MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

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)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Threaded Rail to Rail 22 16 -
Fuel Cooling System
Bolt-Fuel Cooler to
Charge Air Distribution
Pipe14 - 124
Heater Booster, Heater Unit
Bolt- Temperature
Controlled Cut Out to
Heater Booster Control
Module12 - 106
Nut-Threaded Stud to
Electronic Heater Booster18 - 159
SPECIAL TOOLS
SPECIAL TOOL CROSS REFERENCE CHART
MB
TOOL #MILLER
TOOL #DESCRIPTION
N/A 5069-2 FUEL GAUGE
611 589
04 63 008927 COMPRESSION TESTER
ADAPTER
611 589
03 15 008929 CANSHAFT LOCKING
PINS
611 589
00 40 008930 COUNTERHOLDER
N/A 8931 TIMING CHAIN
RETAINER
601 589
02 40 008932 CRANKSHAFT LOCK
603 589
00 40 008934 COUNTERHOLDER
N/A 8938A EXTRACTION CLAW
611 589
00 14 008936 FRONT CRANKSHAFT
SEAL INSTALLER
N/A 8938 EXTRACTION CLAW
613 589
00 33 008940 VIBRATION DAMPER
REMOVER
N/A 8941 SLIDE HAMMER
611 589
00 15 008942 OIL JET INSTALLER
611 589
01 14 008944 REAR MAIN SEAL
INSTALLER
MB
TOOL #MILLER
TOOL #DESCRIPTION
602 589
00 39 008947 RIVETING OPENER
602 589
02 33 008948 CHAIN SEPARATOR
TOOL
602 589
03 63 008949 THRUST PIECE
602 589
04 63 008950 PRESSING SCREW
602 589
02 40 008951 ASSEMBLY LINKS
602 589
02 40 008952 ASSEMBLY INSERTS
N/A 9285 FUEL LINE WRENCH
N/A 9286 GLOW PLUG PLIERS
N/A 9295 COMPRESSION HOSE
ADAPTER
111 5 8 9
25 61 009307 VAVLE SERVICE TOOLS
N/A 8534-16 ENGINE SUPPORT
FIXTURE ADAPTERS
N/A 9308 ENGINE LIFTING
FIXTURE
103 589
01 63 009310 ASSEMBLY INSERTS
602 589
05 63 009311 PRESSING SCREW
9 - 14 ENGINEVA
ENGINE (Continued)

#8927 COMPRESSION TESTER ADAPTER
#8929 CAMSHAFT LOCKING PIN
#8931 TIMING CHAIN RETAINER
#8932 CRANKSHAFT LOCK
VAENGINE 9 - 15
ENGINE (Continued)

#8936 FRONT CRANKSHAFT SEAL INSTALLER
#8938A EXTRACTION CLAW
#8940 VIBRATION DAMPER REMOVER
#8941 SLIDE HAMMER
9 - 16 ENGINEVA
ENGINE (Continued)

#8942 OIL JET INSTALLER
#8944 REAR MAIN SEAL INSTALLER
#9307 VALVE SERVICE TOOLS
#8947 RIVET OPENER
VAENGINE 9 - 17
ENGINE (Continued)

#8948 CHAIN SEPARATOR TOOL
#8949 THRUST PIECE
#8950 PRESSING SCREW
#8951 ASSEMBLY LINKS
9 - 18 ENGINEVA
ENGINE (Continued)

#8952 ASSEMBLY INSERTS
#9285 FUEL LINE WRENCH
# 9286 GLOW PLUG PLIERS
Fig. 8 #9295 COMPRESSION HOSE ADAPTOR
# 9310 ASSEMBLY INSERTS
#9311 PRESSING SCREW
VAENGINE 9 - 19
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

(7) Connect negative battery cable.
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 11).
Cylinder Head
BoltsThread
Diameter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE
NOTE: Only resurface cylinder head contact surface
if porous or damaged. IT IS NOT necessary to
rework minor variations in flatness in the longitudi-
nal direction.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 12).NOTE: The camshaft housing Must Not be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Machine cylinder head contact surface, if nec-
essary.
(8) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 12) CYLINDER
HEAD SPECIFICATIONS.
(9) Measure valve setback at points (2) indicated
(Fig. 12) CYLINDER HEAD SPECIFICATIONS.
NOTE: If measurement is less than dimension ª2º
no further correct valve clearance compensation is
possible; replace valve seat ring or cylinder head if
measurement is greater than specification.
CYLINDER HEAD SPECIFICATIONS
Description Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat RingsExhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
Fig. 11 MEASURING CYLINDER HEAD BOLTS
Fig. 12 CYLINDER HEAD MEASURMENTS
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
VAENGINE 9 - 21
AIR CLEANER HOUSING (Continued)

REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.
(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crank-
case(Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(6) Lower vehicle.(7) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(9) Remove tappets (Fig. 13).
(10) Remove the camshaft housing at the cylinder
head (Fig. 13).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING
WHEN HANDLING FUEL.
(11) Remove the high pressure fuel pump interme-
diate gear (Fig. 13).
(12) Disconnect the engine side of the engine har-
ness and set aside.
(13) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
Fig. 13 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 22 ENGINEVA
CYLINDER HEAD (Continued)