MERCEDES-BENZ SPRINTER 2006 Service Manual

STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash
panel seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension compo-
nents.2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with other
components.4. Reposition hose.
5. Loose or damaged intermediate shaft or
column.5. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR KNOCK-
ING1. Wrong tire size. 1. Verify tire size.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball joints/
tie rod ends).3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if nec-
essary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
19 - 2 STEERINGVA

INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMEN-
TARY INCREASE IN TURNING
EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as nec-
essary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL1. Worn or loose suspension or
steering components.1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as neces-
sary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
VASTEERING 19 - 3

COLUMN
TABLE OF CONTENTS
page page
COLUMN
SPECIFICATIONS - TORQUE CHART.........4
INTERMEDIATE SHAFT
REMOVAL.............................4
INSTALLATION..........................5
KEY/LOCK CYLINDER
REMOVAL.............................5INSTALLATION..........................6
STEERING WHEEL
REMOVAL.............................6
INSTALLATION..........................6
COLUMN
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Steering Wheel With Air-
bag To Steering Shaft80 59 Ð
Jacket Tube For Steering
Shaft To Waist Rail25 18 221
U-Joint To Steering Gear
Shaft24 18 212
INTERMEDIATE SHAFT
REMOVAL
(1) Disconnect the ground cable from the battery.
(2) Remove the air bag module from the steering
wheel.
(3) Turn the steering wheel and lock the steering
wheel in the straight ahead position.The position
of the steering gear must not be altered again
for the entire duration of the work procedure.
(4) Remove the electrical center.
(5) Remove the steering wheel bolt.
(6) Remove the steering wheel from the steering
column.
(7) Remove the clockspring.Unscrew the retain-
ing bolts just enough to be able to remove the
clockspring. Do not twist or disassemble the
clockspring.
(8) Remove the combination switch.
(9) Disconnect the electrical connector for the igni-
tion lock.
(10) Remove the spring for the brake pedal from
the steering column.(11) Remove the fitted bolt from the universal joint
(Fig. 1).
(12) Remove the bolts in the steering column
bracket (Fig. 2).
Fig. 1 U-JOINT REMOVE / INSTALL
1 - FITTED BOLT
2 - U-JOINT
19 - 4 COLUMNVA

(13) Remove the steering shaft with the universal
joint off the steering gear drive shaft (Fig. 1).
(14) Pull the steering shaft out of the rubber grom-
met in the cab floor.
INSTALLATION
(1) Install the steering shaft through the rubber
grommet in the cab floor.Ensure that the rubber
grommet is properly seated.
(2) Install the steering shaft with the universal
joint onto the steering gear shaft (Fig. 1).
(3) Install the bolts in the steering column bracket
(Fig. 2). Tighten to 24 N´m (18 ft. lbs.).
(4) Install the universal joint on the steering gear
shaft (Fig. 1). Tighten to 24 N´m (18 ft. lbs.).
(5) Install the spring for the brake pedal to the
steering column.
(6) Reconnect the electrical connector to the igni-
tion lock.
(7) Install the combination switch.
(8) Install the clockspring.
(9) Install the steering wheel.
(10) Install the electrical center.
(11) Reconnect the ground cable to the battery.
KEY / LOCK CYLINDER
REMOVAL
(1) Remove the securing cover for the central elec-
tronics.
(2) Remove the steering column shroud.
(3) Remove the transponder coil off the ignition
lock (Fig. 3).(4) Insert the key into the ignition lock.
(5) Turn the ignition key to the first detent (Fig.
4).
(6) Turn the cap a 1/4 turn to the left (Fig. 5).
Fig. 2 STEERING COLUMN BOLTS
1 - BOLT
2 - COLUMN BOLT
Fig. 3 TRANSPONDER
1 - TRANSPONDER
2 - STEERING COLUMN
Fig. 4 IGNITION LOCK FIRST DETENT
1 - LOCK HOUSING
2 - FIRST DETENT WITH KEY INSTALLED
VACOLUMN 19 - 5

(7) Remove cap together with the lock cylinder off
the ignition lock (Fig. 6).
INSTALLATION
(1) Install the cap together with the lock cylinder
onto the ignition lock (Fig. 6).
(2) Turn the cap a 1/4 turn to the right.
(3) Turn the ignition key to the first detent (Fig.
4).
(4) Remove the ignition key from the ignition lock.
(5) Install the transponder coil onto the ignition
lock (Fig. 3).
(6) Install the steering column shroud.Pay atten-
tion to the cables routed under the steering col-
umn cover. Do not trap the cables.
(7) Install the cover for the central electronics.
STEERING WHEEL
REMOVAL
(1) Disconnect the ground cable on the battery.
(2) Remove the air bag module from the steering
wheel.
(3) Turn the steering wheel and lock the steering
wheel in the straight ahead position (Fig. 7).
(4) Remove the steering wheel bolt (Fig. 7).
(5) Remove the steering wheel from the steering
column (Fig. 7).
INSTALLATION
(1) Install the steering wheel onto the column (Fig.
7).
(2) Install the steering wheel bolt (Fig. 7). Tighten
to 80 N´m (59 ft. lbs.).
(3) Install the air bag module.
(4) Reconnect the battery ground cable.
(5) Reset all the times and encode the radio.
(6) Perform a road test to check the position of the
steering wheel.
Fig. 5 1/4 TURN LEFT
1 - STEERING COLUMN
2 - 1/4 TURN TO THE LEFT
Fig. 6 LOCK CYLINDER OFF THE IGNITION LOCK
1 - LOCK HOUSING
2 - LOCK CYLINDER
Fig. 7 STEERING WHEEL
1 - STEERING WHEEL
2 - STEERING WHEEL BOLT
19 - 6 COLUMNVA

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION..........................7
REMOVAL.............................7INSTALLATION..........................7
SPECIFICATIONS - TORQUE CHART.........8
GEAR
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part
of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa-
rate the tie rods from the steering knuckles (Fig. 2)
using special tool C-3894±A.
(6) Remove the left outer tie rod end from the
steering gear.
(7) Remove both spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).(8) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from
the steering gear (Fig. 2).
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.
INSTALLATION
(1) Install the gear to the vehicle.
NOTE: Steering gear must be torqued in a three
step procedure below.
(2) Install the steering gear bolts (Fig. 2). Tighten
to an initial torque of 25 N´m (18 ft. lbs.) Then
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR REMOVAL / INSTALL
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
VAGEAR 19 - 7

torque to 45 N´m (33 ft. lbs.) and a final additional
90É turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N´m (18 ft. lbs.).
(4) Install both the power steering hoses to the
steering gear (Fig. 2). Tighten the high pressure hose
to 37 N´m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
(6) Install the left outer tie rod end to the steering
gear.(7) Install both the outer tie rod ends to the steer-
ing knuckle (Fig. 2). Tighten to 130 N´m (96 ft. lbs.).
(8) Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
U-Joint To Steering Gear 24 18 212
High Pressure Hose To
Steering Gear37 27 328
Return Line To Steering
Gear37 27 328
Steering Gear To Frame
Initial Torque25 18 221
Steering Gear To Frame
Second Torque
Then additional 90É turn45 33 398
19 - 8 GEARVA

LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
END ................................9
SPECIFICATIONS - TORQUE CHART.........9
SPECIAL TOOLS
FRONT SUSPENSION..................10TIE ROD END
REMOVAL.............................10
INSTALLATION.........................10
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 Lock-
ing Nut50 37 Ð
Steering Gear Boot
Clamp7Ð62
VALINKAGE 19 - 9

SPECIAL TOOLS
FRONT SUSPENSION
TIE ROD END
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Loosen the lock nut (Fig. 1).
(4) Remove the tie rod end retaining nut (Fig. 1).
(5) Separate the tie rod end from the steering
knuckle (Fig. 1) using special tool C-3894±A.
(6) Remove the outer tie rod end from the inner tie
rod end by unscrewing (Fig. 1).
INSTALLATION
(1) Install the outer tie rod end by screwing it onto
thew inner tie rod end (Fig. 1).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 1).
(3) Tighten the outer tie rod end nut (Fig. 1).
Tighten to 130 N´m (96 ft. lbs.).
(4) Install the front wheels.
(5) Lower the vehicle.
(6) Perform toe adjustment.(7) Tighten the lock nut after toe adjustment (Fig.
1). Tighten to 50 N´m (37 ft. lbs.).
Puller Tie Rod C-3894-A
Fig. 1 OUTER TIE ROD END
1 - OUTER TIE ROD END RETAINING NUT
2 - TIE ROD SEPERATOR TOOL
3 - OUTER TIE ROD END
4 - LOCKING NUT
5 - INNER TIE ROD END
19 - 10 LINKAGEVA

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....11
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............12
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS - TORQUE CHART........13
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE........................13FLUID COOLER TUBE
REMOVAL.............................13
INSTALLATION.........................13
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE...........14
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE.......................14
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE....................14
INSTALLATION
INSTALLATION - PRESSURE HOSE.......14
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE...............14
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE...............14
PUMP
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
VAPUMP 19 - 11