Mercedes-Benz Sprinter / Dodge Sprinter. Manual - part 201

(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 90°C. 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 90°C (194°F).
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

ENGINE

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 90°C (194°F). 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

ENGINE

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

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).

ENGINE

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

ENGINE

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