boot MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
NOTE: The engine manufacturer strongly recom-
mends the use of synthetic engine oils, such as
TMobil 1 SAE 0W-40.
When the next maintenance service is due, this
will be indicated in the multi-function display with
the wrench icon symbol displayed in km/miles or
days.
²One wrench icon showing indicates Oil Service
is necessary.
²Two wrench icons showing indicates Mainte-
nance Service is necessary ± displayed in km/miles or
days.
If the display shows the number of days, a clock
symbol will also appear in the multi-function display.
You should have the maintenance performed
within the stated period/distance.
The service indicator should be reset after an oil
service and/or maintenance service has been per-
formed.
REGULAR CHECK-UPS
To maintain the safe operation of the vehicle, it is
recommended that the following tasks be performed
on a regular basis (i.e. weekly or whenever the vehi-
cle is refueled). Check:
²Engine oil level
²Brake system, clutch mechanism ± fluid level
²Battery ± acid level
²Windshield washer system and headlamp clean-
ing system ± fluid level
²Mechanical assemblies (e. g. engine, transmis-
sion, etc.) ± check for leaks
²Condition of tires and tires pressures
²All exterior lights
SPECIAL MAINTENANCE REQUIREMENTS
If bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehi-
cle, the maintenance requirements and lubrication
intervals specified by the body manufacturer must be
adhered to, in addition to all standard maintenance
requirements.
Brake Fluid
Only use brake fluids approved by the manufac-
turer (DOT 4 plus).
Coolant
Corrosion inhibitor/antifreeze concentration in the
coolant should be checked before the onset of winter
(once year in countries with high prevailing temper-
atures).Replace the coolant every five years or 100,000
miles.
Dust Filter for Heating/Ventilation Replace-
ment
The dust filter and the tailgate interior filter are to
be renewed during routine maintenance service. If
operating conditions are dusty, these filters should be
renewed more frequently.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
At the minimum, change the engine oil and oil fil-
ter once a year ± even if the vehicle mileage per year
is extremely low. For standard oil service schedules
refer to the chapter oil service and maintenance ser-
vice.
Once a Year
Select the viscosity of the engine oil (SAE classes)
according to the outside air temperature.
Only use engine oil approved by DaimlerChrysler
Corporation if following the ASSYST system guide-
lines.
If the fuel used has a sulphur content exceeding
0.05% by weight, the service intervals should be split
in half.
SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
²Engine:
Oil change and filter replacement
Check fluid levels of the following system,
refill as necessary.
²If fluid is lost, trace and eliminate cause ± as a
separate order.
²Power-assisted steering
Lubrication work:
²Trailer tow hitch (original equipment)
Maintenance
²ASSYST maintenance computer reset
Function check
²Signalling system, warning and indicator lamps
²Headlamps, exterior lighting
²Windshield wipers, windshield washer system
Check for leaks and damage.
²Check for abrasion points and ensure that lines
are correctly routed!
²All lines and hoses, sensor cables
²Rubber boots on front axle drive shafts, rubber
boots on front axle suspension ball joints, shock
absorbers
Check fluid levels for the following systems,
correct as necessary.
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
0 - 8 LUBRICATION & MAINTENANCEVA
MAINTENANCE SCHEDULES (Continued)

PROPELLER SHAFT
REMOVAL
(1) Secure vehicle to prevent it from rolling.
(2) Make installing reference marks on propeller
shaft (Fig. 6) and (Fig. 7).
(3) Remove retaining bracket bolts (Fig. 8) and
(Fig. 9).
(4) Remove propeller shaft bolts from rear axle
and transmission at the flange.
(5) Remove propeller shaft intermediate bearing
nuts from retaining bracket and bracket for brake
cable.
NOTE: The brake cable bracket is only installed in
vehicles with wheelbase 3550 mm
(6) Remove shaft from the vehicle.
INSTALLATION
(1) Install propeller shaft intermediate bearing/
bearings to support and tighten nuts to 105 N´m (77
ft. lbs.).(2) Install propeller shaft intermediate bearing
support/supports to frame floor and tighten bolts to
95 N´m (70 ft. lbs.).
(3) Install propeller shaft intermediate bearing
with retaining bracket and bracket for brake cable.
NOTE: The bracket is only installed on vehicles
with wheelbase 3550 mm.
(4) Install propeller shaft to rear axle and trans-
mission flange with installation marks are aligned.
Tighten bolts to 70 N´m (66 ft. lbs.).
(5) Install retaining bracket and tighten bolts to
100 N´m (74 ft. lbs.).
SPLITTER 1130
INSTALLER 9275
INCLINOMETER 7663
Fig. 6 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
Fig. 7 ALIGNMENT MARKS 3 PIECE SHAFT
1 - REFERNCE MARK
2 - CENTER SHAFT
3 - REFERENCE MARK
4 - REAR SHAFT
3 - 6 PROPELLER SHAFTVA
PROPELLER SHAFT (Continued)

CENTER BEARING
REMOVAL
(1) Remove propeller shaft.
(2) Mark shafts for installation alignment (Fig.
10).
(3) Loosen both collar clamps (Fig. 11).
(4) Pull apart propeller shaft.
(5) Remove snap-ring (Fig. 12).
(6) Pull off center bearing with a Bearing Splitter
1130 and Bridge 938, with a plug on the end of the
shaft (Fig. 13).NOTE: The bearing splitter must be positioned
behind the thrust washer of the bearing.
Fig. 10 ALIGNMENT MARKS
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING
Fig. 11 BOOT
1 - BOOT
2 - CLAMP
3 - SHAFT
Fig. 12 CENTER BEARING
1 - SNAP-RING
2 - CENTER BEARING
3 - WASHER
4 - SHAFT
5 - PROTECTIVE CAP
Fig. 13 CENTER BEARING REMOVAL
1 - BRIDGE
2 - PLUG
3 - BEARING SPLITTER
4 - CENTER BEARING
3 - 8 PROPELLER SHAFTVA

INSTALLATION
(1) Press center bearing on propeller shaft with
protective caps and washer with Installer 9275 (Fig.
14).(2) Install snap-ring.
(3) Coat propeller shaft spline with universal
grease.
(4) Push rubber boot onto propeller shaft.
(5) Push together propeller shaft. Pay attention to
alignment markings for installation position.
(6) Ensure rubber seal is correctly installed and
attachnewcollar clamps.
(7) Install propeller shaft.
Fig. 14 CENTER BEARING INSTALLATION
1 - INSTALLER
2 - CENTER BEARING
VAPROPELLER SHAFT 3 - 9
CENTER BEARING (Continued)

LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
END ................................10
SPECIFICATIONS - TORQUE CHART........10
SPECIAL TOOLS
FRONT SUSPENSION..................11TIE ROD END
REMOVAL.............................11
INSTALLATION.........................11
LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
END
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the outer tie rod
end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Outer Tie Rod End Nut 130 96 Ð
Outer Tie Rod End
Locking Nut50 37 Ð
Steering Gear Boot Clamp 7 Ð 62
19 - 10 LINKAGEVA

(2) Tighten door fasteners to 10 N´m (89 in. lbs.).
(3) Install bracket onto check and install bracket
bolt/nut.
(4) Tighten bracket bolt/nut to 6 N´m (53 in. lbs.).
(5) Install check bracket onto a-pillar.
(6) Apply Loctitet243 sealant check strap bolts
and install bolts.
(7) Tighten the M8 bolts to 35 N´m (26 ft. lbs.) or
tighten the M6 bolts to 10 N´m (89 in. lbs.).
(8) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(9) Connect battery negative cable.
DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Position aside the wiring boot and disconnect
the electrical connectors. (Fig. 3)
(4) Remove the bolts and disconnect the door check
from the a-pillar. (Fig. 4)
(5) Support door with a suitable device.
(6) Loosen the hinge set screws. (Fig. 5)
(7) Remove door by lifting off hinge pins.
INSTALLATION
(1) Slide door into hinges.
(2) Install set screws.
(3) Install check bracket onto a-pillar.
(4) Apply Loctitet243 sealant check strap bolts
and install bolts.(5) Tighten the M8 bolts to 35 N´m (26 ft. lbs.) or
tighten the M6 bolts to 10 N´m (89 in. lbs.).
(6) Connect all door electrical connectors and posi-
tion boot back.
(7) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
(8) Adjust door if required. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
(9) Connect battery negative cable.
Fig. 3 ELECTRICAL CONNECTORS
1 - ELECTRICAL CONNECTORS
2 - BOOT
3 - DOOR
Fig. 4 FRONT DOOR CHECK - BODY
1 - DOOR
2 - A-PILLAR BOLTS
3 - DOOR CHECK
Fig. 5 FRONT DOOR
1 - UPPER CHECK BOLT
2 - DOOR CHECK
3 - UPPER HINGE SET SCREW
4 - LOWER HINGE SET SCREW
5 - HINGE RECEIVERS
6 - DOOR
7 - LOWER CHECK BOLT
23 - 14 DOOR - FRONTVA
CHECK (Continued)

(5) Remove bolts.
(6)
Remove crossmember and disconnect hood cable.
INSTALLATION
(1) Connect hood release cable and install cross-
member.
(2) Install crossmember bolts and tighten to 14
N´m (10 ft. lbs.).
(3) Install rubber mounts and retaining clamps.
(4) Install heat shield.
(5) Install headlamps. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/FRONT LAMP
UNIT - INSTALLATION)
(6) Install grille. (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION)
SIDE VIEW MIRROR
REMOVAL
Driver's Side
(1) Disconnect and isolate battery negative cable.
(2) Remove trim plug. (Fig. 3)
NOTE: If the vehicle is not equipped with power
mirrors, skip to step 5.
(3) Remove trim panel. (Refer to 23 - BODY/DOOR
- FRONT/TRIM PANEL - REMOVAL)
(4) Remove tape, expose electrical connector and
disconnect. (Fig. 3)
(5) Remove bolts and remove mirror.
(6) If equipped, Pull wire harness through.
Passenger Side
(1) Disconnect and isolate battery negative cable.
(2) Remove trim plug. (Fig. 4)
NOTE: If the vehicle is not equipped with power
mirrors, skip to step 5.
(3) Separate dust boot from a-pillar.
(4) Disconnect the electrical connector.
(5) Remove bolts and remove mirror.
(6) If equipped, pull wire harness through.
INSTALLATION
Driver's Side
(1) If equipped, pull wire harness through door.
(2) Install mirror and bolts.
(3) Tighten the bolts to 25 N´m (18 ft. lbs.).
NOTE: If vehicle is not equipped with power mir-
rors, skip to step 6.
(4) Connect electrical connector and replace tape.
(5) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(6) Install trim plug.
(7) Connect battery negative cable.
Fig. 2 RADIATOR CROSSMEMBER
1 - HEAT SHIELD
2 - HOOD CABLE
3 - CROSSMEMBER
4 - RUBBER MOUNTS
5 - RETAINING CLAMP
Fig. 3 DRIVERS SIDE MIRROR
1 - ELECTRICAL CONNECTOR
2 - MIRROR
3 - EXTERIOR BOLTS
4 - INNER BOLT
5 - TRIM PLUG
6 - TAPE
23 - 48 EXTERIORVA
RADIATOR CROSSMEMBER (Continued)

Passenger Side
(1) If equipped, pull wire harness through door.
(2) Install mirror and bolts.
(3) Tighten the bolts to 25 N´m (18 ft. lbs.).
NOTE: If vehicle is not equipped with power mir-
rors, skip to step 6.
(4) Connect the electrical connector.
(5) Connect dust boot to a-pillar.
(6) Install trim plug.
(7) Connect battery negative cable.
SIDE VIEW MIRROR - GLASS
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Press mirror glass in at bottom.
(3) Pull mirror glass up and out of the guides.
(Fig. 5)
(4) Disconnect the electrical connectors, if
equipped.
INSTALLATION
(1) Connect the electrical connectors, if equipped.
(2) Push mirror glass down into the guides.
(3) Straighten mirror glass.
(4) Connect battery negative cable.
Fig. 4 PASSENGER SIDE MIRROR
1 - OUTER BOLTS
2 - INNER BOLT
3 - TRIM PLUG
4 - MIRROR
5 - ELECTRICAL CONNECTOR
6 - DUST BOOT
Fig. 5 SIDE VIEW MIRROR - GLASS
1 - MIRROR GLASS
2 - ELECTRICAL CONNECTORS
3 - GUIDES
VAEXTERIOR 23 - 49
SIDE VIEW MIRROR (Continued)