brake MERCEDES-BENZ SPRINTER 2006 Service Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID..........................2
BRAKE FLUID.........................2
HOAT COOLANT.......................2
ENGINE OIL - DIESEL ENGINES...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......5FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........7
MAINTENANCE SCHEDULES
DESCRIPTION..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VALUBRICATION & MAINTENANCE 0 - 1

AXLE FLUID
Use oils approved to MB 235.0 or 235.6, such as
Shell Spirax MB90, Caltex Hypoid LD, or MOPARt
part number 4874469, or equivalent. An API GL-5/
MIL-2105-E SAE 90 Hypoid Gear Oil may be substi-
tuted. Reduced axle durability may result if an
unapproved product is used.
BRAKE FLUID
Use brake fluid approved to MB 331.0, such as
Intac B026D, MOPARtBrake & Clutch Fluid, part
number 04549625AC, or equivalent. If the approved
product is not available, use a DOT 4 brake fluid:
minimum dry boiling point (ERBP) 500ÉF, minimum
wet boiling point (WERBP) 356ÉF, maximum viscos-
ity 1500 mm
2/s, conforming to FMVSS 116 and ISO
4925.
HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Use coolant approved to MB 325.0, such
as EURO Peak Coolant/Anti-freeze (OLD WORLD
INDUSTRIES), Zerex G05 or G48 (The Valvoline
Company), Glysantin G05 (BASF AG), MOPARtpart
number 05066386AA, or an equivalent Extended LifeCoolant with the HOAT inhibitor system. This cool-
ant offers the best engine cooling without corrosion
when mixed with 50% anti-freeze and 50% distilled
water to obtain a freeze point of -37ÉC (-34ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: This coolant may not be mixed with any
other type of antifreeze. Mixing of coolants other
than specified (non-HOAT), may result in engine
damage that may not be covered under the new
vehicle warranty, and decreased corrosion protec-
tion.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise. The increased tempera-
ture can result in engine detonation. In addition, 100
percent ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
0 - 2 LUBRICATION & MAINTENANCEVA

HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
The forward lifting pads should be positioned
against the forward flange of the transmission
crossmember brackets at the bottom of the frame
rail. The real lifting pads should be wedged
between the forward flange of the leaf spring
bracket and the frame rail. Safety stands should be
placed under the frame rails at the front and rear
ends.
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
Fig. 2 HOIST LOCATIONS
1 - TRANSMISSION CROSSMEMBER SUPPORT
2 - REAR LEAF SPRING MOUNT - FRONT
3 - TRANSMISSION CROSSMEMBER
0 - 6 LUBRICATION & MAINTENANCEVA

(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNING: Do not tow the vehicle if the key cannot
be turned in the ignition lock. If the key cannot be
turned, the ignition lock remains locked and the
vehicle cannot be steered. With the engine not run-
ning there is no power assistance for the braking
and steering systems. In this case, it is important to
keep in mind that a considerably higher degree of
effort is necessary to brake and steer the vehicle.
The vehicle must not be towed with the front axle
raised and the key in position 2 in the ignition lock
as the drive wheels could then lock due to the
acceleration skid control (ASR)
If the Engine is Damaged
For towing distances up to 30 miles (about 50
km)
²Shift selector lever in ªNº position.
²Do not exceed a towing speed of 30 m.p.h. (50
km/h).
For towing distances greater than 30 mile
(about 50 km)
²Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Transmission is Damaged
²Remove the propeller shafts leading to the drive
axles. The vehicle can be towed without restriction.
If the Front Axle is Damaged
²Raise the front axle.
²Observe the same towing restrictions as for
engine damage.
If the Rear Axle is Damaged
²Raise the rear axle.
NOTE: Comply with local legal regulations regard-
ing towing vehicles.
SAFETY PRECAUTIONS
NOTE: The following safety precautions must be
observed when towing a vehicle.
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Remove exhaust pipe tips that interfere with the
tow sling and crossbar
²Padding should be placed between the tow sling/
crossbar and any painted surfaces
²When placing tow hooks on the rear axle, posi-
tion them so they do not damage the brake tubing or
hoses
²Do not tow the vehicle by connecting to the front
or rear shock absorbers
²Do not tow a heavily loaded vehicle. Damage to
the vehicle may result. Use a flatbed device to trans-
port a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain, steep rises in the road or if the vehicle
is equipped with air dams, spoilers, and/or ground
VALUBRICATION & MAINTENANCE 0 - 7

effect panels. If necessary, remove the wheels from
the lifted end of the vehicle and lower the vehicle
closer to the ground, to increase the ground clearance
at the opposite end of the vehicle. Install lug nuts on
wheel attaching studs to retain brake drums.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies.
MAINTENANCE SCHEDULES
DESCRIPTION
The use of special lubricant additives is not recom-
mended. The use of such additives may affect the
warranty rights. With regard to legal stipulations
concerning emissions control, please note that
engines have to be serviced and adjusted in accor-
dance with special instructions and using special
measuring equipment. Modifications to or interfer-
ence with the emissions control systems are not per-
missible.
MAINTENANCE - WITHOUT ASSYST MAINTE-
NANCE COMPUTER
Maintenance Intervals
²Oil service ±Normal Operationevery 10,000
miles or 16,000 km or 12 months.
²Maintenance service every 30,000 miles or
48,000 km.
Additional work must be carried out at yearly
intervals.
MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
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 will be reset after an oil ser-
vice and/or maintenance service has been performed.
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 - 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.
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 Replacement
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 a minimum, change the engine oil and oil filter
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.
0 - 8 LUBRICATION & MAINTENANCEVA

SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
²Engine: Oil change and filter replacement
Check fluid levels of the following system, refill as neces-
sary.
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
²Check fluid levels for the following systems, cor-
rect as necessary
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
²Engine cooling system. Check corrosion inhibi-
tor/antifreeze, refill as necessary.
²Hydraulic brake system
²Battery
²Windshield washer system
Engine
²Fuel filter renewal - Every oil service
²Air cleaner with maintenance indicator:
²Check degree of contamination.
²Air cleaner filter element renewed as necessary.
Chassis and body
²Trailer coupling: Check operation, play and
retaining fixtures
²Secondary rubber springs: Visual check
²Tire pressures: Correct as necessary, including
spare tire
²Check thickness of brake pads
²Brake test
²Check condition of steering mechanism
²Heating/ventilation dust filter renewal
ADDITIONAL MAINTENANCE WORK
Automatic transmission once only at 80,000 miles / 128000
km
²Oil and filter change
During every second maintenance service
²Air cleaner without maintenance indicator:
²Air cleaner filter element renewal
²Check poly-V-belt for wear and signs of damage
During every fourth maintenance service
²Change rear axle fluid
ADDITIONAL MAINTENANCE WORK AFTER YEARS
Every 2 years
²Change brake fluid.
Every 3 years
²Air cleaner filter element renewal (note installa-
tion date)
Every 15 years or 100,000 miles
²Coolant renewal
²Note coolant composition
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).
Fig. 3 INTERNATIONAL SYMBOLS
VALUBRICATION & MAINTENANCE 0 - 9

HUB / BEARING
DIAGNOSIS AND TESTING -
(1) Raise and support the vehicle.
(2) Remove the grease cap.
(3) Position a dial indicator against the face of the
wheel hub (Fig. 3).
(4) Tighten the locking screw on the clamping nut
(Fig. 3).
(5) Pull the wheel hub firmly back and forth and
read off the wheel bearing play on the dial gauge.
(Wheel bearing play should be 0.02 - 0.04 mm
(0.000787 - 0.00158 in.).
(6) If necessary, loosen the locking screw and
adjust the wheel bearing play by loosing or tighten-
ing the clamping nut.
(7) Retighten the locking screw and recheck the
wheel bearing play.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(3) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the wheel flange ring (if equipped with
dual rear wheels) (Fig. 5).
(5) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(6) Remove the grease cap (Fig. 4).
(7) Loosen the bolt on the clamping nut and
remove the clamping nut (Fig. 4).
(8) Remove the thrust washer (Fig. 4).
(9) Remove the wheel hub and tapered roller bear-
ing from the stub axle assembly (Fig. 4).
Fig. 2 LCA BUSHING INSTALL
1 - SPECIAL TOOL C-4212F (PRESS)
2 - SPECIAL TOOL 9302-1 (DRIVER)
3 - BUSHING
4 - SPECIAL TOOL 9302-2 (SIZER CUP)
5 - LOWER CONTROL ARM
6 - SPECIAL TOOL 9302-4 (RECEIVER CUP)
Fig. 3 MEASURING & ADJUSTING WHEEL BEARING
1 - WHEEL HUB
2 - LOCKING SCREW
3 - DIAL INDICATOR
2 - 4 FRONTVA

INSTALLATION
(1) Install the wheel hub with the tapered roller
bearing on the stub axle (Fig. 4).
(2) Grease the outer tapered roller bearing thor-
oughly and push onto the steering knuckle (Fig. 4).
NOTE: The smooth side of the thrust washer must
point toward the wheel bearing.
(3) Install the thrust washer (Fig. 4).
(4) Install the clamping nut (Fig. 4). Tighten to 12
N´m (9 ft. lbs.) and then loosen a half of a turn.
(5) Check for wheel bearing end play. End play
should be 0.02- 0.04 mm (0.000787 - 0.00158 in.)
(Fig. 3) (Refer to 2 - SUSPENSION/FRONT/HUB /
BEARING - DIAGNOSIS AND TESTING).
(6) Pack the grease cap half with grease and coat
at the edge with sealant and install the cap (Fig. 4).
(7) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(9) Install the wheel flange ring (if equipped with
dual rear wheels) (Fig. 5).
(10) Install the front tire & wheels assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - INSTAL-
LATION).
(11) Lower the vehicle.
KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(3) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the hub/bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - REMOVAL).
(5) Separate the outer tie rod from the steering
knuckle (Fig. 6) using special tool C-3894±A.
(6) Raise the lower control arm approximately 10
mm using a jack.In order to eliminate tensile
force in the damper strut.
(7) Remove the ABS sensor from the knuckle by
pulling straight out.
(8) Remove the strut at the knuckle (Fig. 6).
(9) Separate the lower ball joint from the steering
knuckle using special tool 9282 (Fig. 6).
(10) Remove the steering knuckle from the vehicle
(Fig. 6).
Fig. 4 FRONT WHEEL HUB WITH SINGLE REAR
WHEELS (SRW)
1 - CALIPER ADAPTER BOLT
2 - DISC BRAKE CALIPER
3 - INNER BEARING
4 - WHEEL HUB
5 - DISC BRAKE ROTOR
6 - OUTER BEARING
7 - THRUST WASHER
8 - CLAMPING NUT
9 - GREASE CAP
10 - LOCKING BOLT
11 - GREASE SEAL
12 - STEERING KNUCKLE
Fig. 5 FRONT WHEEL HUB WITH DUAL REAR
WHEELS (DRW)
1 - ADAPTER BOLT
2 - DISC BRAKE CALIPER
3 - INNER BEARING RACE
4 - WHEEL HUB
5 - DISC BRAKE ROTOR
6 - LOCKING BOLT
7 - WHEEL FLANGE RING
8 - OUTER BEARING
9 - THRUST WASHER
10 - CLAMPING NUT
11 - GREASE CAP
12 - WHEEL FLANGE RING MOUNTING BOLT
13 - GREASE SEAL
14 - STEERING KNUCKLE
VAFRONT 2 - 5

INSTALLATION
(1) Install the steering knuckle on the lower ball
joint stud (Fig. 6).
(2) Install the lower ball joint nut (Fig. 6). Tighten
to 280 N´m (206 ft. lbs.)
(3) Install the strut to the steering knuckle (Fig.
6). Tighten to 185 N´m (136 ft. lbs.).
(4) Install the outer tie rod end to the steering
knuckle (Fig. 6) and tighten the nut to 130 N´m (96
ft. lbs.).
(5) Install the ABS sensor by pushing the sensor
all the way into the knuckle and the sensor will self
adjust when the wheel is turned.
(6) Install the hub/bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - INSTALLATION).
(7) Install the disc brake caliper adapter with the
brake caliper (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/DISC BRAKE CALIPER ADAPTER -
INSTALLATION).
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
(10) Check and set toe if necessary (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
LOWER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - REMOVAL).(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Remove the lower ball joint using special tool
9294-1 (Driver) with 9294-2 (Reciever) and C-4212±F.
(Fig. 7).
INSTALLATION
(1) Install the ball joint into the lower control arm
using special tool 9294-3 (Installer ring) inserted in
9294-2 (Reciever) and C-4212±F (Fig. 7).
(2) Install the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - INSTALLATION).
(3) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(4) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
(6) Check the front wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - SPECIFICA-
TIONS).
LOWER CONTROL ARM
REMOVAL
(1) Insert spring blocks special tool 9288 between
the spring and the spring clamp plates, While the
vehicles wheels are on the ground.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Hang
the caliper. Do not allow brake hose to support
the caliper weight.
(5) Remove the retaining nut holding the tie rod to
the steering knuckle (Fig. 8).
Fig. 6 STEERING KNUCKLE
1 - STRUT
2 - STRUT BOLT
3 - STEERING KNUCKLE
4 - LOWER BALL JOINT NUT
5 - OUTER TIE ROD END RETAINING NUT
6 - INNER TIE ROD END
7 - LOWER CONTROL ARM
Fig. 7 LOWER BALL JOINT
1 - LOWER CONTROL ARM
2 - LOWER BALL JOINT
2 - 6 FRONTVA

(6) Seperate the tie rod off the steering knuckle
(Fig. 8) using special tool C-3894±A.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.
(7) Remove the strut bolts from the steering
knuckle (Fig. 8).
(8) Remove the stop plate bolts and rotate the
plate upwards with the stabilizer link attached (Fig.
8).
(9) Lower the lower control arm.
(10) Remove the lower ball joint nut from the
steering knuckle (Fig. 8).
(11) Separate the lower ball joint from the knuckle
using special tool 9282.
(12) Remove the lower control arm nuts and bolts
from the frame (Fig. 8).
(13) Remove the lower control arm.
INSTALLATION
(1) Install the lower control arm to the frame.
Hand tighten the nuts and bolts.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.(2) Install the lower ball joint into the steering
knuckle. Tighten to 280 N´m (206 ft. lbs.).
(3) Install the strut bolts to the steering knuckle
(Fig. 8). Tighten to 185 N´m (136 ft. lbs.).
(4) Install the stop plate (Refer to 2 - SUSPEN-
SION/FRONT/SPRING STOP PLATES - INSTALLA-
TION).
(5) Lower the lower control arm.
(6) Attach the tie rod to the steering knuckle (Fig.
8). Tighten the nut to 130 N´m (96 ft. lbs.)
(7) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION)
(Fig. 8).
(8) Install the front tire & wheel assembly (Refer
to 22 - TIRES/WHEELS/WHEELS - INSTALLA-
TION).
(9) Lower the vehicle.
(10) Remove the spring blocks between the spring
and the spring clamp plates, While the vehicles
wheels are on the ground.
(11) Roll the vehicle approximately 1 mm forwards
and the backwards, and rock firmly.
(12) Tighten the lower control arm nuts and bolts
to the frame to 150 N´m (110 ft. lbs.) (Fig. 8).
(13) Apply brake to actuate brake pressure.
SPRING
REMOVAL
(1)To do this next step the vehicle must be
on the ground.Remove the front and rear bolts on
the left and right spring clamp plates (Fig. 9).
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the brake caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Do not
allow the caliper to hang by the hose, support
the caliper accordingly.
(5) Remove the ABS sensor from the mounting
bore in the steering knuckle (Fig. 9).
(6) Remove the outer tie rod retaining nut and
separate the tie rod from the knuckle (Fig. 9) using
special tool C-3894±A.
NOTE: In order to remove tension from the strut,
Raise the lower control arm approximately 10 mm
with a jack.
(7) Remove the strut bolts from the steering
knuckle.
(8) Remove both stop plate bolts and rotate the
plates upwards with the stabilizer link attached.
(9) Lower the lower control arm.
(10) Remove the lower ball joint nut from the
steering knuckle.
Fig. 8 LOWER CONTROL ARM
1 - STRUT
2 - LOWER CONTROL ARM BOLT
3 - STOP PLATE BOLT
4 - STOP PLATE
5 - CALIPER ADPTER BOLT
6 - DISC BRAKE CALIPER
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
9 - OUTER TIE ROD END RETAINING NUT
10 - OUTER TIE ROD END
11 - LOWER BALL JOINT NUT
12 - LOWER BALL JOINT
13 - LOWER CONTROL ARM NUTS
14 - STRUT BOLT
VAFRONT 2 - 7