant system to proper level with appro-
priate coolant mixture (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE).
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(9) Start engine and inspect for leaks.
Fig. 8 THERMOSTAT HOUSING ASSEMBLY
1 - O-RING
2 - CLAMP
3 - COOLANT TEMPERATURE SENSOR
4 - FUEL LINE W/BRACKET
5 - THERMOSTAT HOUSING ASSEMBLY
6 - COOLANT HOSE
7 - CLAMP
8 - COOLANT HOSE
9 - GASKET
7 - 16 ENGINEVA

(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