Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 197
INSTALLATION
(1) Install the hydraulic control unit into the rub-
ber mounts (Fig. 17).
(2) Reconnect the brake lines to the hydraulic con-
trol unit (Fig. 17). Do not mix up the brake lines.
Tighten the lines to 16 N·m (142 in. lbs.)
(3) Reconnect the multiplug to the control module
(Fig. 17).
(4) Reconnect the ground cable on the battery.
(5) Bleed the brake system.
(6) Check the fluid in the reservoir and correct if
necessary.
(7) Perform function test.
VA
BRAKES - ABS
5 - 37
COOLING
TABLE OF CONTENTS
page
page
COOLING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COOLING
OPERATION - COOLING 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:
• PROLONGED IDLE
• VERY HIGH AMBIENT TEMPERATURE
• SLIGHT TAIL WIND AT IDLE
• SLOW TRAFFIC
• TRAFFIC JAMS
• HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at
end of normal range.
• Increasing 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:
• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt(s)
• Brakes (possibly dragging)
• Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
• Reconditioned 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)
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COOLING
7 - 1
COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATUREGAUGE READS
LOW
1. Vehicle is equipped with a
heavy duty cooling system.
1. None. System operating norma-
ly.
2. Temperature gauge not connect-
ed
2. Connect gauge.
3. Temperature gauge connected
but not operating.
3. Check gauge. Refer (Refer to 8
- ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
4. Coolant level low.
4. Fill cooling system. (Refer to 7 -
COOLING - STANDARD PROCE-
DURE)
TEMPERATURE GAUGE READS
HIGH. COOLANT MAY OR MAY
NOT BE LEAKING FROM SYS-
TEM
1. Vehicle overloaded, high ambi-
ent (outside) temperatures with
A/C turned on, stop and go driving
or prolonged operation at idle
speeds.
1. Temporary condition, repair not
required. Notify customer of vehicle
operation instructions located in
Owners Manual.
2. Temperature gauge not function-
ing correctly.
2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING)
3. Air traped in cooling
3. Drain cooling system (Refer to 7
- COOLING - STANDARD PROCE-
DURE) and refill (Refer to 7 -
COOLING - STANDARD PROCE-
DURE)
4. Radiator cap faulty.
4. Replace radiator cap.
5. Plugged A/C or radiator cooling
fins.
5. Clean all debre away from A/C
and radiator cooling fins.
6. Coolant mixture incorrect.
6. Drain cooling system (Refer to 7
- COOLING - STANDARD PROCE-
DURE) refill with correct mixture
(Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
7. Thermostat stuck shut.
7. Replace thermostat.
8. Bug screen or winter front being
used.
8. Remove bug screen or winter
front.
9. Viscous fan drive not operating
properly.
9. Check viscous fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
10. Cylinder head gasket leaking.
10. Check for leaking head gaskets
(Refer to 7 - COOLING - DIAGNO-
SIS AND TESTING).
11. Heater core leaking.
11. Replace heater core.
12. cooling system hoses leaking.
12. Tighten clamps or Replace
hoses.
7 - 2
COOLING
VA
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