Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 199
CONDITION
POSSIBLE CAUSES
CORRECTION
LONGITUDAL BELT CRACKING
1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn
away rubber to tensile member
2. Replace belt
9
GROOVE JUMPING”
(Belt does not maintain correct po-
sition on pulley)
1. Incorrect belt tension
1. Inspect/Replace tensioner if nec-
essary
2. Pulley(s) not within design toler-
ance
2. Replace pulley(s)
3. Foreign object(s) in grooves
3. Remove foreign objects from
grooves
4. Pulley misalignment
4. Align component
5. Belt cordline is broken
5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Incorrect belt tension
1. Replace Inspect/Replace ten-
sioner if necessary
2. Tensile member damaged dur-
ing belt installation
2. Replace belt
3. Severe misalignment
3. Align pulley(s)
4. Bracket, pulley, or bearing fail-
ure
4. Replace defective component
and belt
NOISE (Objectional squeal,
squeek, or rumble is heard or felt
while drive belt is in operation)
1. Incorrect belt tension
1. Inspect/Replace tensioner if nec-
essary
2. Bearing noise
2. Locate and repair
3. Belt misalignment
3. Align belt/pulley(s)
4. Belt to pulley mismatch
4. Install correct belt
5. Driven component induced vi-
bration
5. Locate defective driven compo-
nent and repair
6. System resonent frequency in-
duced vibration
6. Vary belt tension within specifi-
cations
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside, circum-
ference of belt has cracked or sep-
arated from body of belt)
1. Tension sheeting contacting sta-
tionary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
1. Incorrect belt tension
1. Inspect/Replace tensioner if nec-
essary
2. Belt contacting stationary object
2. Replace belt
3. Pulley(s) out of tolerance
3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt
VA
ACCESSORY DRIVE
7 - 7
REMOVAL
REMOVAL
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
(1) Remove A/C compressor drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(2) A 3/8 inch square hole is provided in the auto-
matic belt tensioner. Attach a 3/8 inch drive-long
handle ratchet to this hole (Fig. 3).
(3) Rotate ratchet and tensioner assembly counter-
clockwise (as viewed from front) until tension has
been relieved from belt (Fig. 3).
(4) Remove belt from water pump pulley first.
(5) Remove belt from vehicle.
REMOVAL
(1) Loosen tension adjuster.
(2) Remove A/C compressor drive belt.
INSTALLATION
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be the correct length and routed cor-
rectly. If not, engine may overheat due to water
pump rotating in wrong direction.
(1) Position drive belt over all pulleys except
water pump pulley (Fig. 4).
(2) Attach a 3/8 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner counterclock-
wise. Place belt over water pump pulley. Let ten-
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
(4) Install A/C compressor drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
INSTALLATION
(1) Position A/C compressor drive belt over crank-
shaft pulley and A/C compressor pulley.
(2) Tighten drive belt tensioner.
Fig. 3 DRIVE BELT TENSIONER
1 - ACCESSORY DRIVE BELT TENSIONER
2 - RATCHET WRENCH
Fig. 4 ACCESSORY DRIVE BELT ROUTING
1 - A/C COMPRESSOR
2 - POWER STEERING
3 - DRIVE BELT TENSIONER
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - GENERATOR
7 - IDLER PULLEY
7 - 8
ACCESSORY DRIVE
VA
ENGINE
TABLE OF CONTENTS
page
page
COOLANT
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . 10
COOLANT LEVEL SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 14
RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE BLOCK HEATER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE COOLANT TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE COOLANT THERMOSTAT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 16
FAN DRIVE VISCOUS CLUTCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 17
RADIATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 19
RADIATOR PRESSURE CAP
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - RADIATOR
. . . . . . . . . . . . . . . . . . . . . . 20
WATER PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 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 -37° C (-35° F). The antifreeze
concentration must always be 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 -67.7° C (-90° 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
149° C (300° 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 -22° C (-8° 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 -32° C (-26° F). 5° C higher than ethyl-
ene-glycol’s freeze point. The boiling point (protection
against summer boil-over) of propylene-glycol is 125°
C (257° F ) at 96.5 kPa (14 psi), compared to 128° C
(263° 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.
VA
ENGINE
7 - 9
Propylene - glycol / Ethylene - glycol Mixtures - Should Not
Be Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol
Mixtures
can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
DIAGNOSIS AND TESTING
COOLING SYSTEM LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate engine until radiator
upper hose is warm to touch. Aim the commercially
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 1).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: Hot, pressurized coolant can cause
injury by scalding.
Carefully remove coolant recovery pressure con-
tainer cap and check coolant level. Push down on cap
to disengage it from stop tabs. Wipe inside of con-
tainer and examine lower inside sealing seat for
nicks, cracks, paint, dirt and solder residue. Inspect
radiator-to- pressure container hose for internal
obstructions. Insert a wire through the hose to be
sure it is not obstructed.
Inspect cams on outside of pressure container. If
cams are damaged, seating of pressure cap valve and
tester seal will be affected.
Attach pressure tester (7700 or an equivalent) to
coolant pressure container (Fig. 2).
Fig. 1 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
7 - 10
ENGINE
VA
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