MERCEDES-BENZ SPRINTER 2006 Service Manual

(5) Remove the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(6) Remove the fuel rail support block between cyl-
inders #1 and #2 (Fig. 68).
(7) Disconnect the charge air hose at the intake
manifold (Fig. 69).
Fig. 68 FUEL INJECTORS AND HIGH PRESSURE
FUEL LINES
1 - FUEL RAIL
2 - HIGH PRESSURE FUEL INJECTOR LINES
3 - INTAKE MANIFOLD
4 - FUEL INJECTOR
5 - CRANKCASE VENTILATION BREATHER
6 - CAMSHAFT POSITION SENSOR
9 - 66 ENGINEVA

(8) Disconnect the EGR wiring harness connector
(Fig. 69).
(9) Remove the bolt retaining the engine wiring
harness to the intake manifold.
(10) Disconnect the coolant hose at the EGR valve.
NOTE: Collect and store any fluid spillage when
disconnecting components.
(11) Disconnect both fuel lines at the fuel filter
(Fig. 69).
(12) Remove the lower intake manifold support
bracket (Fig. 70).
(13) Raise and support the vehicle.
(14) Remove the rear intake manifold mounting
bolts while accessible from below.
(15) Lower the vehicle.
Fig. 69 INTAKE MANIFOLD
1 - CLIP 6 - ENGINE OIL COOLER
2 - INTAKE MANIFOLD 7 - HIGH PRESSURE FUEL RAIL
3 - EGR VALVE 8 - COOLANT TEMPERATURE SENSOR
4 - EGR VALVE COOLANT HOSE 9 - FUEL RAIL PRESSURE SENSOR
5 - FUEL FILTER 10 - CHARGE AIR HOSE
VAENGINE 9 - 67

NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.
(16) Remove the remaining intake manifold bolts,
lift the intake manifold up and out while guiding the
engine wiring harness and fuel lines through the
openings in the intake manifold, then remove the
gasket (Fig. 70).
NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.
INSTALLATION
NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.
(1) Clean both mating surfaces and install a new
intake manifold gasket with the intake manifold.
Guide the engine wiring harness and fuel lines
through the intake manifold openings. Tighten man-
ifold bolts to 16 N´m (142 lbs. in.) in a cross direc-
tional pattern beginning with the middle bolts and
tightening outward to the ends.
(2) Raise and support the vehicle.
(3) Install the rear intake manifold bolts and
tighten to 16 N´m (142 lbs. in.) (Fig. 70).
(4) Install the lower intake manifold support
bracket. Tighten bolts to 20 N´m (177 lbs. in.) (Fig.
70).
(5) Lower the vehicle.(6) Connect both fuel lines to fuel filter assembly
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL FILTER - INSTALLATION).
(7) Connect the coolant hose at the EGR valve
(Fig. 69).
(8) Secure the engine wiring harness and cable
duct to the intake manifold. tighten fastener to 9N´m
(80 in. lbs.).
(9) Connect the EGR wiring harness connector
(Fig. 69).
(10) Connect the fuel pressure sensor electrical
connector
(11) Install the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - INSTALLA-
TION).
NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.
(12) Install the high pressure fuel lines (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).
(13) Connect the charge air hose to the intake
manifold (Fig. 69).
(14) Install the engine cover (Refer to 9 - ENGINE
- INSTALLATION).
(15) Fill the cooling system.
(16) Connect the negative battery cable.
(17) Start the engine, run until warm, turn engine
off and inspect for leaks. Care must be taken to
observe the fuel system warning. (Refer to 14 - FUEL
SYSTEM - WARNING).
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the exhaust heat shield.
(3) Raise and support the vehicle.
(4) Remove the turbocharger support bracket.
(5) Loosen the exhaust pipe to engine bracket fas-
teners at the rear of the engine block.
(6) Remove the exhaust hanger fasteners at the
muffler.
(7) Disconnect the front exhaust pipe to turbo-
charger fastener (Fig. 71).
Fig. 70 INTAKE MANIFOLD
1 - INTAKE BOLT ACCESS HOLE
2 - INTAKE MANIFOLD
3 - SUPPORT BRACKET
9 - 68 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

(8) Install the exhaust hanger fasteners at the
muffler.
(9) Tighten the exhaust hanger bracket to engine
block.
(10) Install the turbocharger support bracket.
(11) Lower the vehicle.
(12) Install the air cleaner duct to the turbo-
charger (Fig. 71).
(13) Install the exhaust heat shield.
(14) Connect the negative battery cable.
TIMING CHAIN COVER
REMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS TEMPERATURE IS BELOW 90ÉC (194ÉF).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(2) Position piston of cylinder 1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).
(8) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(9) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(12) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(13) Remove accessory drive belt pulley and vibra-
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).
(14) Remove the power steering pump.NOTE: NO NOT open the air conditioning system.
(15) Unplug AC compressor electrical connector
and unbolt AC compressor. Relocate in lower engine
compartmentwith outopening the system.
(16) Remove the generator with wiring attached
and relocate somewhere in the engine compartment.
(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 73).
(20) Remove the cylinder head to timing cover
bolts (Fig. 73).
(21) Remove the timing cover bolts and cover (Fig.
73).
(22) Remove remaining ancillary components
attached to the timing case cover (Fig. 73).
NOTE: Inspect condition of hoses and clamps,
replace as necessary.
(23) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 73).
Fig. 73 TIMING CHAIN COVER
1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER
9 - 70 ENGINEVA

INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.
(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace the front crankshaft seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 74).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N´m (177 lbs in) (Fig. 73).(6) Install the M8 bolts of cylinder head on timing
case cover. Tighten bolts to 20 N´m (177 lbs in) (Fig.
73).
(7) Install timing chain tensioner with new seal
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
(8) Position and install the oil pan. Tighten M6
bolts to 9 N´m (80 lbs in) and M8 bolts to 20 N´m
(177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
M8.8 bolt in two stages, 200N´m (147 lbs ft.) then
90É, M10.9 bolt 325N´m (240 lbs ft) then 90É.
(10) Remove the engine support fixture.
(11) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditioning compressor.
(13) Install the power steering pump.
(14) Install water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sealant to lower portion of, and install,
front cover to cylinder block. Tighten bolts to 20N´m
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
- INSTALLATION).
(18) Remove retaining lock for crankshaft/starter
ring gear.
(19) Tighten the oil drain plug to 30N´m (265 lbs
in).
(20) Install a new oil filter. tighten screw cap for
filter to 25N´m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).
(23) Install air intake hose.
(24) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(25) Fill the crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(26) Connect the negative battery cable.
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 CLOTHES.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
Fig. 74 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VAENGINE 9 - 71

(27) Start engine and inspect for leaks. care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
TIMING CHAIN AND SPROCK-
ETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE RAILS
NOTE: If it necessary to replace the tensioning rail,
slide rail or tensioning arm, they are always
replaced together.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
(3) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(4) Pull the tensioning rail off of the bearing pins
(Fig. 75).
(5) Release the spring at the slide rail and take it
off of the tensioning arm (Fig. 75).
9 - 72 ENGINEVA

REMOVAL - INTERMEDIATE GEAR
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
WARNING: NO FIRE, FLAMES OR SMOKING. RISK
OF POISONING FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. POUR FUELS ONLY INTO
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS. WEAR PROTECTIVE CLOTHING.
(3) Remove fuel high pressure lines injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).(6) Insert locking pin through first camshaft bear-
ing cap into hole in inlet camshaft sprocket to lock
inlet camshaft.
(7) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(8) Remove high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(9) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove top slide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: Note position of dowel pin for camshaft
sprocket alignment during reassembly.
(11) Unbolt exhaust camshaft sprocket and
remove.
Fig. 75 TENSIONING AND SLIDE RAILS
1 - TENSIONING RAIL 5 - TENSIONING CLAMP
2 - BEARING PIN 6 - BEARING PIN
3 - SLIDE RAIL 7 - SPRING
4 - BEARING PIN 8 - OIL PUMP
VAENGINE 9 - 73

(12) Remove the intake camshaft (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
REMOVAL).
(13) Remove intermediate gear and bushing (Fig.
76).
REMOVAL - TIMING CHAIN TENSIONING RAIL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
(3) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(4) Remove tensioning rail from bearing pin (Fig.
77).
REMOVAL - TIMING CHAIN
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
NOTE: Cover the timing chain area. Care must be
taken not to drop any repair debris or pieces into
the engine when separating the timing chain links.
(2) Install special tool # 9525 using two of the cyl-
inder head cover bolts (Fig. 78).
Fig. 76 HIGH RESSURE PUMP INTERMEDIATE
GEAR
1 - CAMSHAFT SPROCKET BOLTS
2 - INTAKE CAMSHAFT
3 - DOWEL PIN
4 - INTERMEDIATE GEAR BUSHING
5 - INTERMEDIATE GEAR
6 - CAMSHAFT LOCKING PIN #8929
7 - INTAKE CAMSHAFT SPROCKET
Fig. 77 TIMING CHAIN TENSIONING RAIL
1 - TIMING CHAIN COVER
2 - TENSIONING RAIL
3 - BEARING PIN
4 - OIL PAN
9 - 74 ENGINEVA

(3) Assemble special tool #9312±1 using 9312± 3
and 9312±4. Install insert #9312±13 and retain with
screw provided. (Fig. 79).
CAUTION: Care must be taken not to drop the tim-
ing chain plates into the engine once the timing
chain is separated.
NOTE: When installing special tool #9312±1 onto
timing chain link, be sure to back off the smaller
nut of the thrust pin #9312±3 until the pin is
recessed inside of the spindle, #9312±4. Screw the
thrust spindle #9312±4 in until it is seated and
aligned properly over the rivet of the timing chain.
NOTE: When fitting the thrust spindle, ensure that
the thrust pin is positioned at the left timing chain
pin of a chain link.
(4) Install special tool #9312 onto timing chain
link (Fig. 79).NOTE: Cover the timing chain area. Care must be
taken not to drop any repair debris or pieces into
the engine when separating the timing chain links.
(5) Carefully turn the thrust pin #9312±3 of spe-
cial tool #9312±1 clockwise while holding the handle
until the rivet is pressed out and the chain is sepa-
rated (Fig. 80). Discard the loose link and plates.
NOTE: One whole timing chain link must be
removed.
Fig. 78 SPECIAL TOOL 9525
1 - SPECIAL TOOL 9525
Fig. 79 SPECIAL TOOL #9312±1 WITH INSERT
9312±13
1 - SPECIAL TOOL #9312-1
2 - SPECIAL TOOL #9312-13 - INSERT
3 - SPECIAL TOOL #9312-3 - THRUST PIN
4 - SPECIAL TOOL #9312-4 - SPINDLE
VAENGINE 9 - 75