heater MERCEDES-BENZ SPRINTER 2006 Service Manual

(30) Disconnect the engine valley drain hose fas-
tener from the transmission (Fig. 5).
(31) Remove the steering gear mounting bolts.
(32) Disconnect the transmission cooler lines at
transmission and oil pan.
(33) Remove the torque converter access plate.
(34) Remove the torque converter bolts.
(35) Remove the crank position sensor.
(36) Remove the transmission housing to engine
mounting bolts.
(37) Remove the starter mounting bolts (Fig. 5).
(38) Support the transmission with a transmission
jack.
(39) Place a wood block between the transmission
housing and the front frame cross over.
(40) Remove the transmission jack.
(41) Remove the exhaust bracket (right side).
(42) Remove the engine ground strap (left side).
(43) Lower the vehicle.
(44) Remove the heater housing filter and lower
housing.(45) Connect the engine lifting fixture #9308 to the
engine lifting eyes.
(46) Remove the engine mount bolts.
(47) Remove the transmission oil level indicator
tube mounting bolt.
Fig. 5 2.7L CDI ENGINE
1 - INTAKE MANIFOLD 5 - FUEL FILTER
2 - ENGINE VALLEY DRAIN HOSE 6 - AIR CONDITIONING COMPRESSOR
3 - STARTER 7 - POWER STEERING PUMP
4 - ENGINE OIL LEVEL SENSOR 8 - EGR VALVE
9 - 8 ENGINEVA

(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(13) Connect the engine valley drain hose to the
transmission (Fig. 5).
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(15) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and
CCV heater at the turbocharger (Fig. 4).
(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the
vacuum pump.(24) Connect the fuel lines at the filter assembly
(Fig. 9).
(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser and fan assemblies Con-
nect the fan harness connector.
(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).
(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-
tor.
(32) Install air cleaner housing and connect the air
inlet duct and air flow sensor.
(33) Connect the charge air cooler hose at intake
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).
(34) Route the engine wiring harness inside the
vehicle and connect.
(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
Fig. 8 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
Fig. 9 FUEL FILTER
1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
9 - 10 ENGINEVA

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat Ex-
changer 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 En-
gine 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, 90É -
Bolt-Engine Mount to En-
gine Bracket55 40.5 -
Bolt-Front Engine Mount
to Front Axle Carrier35 26 -
Bolt-Rear Engine Cross
Member to Body40 30 -
Bolt-Rear Engine Mount
to Rear Engine Cross
Member35 26 -
Bolt/Nut- Rear Engine
Mount to Transmission40 26 -
Bolt-Shrowd to Engine
Bracket10 - 88.5
Nut-Front Engine Mount
to Engine Bracket65 48 -
Nut-Engine Mount to Ve-
hicle Frame35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
9 - 14 ENGINEVA

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Bracket to High Pres-
sure 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 Cyl-
inder 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, 1 torque angle)7/90É - 62, 90É
Rail-Pressure Sensor to
Rail22 16 -
Pressure Pipe Connection
to Injector42 31 -
Threaded Rail to Rail 22 16 -
Fuel Cooling System
Bolt-Fuel Cooler to
Charge Air Distribution
Pipe14 - 124
Heater Booster, Heater Unit
Bolt- Temperature Con-
trolled Cut Out to Heater
Booster Control Module12 - 106
Nut-Threaded Stud to
Electronic Heater Booster18 - 159
9 - 16 ENGINEVA

(5) Remove the belt pulley/vibration damper (Fig.
47).
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. 47).
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) Install the additional A/C compressor drive belt
(if equipped).
(6) Install the coolant module (if equipped with the
additional A/C compressor).
(7) 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.
(8) 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.
Fig. 47 VIBRATION DAMPER/CRANKSHAFT PULLEY
1 - SPECIAL TOOL #8932
2 - RETAINING BOLTS
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY
4 - WASHER
5 - CRANKSHAFT BOLT
9 - 54 ENGINEVA

(8) Position the front exhaust pipe aside.
(9) Lower the vehicle.
(10) Remove the air cleaner housing hose from the
turbocharger and position aside (Fig. 71).
(11) Remove the turbocharger oil cooler lines (Fig.
72).(12) Remove the turbocharger to exhaust manifold
fasteners and remove turbocharger (Fig. 72).
(13) Remove the self locking exhaust manifold fas-
teners (Fig. 72).
(14) Remove exhaust manifold and clean mating
surface.
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.
(2) Inspect exhaust manifold for cracks or distor-
tion.
(3) Install new exhaust manifold gasket over the
studs.
(4) Position the exhaust manifold over to studs
and tighten retaining nuts to 30 N´m (22 lbs.ft.).
NOTE: Replace the turbocharger oil cooler line
banjo bolt seals before installing the oil cooler line.
(5) Install turbocharger (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSTALLATION).
(6) Raise and support the vehicle.
(7) Install the front exhaust pipe to turbocharger
(Fig. 71).
Fig. 71 TURBOCHARGER
1 - EXHAUST MANIFOLD
2 - HEATER PIPE
3 - AIR INLET TUBE
4 - TURBOCHARGER
5 - AIR CLEANER HOUSING
6 - EXHAUST CLAMP
7 - FRONT EXHAUST PIPE
Fig. 72 EXHAUST MANIFOLD
1 - CYLINDER HEAD
2 - TURBOCHARGER OIL COOLER LINE
3 - TIMING CHAIN TENSIONER
4 - BANJO BOLT
5 - EXHAUST MANIFOLD
VAENGINE 9 - 69

INSTALLATION
(1) Position the MAF sensor to air cleaner housing
and install the retaining screws (Fig. 24).
(2) Connect the air intake hose to the MAF sensor
and tighten clamp.
(3) connect the MAF wiring harness connector.
(4) Connect negative battery cable.
O2 SENSOR
DESCRIPTION
The wide band oxygen sensor measures the oxygen
content in the exhaust gas to monitor EGR. The sen-
sor is mounted in the exhaust pipe at a 30 degree
angle to prevent the collection of moisture between
the sensor housing and element. The sensor is
located close to the turbocharger for a quicker
response time.
The oxygen sensor has five wires (heater power
and ground, reference voltage, and 2 wires for a
pump cell). The oxygen sensor connects to a six wire
harness connector. A non serviceable trimming resis-
tor is built into the sensor connector. The resistance
is dependent on the over all length and type of sen-
sor.
OPERATION
The O2 sensor is a planar zirconium dioxide (ZrO2)
dual cell limiting current probe with a integralheater. The term wide ban, refers to the ability of the
O2 sensor to generate a clear signal over a wide air-
fuel ratio measuring range. As a dual sensor, it incor-
porates a second O2 chamber (oxygen pump cell),
which requires a separate voltage supply.
The sensor element combines a sensor cell (8) and
an oxygen pump cell (9). Both cells are made of zir-
conium-dioxide (ZrO2) and are coated with porous
platinum electrodes. The sensor cell operates just
like a typical O2 sensor. The oxygen pump cell trans-
port oxygen ions when voltage is applied.
A gas sample chamber (5) is sandwiched between
the oxygen pump cell and the sensor cell. A pump
electrode and sensor cell electrode are located in the
sample chamber. A sample passage (10) connects the
sample chamber to the surrounding exhaust gas. A
sensor cell electrode is located in the reference air
channel (6), which connects to the outside air (Fig.
25).
Fig. 24 MANIFOLD AIR FLOW SENSOR
1 - WIRING HARNESS
2 - AIR INTAKE HOSE
3 - CLAMP
4 - MAF SENSOR
5 - AIR CLEANER HOUSING
VAFUEL INJECTION 14 - 45

At high temperatures, certain ceramic materials,
such as zirconium-dioxide (ZrO2) become oxygen ion
conductors. In a typical O2 sensor, the ZrO2 is used
as a solid electrolyte, which conducts oxygen ions.
The solid electrolyte is sandwiched between two plat-
inum electrodes. The sensor generates a small volt-
age when oxygen moves from the high concentration
side to the low concentration side.
The same hold true if the process is reversed. If
voltage is applied to the platinum electrodes, oxygen
can be pumped from one side of the solid electrolyte
to the other (from cathode to anode), becoming an
oxygen pump. The amount of current flow is directly
proportional to the amount of oxygen pumped by the
sensor. When the oxygen level on the supply side
reaches zero, the current stops.
The ECM activates the integral heater element to
raise the temperature of the sensor to 700C (192ÉF)
for the ZrO2 to become conductive. The heater ele-
ment is designed to reach this temperature within 8seconds and maintaining it at this level. In cold tem-
peratures, this can be delayed up to 5 minutes to
prevent damaging the ceramic coating of the sensor
from water condensation. Once the sensor is heated,
the exhaust gas components diffuse through the gas
sample chamber. Upon reaching the electrodes on the
oxygen pump and concentration cells they reach state
of thermodynamic balance (Fig. 26).
Fig. 25 O2 CONSTRUCTION
1 - EXHAUST PIPE 6 - REFERENCE AIR CHANNEL
2 - EXHAUST GAS FLOW 7 - HEATER ELEMENT
3 - O2 SENSOR CONNECTOR 8 - SENSOR CELL
4 - TRIMMING RESISTOR 9 - OXYGEN PUMP CELL
5 - GAS SAMPLE CHAMBER 10 - SAMPLE PASSAGE
14 - 46 FUEL INJECTIONVA

aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror canalso be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
23 - 2 BODYVA

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Install the instrument panel.
NOTE: The guides on the bottom of the instrument
panel must engage in the cutouts on the left and
right next to the heater housing. (Fig. 21) (Fig. 22)(2) Route wire harness through the panel.
(3) Install and tighten 12 instrument panel screws.
(Fig. 20)
CAUTION: The position of the steering gear must
not be altered.
(4) Raise steering column into position and install
the bolts. (Fig. 19)
(5) Tighten steering column bolts to 25 N´m (18 ft.
lbs.).
(6) Install ignition transponder onto column lock.
(Fig. 18)
NOTE: The dome on the transponder must engage
into the groove on the ignition switch.
(7) Install brake pedal spring. (Fig. 17)
(8) Install vent hose. (Fig. 16)
Fig. 21 ALIGNMENT CUTOUT - 1
1 - CUTOUT
2 - HEATER HOUSING
Fig. 22 ALIGNMENT CUTOUT - 2
1 - CUTOUT
2 - HEATER HOUSING
VAINSTRUMENT PANEL 23 - 63