sensor MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Oil Outlet Line to
Turbo Charger9-80
Connection-Flange of
Exhaust Manifold to Turbo
Charger30 22 -
Connection-Turbo Charger
to Front Catalytic
Converter30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air
Distribution Pipe16 - 141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe9-80
Bolt-Support to Charge Air
Distribution Pipe20 - 177
Bolt-Support to Engine
Bracket40 30 -
Clamp-Charge Air
Pipes/Hoses3-27
Belt Tensioning Device
Bolt-Guide Pulley to
Coolant Pump35 26 -
Bolt-Guide Pulley to
Timing Case Cover35 26 -
Bolt-V-Belt Tensioning
Device to Tensioning
Pulley36 26.5 -
Bolt-V-Belt Tensioning
Device to Timing Case
Cover30 22 -
Exhaust Manifold
Nut-Exhaust Manifold at
Cylinder Head30 22 -
Position Sensor
Nut/Bolt-Camshaft
Position Sensor to
Cylinder Head Cover11 - 9 7
Nut/Bolt-Crankshaft
Position Sensor to Engine
Block8-70
Pre-Glow System
Cylinder Head to Glow
Plug12 - 106
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of Circuit
3014 - 124
9 - 10 ENGINEVA
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut-Connection of Circuit
506-53
Alternator
Bolt-Generator to Timing
Case Cover20 15 -
Bolt-Generator to Cooler
Housing6-53
Bolt-Cooler Housing of
Generator to Crankcase20 - 177
Nut-B+ Circuit to
Generator13-18 - 115-159
Nut-D+ Circuit to
Generator5-44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to
Crankcase18
- 133
Bolt-Oil Pipe to Crankshaft
Bearing Cap8-70
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat
Exchanger to Timing
Cover Case15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube
to Cylinder Head14 - 123
Bolt-Oil Level Sensor to
Oil Pan14 - 123
Coolant Pre-Heater
Coolant Pre-Heater in
Engine Block35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant
Pump8-35 6 - 26 -
Bolt-Coolant Pump to
Timing Case Cover 6m/8m14/20 10 - 15 -
Bolt-Thremostat Housing
to Cylinder Head9-80
Coolant Drain Plug to
Crankcase30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage,
torque, torque angle)20/90É 15 -
VAENGINE 9 - 11
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Refrigerant Compressor
Bolt-Refrigerant
Compressor to Timing
Case Cover20 - 177
Bolt-Refrigerant
Compressor to Bracket20 - 177
Bolt-Refrigerant Lines to
Refrigerant Compressor20 - 177
Timing Chain, Chain Tensioner
Bolt-Camshaft Sprocket to
Exhaust Camshaft18 - 159
Bolt-Intermediate Gear of
High Pressure Pump to
Cylinder Head40 29.5 -
Timing Chain Tensioner to
Timing Case Cover80 59 -
Camshaft
Bolt-Camshaft Bearing
Cap to Cylinder Head9-80
Bolt-Driver to Inlet
Camshaft50 37 -
Common Rail Diesel Injection
Bolt-Banjo Bolt of Leak Oil
Line to Rail20 - 177
Bolt-Bracket to High
Pressure Pump9-80
Bolt-High Pressure Pump
to Cylinder Head14 - 124
Bolt-Pre-delivery Pump to
Top Cover of Cylinder
Head9-80
Bolt-Pressure Control
Valve to Rail (2 stage,
torque)3/5 - 26/44
Bolt-Rail to Cylinder Head 14 - 124
Bolt-Shutoff Valve to
Cylinder Head8-70
Nut-Pressure Line to
Rail/Injector (New,Reused)22/25 16/18.5 -
Nut-Pressure Line to High
Pressure Pump/Rail22 16 -
Screw-Tensioning Claw to
Injector (2 stage, 1 torque,
2 torque angle)7/90É - 62
Rail-Pressure Sensor to
Rail22 16 -
Pressure Pipe Connection
to Injector42 31 -
VAENGINE 9 - 13
ENGINE (Continued)

AIR CLEANER ELEMENT
REMOVAL
(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.
9).
(3) Unclip the air cleaner housing lid (Fig. 9).
(4) Remove air cleaner element (Fig. 9).
INSTALLATION
(1) Position and seat the air cleaner element into
the lower housing (Fig. 9).
(2) Install the housing cover and snap retainers
into place (Fig. 9).
(3) Install air flow sensor into housing cover (Fig.
9).
(4) Install heat shield.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the Air Flow sensor(Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/MANIFOLD AIR
FLOW (MAF) SENSOR - REMOVAL).
(4) Unclip the top of the air cleaner housing and
remove (Fig. 10).(5) Take out air cleaner element (Fig. 10).
(6) Detach bottom part of the air cleaner housing
at the body (Fig. 10).
(7) Take air intake hose out of inner fender and
out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 10).
(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 10).
INSTALLATION
NOTE: Ensure that the seal betwwen the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 10).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 10).
(3) Install air cleaner element (Fig. 10).
(4) Install and clip air cleaner top to air cleaner
body (Fig. 10).
(5) Install Air Flow sensor (Fig. 10).
(6) Install heat shield.
Fig. 9 AIR CLEANER ELEMENT
1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSINGFig. 10 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR CLEANER HOUSING COVER
9 - 20 ENGINEVA

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 CLOTHING.
(14) Start engine and inspect for leaks.Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
(15) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect the air inlet and set aside.
(3) Detach hose from oil separator.
(4) Disconnect the camshaft position sensor.
(5) Disconnect fuel injector and glow plug harness
and set aside.(6) Remove fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(7) Disconnect the out let line.
(8) Remove cylinder head cover retaining bolts and
remove cover (Fig. 21).
INSTALLATION
NOTE: Do Not tighten the cylinder head cover first.
The fuel injectors are aligned by way of the cylinder
head cover.
(1) Fit cylinder head cover with new gasket and
install bolts (Fig. 21).
(2) Insert all fuel injectors and tensioning claws.
Insert new bolts and tighten in the following order:
3, 4, 5, 2, 1.(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION).
(3) Tighten cylinder head cover bolts to 9 N´m (80
lbs. in.).
(4) Install and properly route fuel injector and
glow plug wiring harness, making appropriate con-
nections.
Fig. 21 CYLINDER HEAD COVER
1 - ENGINE WIRING HARNESS 7 - GASKET
2 - GLOW PLUG CONNECTOR 8 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR 9 - CRANKCASE VENT LINE
4 - OUTLET LINE 10 - GASKET
5 - INTAKE MANIFOLD 11 - FUEL INJECTOR
6 - GASKET 12 - GROUND
9 - 30 ENGINEVA
CAMSHAFT(S) (Continued)

(5) Connect the camshaft position sensor.
(6) Connect the return flow line.
(7) Attach oil separator hose.
(8) Install the fuel injector lines (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).
(9) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(10) Start engine and inspect for leaks. Care must
be take to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS
(1) Disconnect negative battery cable.
(2) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(3) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(6) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(7) Remove top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: The timing chain must be held in up position
so as not to jam during procedure.
(9) Position piston of cylinder to be processed to
DTC by rotating the crankshaft clockwise.DO NOT
crank engine.DO NOT rotate engine backward.
(10) Install crankshaft lock, special tool #8932.
(11) Seal injector hole with connection piece and
retain with orginal tensioning claw.(12) Connect cylinder leak tester with adaptors
and pressurize the cylinder to 5 bar (73 psi.).
WARNING: Valve springs and retainers must be
kept in order of the cylinder they were removed.
NOTE: Using valve service tools #9307, screw
retaining fork into threaded edge of cylinder head
and position thrust piece vertically at top of valve
spring retainer.
(13) Compress valve spring (Fig. 22).
(14) Remove valve collets (Fig. 22).
(15) Remove top valve spring retainer and valve
spring (Fig. 23).
(16) Remove valve stem seals (Fig. 24).
(17) Remove bottom valve spring retainer (Fig. 23).
NOTE: Inspect all cylinder head components for
wear or damage.
(18) Repeat procedure for each cylinder as neces-
sary.
REMOVAL - VALVES
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
Fig. 22 VALVE COMPRESSOR
1 - VALVE ASSEMBLY TOOL
2 - VALVE COLLET
3 - MAGNET
VAENGINE 9 - 31
CYLINDER HEAD COVER(S) (Continued)

OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534±16, to the engine lifting eye and
raise engine slightly.
(6) Remove engine mounts and raise engine.
(7) Disconnect the oil level sensor.
(8) Remove the transmission cooler lines from the
oil pan bolts and carefully position the lines aside
(9) Remove the oil pan bolts.
(10) Remove oil pan and gasket (Fig. 51).
INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 53).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, fill it with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Install the oil pan gasket and coat places indi-
cated with an arrow with sealant (Fig. 52).
(2) Install the oil pan. Tighten M6 bolts to 9N´m
(80 lbs. in.) and M8 bolts to 20N´m (15 lbs. ft.) (Fig.
53).
Fig. 51 OIL PAN
1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
9 - 52 ENGINEVA

(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)

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)