warning MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

NOTE: If grooves can be felt in the belt pulley/vibra-
tion damper during inspection, the pulley/damper
must be replaced.
(6) Inspect hub at belt pulley/vibration damper for
wear grooves.
(7) Replace front crankshaft seal.
INSTALLATION
NOTE: Align parallel key, fix in place with grease.
Turn to ensure the slot is aligned with parallel key
in crankshaft.
NOTE: Front crankshaft seal must be replaced
before installing the belt pulley/vibration damper.
(1) Position the belt pulley/vibration damper.
(2) Install crankshaft center bolt and washer.
Tighten bolt in two stages. M8.8 bolt to 200N´m (148
lbs. ft.) then 90É, M10.9 bolt to 325N´m (240 lbs. ft.)
then 90É.
(3) Remove the retaining lock for the crankshaft/
ring gear (Fig. 43).
NOTE: Inspect accessory drive belt for wear.
Replace as necessary.
(4) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start vehicle and inspect for leaks.
VACUUM PUMP
DESCRIPTION
The vacuum pump is operated by a slotted exten-
sion attached to the vacuum pump shaft. The vac-
uum pump shaft slotted extension fits into, and is
driven by, the exhaust camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum pump rotating components are inter-
nally lubricated.The vacuum pump is not serviceable and must be
replaced as a unit. Do not disassemble or attempt to
repair the pump.
OPERATION
Vacuum pump output is transmitted to the Heater,
Electronic, Vacuum, Air Conditioner (HEVAC) and
speed control, systems through a supply hose. The
hose is connected to an outlet port on the pump hous-
ing and uses an in-line check valve to retain system
vacuum when vehicle is not running.
Pump output ranges from a minimum of 8.5 to 25
inches vacuum.
The pump rotor and vanes are rotated by the pump
drive gear. The drive gear is operated by the exhaust
camshaft gear.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove vacuum line at vacuum pump (Fig.
44).
NOTE: Observe position of driver on rear of pump.
(3) Remove vacuum pump and seals (Fig. 44)
(4) Clean all sealing surfaces.
Fig. 44 VACUUM PUMP
1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING
4 - O-RING
5 - EXHAUST CAMSHAFT
6 - BOLTS
9 - 48 ENGINEVA
VIBRATION DAMPER (Continued)

INSTALLATION
(1) Clean all sealing surfaces.
(2) Position driver on rear of pump and install vac-
uum pump with new seals. Tighten bolts to 14N´m
(124 lbs. in.). (Fig. 44)
(3) Install vacuum line to vacuum pump (Fig. 44).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(5) Start the engine and inspect for leaks.
LEFT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534±16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 45)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 45)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 45)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
45)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 45)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 45).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 45)
(7) Remove the engine support fixture and adap-
tors.
RIGHT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534-16 and raise the engine slightly.(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 46)
(4) Lower the vehicle.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 46)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 46)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
46)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 46)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 46).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 46)
Fig. 45 LEFT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - BRACKET
7 - GROUND CABLE
8 - WASHER
9 - BOLT
VAENGINE 9 - 49
VACUUM PUMP (Continued)

(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOTOPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 47).
(4) Remove the oil cooler from the timing case
cover (Fig. 47).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 47).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 47).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
Fig. 46 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
Fig. 47 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
9 - 50 ENGINEVA
RIGHT MOUNT (Continued)

(3) Tighten the bolt of the transmission bell hous-
ing to oil pan to 40N´m (30 lbs. ft.).(4) Install the wiring harness duct (Fig. 51).
(5) Install the transmission lines (Fig. 51).
(6) Connect the oil level sensor (Fig. 51).
(7) Lower the vehicle.
(8) Lower the engine until the engine mount and
engine supports make contact.
(9) Start and hand tighten the engine mount bolts.
(10) Lower the engine the rest of the way and
remove the engine support fixture.
(11) Tighten the engine mount bolts to 83 N´m (61
lbs. ft.).
(12) Install the sway bar and tighten bolts to 30
N´m (22 lbs. ft.).
(13) Refill crankcase with the proper engine oil to
the proper level. Refer to owners manual for specifi-
cation.
(14) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(15) Start the engine and inspect for leaks.
OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 51).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 51).
REMOVAL- OIL PUMP CHAIN
(1) Disconnect negative battery cable.
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
NOTE: Make sure the pin of the thrust spindle is
backed out into the thrust spindle before seating
the thrust spindle to the oil pump chain.
(4) Using special tool #8948 and thrust pin #9311,
position and fit chain seperating tool and thrust spin-
dle onto a link of the oil pump chain (Fig. 54).
(5) Screw the thrust pin in and seperate the oil
pump chain link.
Fig. 52 OIL PAN GASKET
Fig. 53 OIL PAN BOLTS
1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55
VAENGINE 9 - 53
OIL PAN (Continued)

(6) Remove pressed - out oil pump chain pin from
chain seperation tool.
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the oil pump chain is followed exactly.
Failure to do so will result in severe engine dam-
age.
INSTALLATION
INSTALLATION
NOTE: If the oil pump is dry, fill it with clean engine
oil before installation. Clean the oil pick±up tube
and strainer.
(1) Clean all sealing surfaces.
(2) Position the oil pump onto the drive chain and
reset tensioner.
(3) Install oil pump retaining bolts and tighten to
18 N´m (160 lbs. in.).
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Refill the crankcase to the appropriate level
with the proper engine oil (see owners manual).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOURHANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) Start the vehicle and inspect for leaks.
INSTALLATION - OIL PUMP CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
55).
(2) Slowly rotate crankshaft in a clockwise direc-
tion until it is possible to connect the ends of the new
and old oil pump chains.
(3) Remove assembly locking element, outer plate
and assembly link (Fig. 56).
CAUTION: Insert new riveted link from the rear.
(4) Connect ends of new oil pump chain with new
riveted link (Fig. 57).
NOTE: When assembling riveting tool, one piece is
secured by a screw and the other can move loosely
on the thrust spindle.
Fig. 54 OIL PUMP CHAIN LINK REMOVAL
1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
3 - SPECIAL TOOL #8948
Fig. 55 INSTALLING OIL PUMP CHAIN TEMPORARY
LINK
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OLD OIL PUMP CHAIN
3 - NEW OIL PUMP CHAIN
4 - TEMPORARY LINK
9 - 54 ENGINEVA
OIL PUMP (Continued)

NOTE: Rivet pins of the riveted link individually.
(17) Position riveting tool exactly over middle of
pin (Fig. 60).
(18) Tighten riveting tool spindle until it stops.
(19) Remove riveting tool, inspect riveting, rerivet
if necessary (Fig. 61).(20) Repeat procedure for both rivets.
(21) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(22) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(23) Refill engine with proper oil to the correct
level.
(24) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR
THE PULLEYS, BELT OR FAN. DO NOT WEAR
LOOSE CLOTHES.
(25) Start engine and inspect for leaks.
OIL TEMPERATURE SENSOR
DESCRIPTION
Oil level, oil temperature and oil quality are
detected by means of an oil sensor located in the oil
pan. The sensor which operates on the capacitance
principle features an integrated electronic circuit
which analyzes the three signals. the signals are con-
stantly relayed to the ECM and over the CAN bus to
the instrument cluster by means of PWM signal.
OPERATION
Oil quality is detected for indicating the need-
based oil change interval. The oil quality is detected
on the basis of the capacitance of the engine oil
(dielectrics, does not conduct electricity), this being
as much as six times greater in case of poor quality.
Fig. 59 INSTALLING RIVETING INSERTS INTO
RIVETING TOOL
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #9310
Fig. 60 NEW LINK RIVETING
1 - SPECIAL TOOL #8947
2 - OIL PUMP CHAIN
Fig. 61 RIVET INSPECTION
9 - 56 ENGINEVA
OIL PUMP (Continued)

Oil level and oil quality are separate of each other.
The information is first of all compensated in the
ECM before being transmitted over the CAN bus.
Faults at the oil sensor are detected by the ECM
and entered into fault memory. The voltage for the
oil sensor (approx.5V) is supplied by the ECM.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain engine oil into a suitable, and appropri-
ately marked container.
(4) Remove engine mount to chassis nuts.
(5) Lower vehicle and install engine support.
(6) Raise engine until the weight of the engine no
longer rests on the engine mounts.
(7) Raise and support the vehicle.
(8) Detach the front stabilizer bar at the front axle
and rotate it downward.
(9) Unplug the oil level sensor (Fig. 62).
(10) Remove the oil level sensor retaining screw,
oil level sensor and discard the gasket (Fig. 62).
INSTALLATION
(1) Seat O-ring on oil level sensor and lubricate
O-ring with clean engine oil (Fig. 62).
(2) Install the oil level sensor into the oil pan and
tighten screw to 124 lbs. in.(14N´m) (Fig. 62).(3) Connect oil level sensor wiring harness connec-
tor (Fig. 62).
(4) Rotate front stabilizer bar upward and secure
to axle beam. Tighten to 22 lbs.ft. (30 N´m)
(5) Lower the vehicle.
(6) Lower the engine into the mounts.
(7) Remove engine support fixture.
(8) Raise and support the vehicle.
(9) Tighten both engine mount to chassis nuts.
(10) Install and tighten oil drain plug.
(11) Lower vehicle and install the appropriate
engine oil.
INTAKE MANIFOLD
REMOVAL
WARNING: NO FIRE, SPARKS OR SMOKING.
STORE FUELS ONLY INTO SUITABLE AND APPRO-
PRIATELY MARKED CONTAINERS, AND WEAR
PROTECTIVE CLOTHING. (Refer to 14 - FUEL SYS-
TEM - WARNING).
WARNING: DO NOT OPEN THE COOLING SYSTEM
UNLESS THE COOLANT TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN RADIATOR CAP SLOWLY TO
RELEASE PRESSURE. STORE COOLANT ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS, WEAR PROTECTIVE CLOTHING AND
EYE PROTECTION.
(1) Disconnect the negative battery cable.
(2) Drain coolant from the radiator.
(3) Remove the engine cover.
(4) Disconnect the engine wiring harness from
inside the vehicle and carefully guide the harness
into the engine compartment.
(5) Disconnect the charge air hose at the intake
manifold (Fig. 63).
(6) Disconnect the EGR wiring harness connector
(Fig. 63).
(7) Remove the bolt retaining the engine wiring
harness to the intake manifold (Fig. 63).
(8) Disconnect the coolant hose at the connection
junction through the intake manifold support bracket
(Fig. 63).
NOTE: Collect and store any fluid spillage when
disconnecting components.
(9) Disconnect both fuel lines at the fuel filter (Fig.
63).
(10) Remove the lower intake manifold support
bracket (Fig. 63).
Fig. 62 OIL LEVEL SENSOR
1 - OIL PAN
2 - O-RING
3 - WIRING HARNESS
4 - BOLT
5 - OIL LEVEL SENSOR
VAENGINE 9 - 57
OIL TEMPERATURE SENSOR (Continued)

(7) Install the right intake manifold support brack-
ets. Tighten the bolts to 14 N´m (124 lbs. in.) (Fig.
63).
(8) Install the lower intake manifold support
bracket. Tighten bolts to 20 N´m (177 lbs. in.) (Fig.
63).
(9) Connect both fuel lines to fuel filter assembly
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL FILTER - INSTALLATION).
(10) Connect the coolant hose at the connection
junction above the lower intake manifold support
bracket (Fig. 63).
(11) Secure the engine wiring harness and cable
duct to the intake manifold (Fig. 63).
(12) Connect the EGR wiring harness connector
(Fig. 63).
(13) Connect the charge air hose to the intake
manifold (Fig. 63).
(14) Carefully route the engine wiring harness
through and into the passenger compartment and
reconnect.
(15) Install the engine cover.
(16) Fill the cooling system.
(17) Connect the negative battery cable.
(18) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warnin-
g.(Refer to 14 - FUEL SYSTEM - WARNING).
EXHAUST MANIFOLD
REMOVAL
(1) Remove the turbocharger (Refer to 11 -
EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
TURBOCHARGER - REMOVAL).
(2) Remove the self locking exhaust manifold nuts
(Fig. 64).
(3) Remove exhaust manifold and clean mating
surfaces (Fig. 64).
INSTALLATION
NOTE: Exhaust manifold surface must be flat within
0.006 in. per foot (0.15mm per 300mm) of manifold
length.
(1) Inspect exhaust manifold gasket surface for
flatness with a straight edge (Fig. 64).
(2) Inspect exhaust manifold for cracks or distor-
tion (Fig. 64).
(3) Install new exhaust manifold gasket (Fig. 64).
(4) Position the exhaust manifold over to studs
and tighten retaining nuts to 22 lbs. ft. (30 N´m (Fig.
64)).
(5) Install turbocharger (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSTALLATION).
TIMING CHAIN COVER
REMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS TEMPERATURE IS BELOW 90ÉC (194ÉF).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(2) Position piston of cylinder 1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
Fig. 64 EXHAUST MANIFOLD
1 - EXHAUST MANIFOLD
2 - GASKET
3 - STUD
4 - NUT
VAENGINE 9 - 59
INTAKE MANIFOLD (Continued)

(8) Position and install the oil pan. Tighten M6
bolts to 9 N´m (80 lbs in) and M8 bolts to 20 N´m
(177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
M8.8 bolt in two stages, 200N´m (147 lbs ft.) then
90É, M10.9 bolt 325N´m (240 lbs ft) then 90É.
(10) Remove the engine support fixture.
(11) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditioning compressor.
(13) Install the power steering pump.
(14) Install water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sealant to lower portion of, and install,
front cover to cylinder block. Tighten bolts to 20N´m
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
- INSTALLATION).
(18) Remove retaining lock for crankshaft/starter
ring gear.
(19) Tighten the oil drain plug to 30N´m (265 lbs
in).
(20) Install a new oil filter. tighten screw cap for
filter to 25N´m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).(23) Install air intake hose.
(24) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(25) Fill the crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(26) Connect the negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
(27) Start engine and inspect for leaks. care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE RAILS
NOTE: If it necessary to replace the tensioning rail,
slide rail or tensioning arm, they are always
replaced together.
(1) Disconnect negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
(4) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Pull the tensioning rail off of the bearing pins
(Fig. 67).
(6) Release the spring at the slide rail and take it
off of the tensioning arm (Fig. 67).
REMOVAL - INTERMEDIATE GEAR
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
Fig. 66 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VAENGINE 9 - 61
TIMING CHAIN COVER (Continued)

WARNING: NO FIRE, FLAMES OR SMOKING. RISK
OF POISONING FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. POUR FUELS ONLY INTO
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS. WEAR PROTECTIVE CLOTHING.
(3) Remove fuel high pressure lines injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Insert locking pin through first camshaft bear-
ing cap into hole in inlet camshaft sprocket to lock
inlet camshaft.(7) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(8) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(9) Remove top slide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(10) Remove high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(11) Mark camshaft sprocket relative to timing
chain.
(12) Unbolt camshaft sprocket from exhaust cam-
shaft.
NOTE: Note position of dowel pin for camshaft
sprocket alignment during reassembly.
(13) Secure camshaft sprocket to timing chain with
tie strap.
Fig. 67 TENSIONING AND SLIDE RAILS
1 - TENSIONING RAIL 5 - TENSIONING CLAMP
2 - BEARING PIN 6 - BEARING PIN
3 - SLIDE RAIL 7 - SPRING
4 - BEARING PIN 8 - OIL PUMP
9 - 62 ENGINEVA
TIMING BELT/CHAIN AND SPROCKETS (Continued)