ECU MERCEDES-BENZ SPRINTER 2006 Service Manual

INSTALLATION
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
NOTE: When removing injectors, the seal rings and
retaining stretch bolts must always be replaced.
Coat the injector body with the anti-seize com-
pound before installing. Keep lubricant away from
the injector nozzle.
(1) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(2) Coat injector body with anti seize lubricant
then install injectors with new seals.
(3) Install tensioning claws with new screws at
injectors. Tighten screws in two stages, 7 N´m (62
lbs. in.) then 90É (Fig. 13).
NOTE: If locking clamp has been pulled off at injec-
tor, the locking clamp must be replaced.
(4) Position fuel return line at injectors and secure
locking clamps (Fig. 13).
NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors. DO
NOT over tighten.
(5) Install high pressure injection lines (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).
(6) Reconnect injector electrical connectors (Fig.
13).
(7) Connect negative battery cable.
NOTE: Fuel Injectors have different flow rates.
When injectors are removed, re-enter all injector six
digit codes.
(8) Program all injector codes into the ECM using
the scan tool.
(9) Start engine, allow to run, turn engine off and
inspect for leaks (Refer to 14 - FUEL SYSTEM -
WARNING).
CAUTION: Care must be taken when installing the
engine cover. Assure the proper routing of the fuel
injector return fuel hose to the banjo bolt fitting in
the left rear corner of the cover. Failure to do so
may pinch or damage the hose causing fuel leakage
or a driveability concern.(10) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION)..
FUEL PRESSURE SENSOR
DESCRIPTION
The fuel rail pressure sensor measures the current
fuel rail pressure and supplies an appropriate voltage
signal to the ECM. The non-constant fuel system
pressure influences the position of the internal dia-
phragm. This results in a variation in the electrical
resistance which is analyzed by the ECM.
OPERATION
The fuel rail pressure sensor measures the current
fuel rail pressure and sends a voltage signal to the
ECM. The ECM then actuates the fuel rail pressure
control valve until the desired rail pressure is
achieved.
REMOVAL
(1) (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION - WARNING) Disconnect the negative battery
cable.
(2) Remove the mixing housing.
(3) Unplug the sensor (Fig. 14).
(4) Counter-hold the threaded connection at the
fuel rail and unscrew the sensor (Fig. 14).
Fig. 14 FUEL RAIL PRESSURE SENSOR
1 - WIRING CONNECTOR
2 - FUEL RAIL PRESSURE SENSOR
3 - SEALING RING
4 - FUEL RAIL
VAFUEL INJECTION 14 - 39

STANDARD PROCEDURE - FUEL PRESSURE
SOLENOID TEST
(1) Disconnect the large fuel rail return hose at
the banjo fitting and clamp it off. Attach a jumper
hose to the banjo fitting and direct the hose into a
test vial. Crank the engine for 10 seconds (Fig. 17).
If return fuel is present in the test vial, replace the
fuel pressure solenoid.
REMOVAL
Review the high pressure fuel system warning before
beginning repair (Refer to 14 - FUEL SYSTEM - WARNING)
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
(1) Disconnect negative battery cable.
(2) Remove fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL INJECTOR - REMOVAL).
(3) Clamp fuel rail securely in vise with protective
jaws.
NOTE: Once removed, the solenoid must always be
replaced.
(4) Counterhold and unscrew the fuel pressure
solenoid and discard the sealing ring (Fig. 18).
INSTALLATION
Review the high pressure fuel system warning before
beginning repair (Refer to 14 - FUEL SYSTEM - WARNING)
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
CAUTION: There is a special tightening procedure
for the fuel rail solenoid that must be followed
along with the proper use of a torque wrench.
Therefore the fuel rail must be removed before
installing the fuel pressure solenoid. Attention must
be paid to the sealing ring before assembly. If the
sealing ring is damaged when assembling, this
could result in a not so visible leak.
NOTE: Observe the alignment of the pressure sole-
noid. The electrical connection must point in the
same direction as the connection of the injection
line at the fuel rail.
(1) Screw the fuel pressure solenoid with new seal-
ing disc to the fuel rail until hand tight (Fig. 18).
(2) Tighten the fuel rail solenoid as follows :
Fig. 17 CHECKING FUEL RAIL PRESSURE
SOLENOID LEAKAGE
1 - CLAMP RUBBER FUEL RETURN HOSES
2 - ATTACH SEPARATE RUBBER FUEL HOSE
3 - CONTAINER TO MEASURE FUEL LEAKAGE
4 - DISCONNECT RUBBER RETURN HOSE
Fig. 18 FUEL PRESSURE SOLENOID
1 - FUEL PRESSURE SOLENOID
2 - METAL SEALING DISC
3 - FUEL RAIL
4 - VISE
VAFUEL INJECTION 14 - 41

(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

(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4) Remove the return hose from the pump (Fig.
1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
19 - 12 PUMPVA

(16) Disconnect ground strap and tie back to one
side.
(17) Remove bolts (A) (Fig. 37) on underside of
transmission. Two bolts (A) on top of transmission
must remain in the housing.
(18) Place hydraulic transmission jack under
transmission and raise slightly. Secure transmission
on hydraulic jack with a strap or ask an assistant to
hold it.
(19) Remove rear engine cross member (4) (Fig.
37). First remove the nuts (5) at the outside ends of
the engine crossmember. Then remove the bolts (1) of
the transmission mount.
(20) Remove the last bolts (A, B) (Fig. 37) on the
top of the transmission.
(21) Remove the transmission towards the rear
and lower. Ensure that the converter remains in the
transmission housing when the transmission is
removed.
(22) Remove the torque converter.DISASSEMBLY
(1) Remove the torque converter (1) (Fig. 38).
(2) Place transmission in a vertical position.
(3) Measure input shaft end play as follows: (Fig.
39)
Fig. 37 Support Transmission and Remove Bolts
1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
5 - NUT, ENGINE CROSSMEMBER
6 - NUT, TRANSMISSION SUPPORT
Fig. 38 Remove Torque Converter
1 - TORQUE CONVERTER
2 - CONVERTER HOUSING
Fig. 39 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
21 - 46 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(a) Attach Adapter 8266-18 (2) to Handle 8266-8
(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 (2) to secure it to the
input shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move the input shaft in and out. Record the
maximum travel for assembly reference.
(4) Loosen guide bushing (12) (Fig. 40) and remove
from transmission housing.
(5) Detach oil pan (5) (Fig. 40).
(6) Remove oil filter (4) (Fig. 40).
(7) Unscrew Torx socket bolts (3) and remove elec-
trohydraulic unit (2).(8) Place the transmission in PARK to prepare for
the removal of the output shaft nut.
(9) Remove the nut holding the propeller shaft
flange to the output shaft and remove the flange.
(10) Remove the transmission rear oil seal with a
suitable slide hammer and screw.
(11) Remove the transmission output shaft washer.
Be sure to tag the washer since it is very similar to
the geartrain end-play shim and they must not be
interchanged.
(12) Remove the transmission rear output shaft
bearing retaining ring (1) (Fig. 41).
Fig. 40 Remove Electrohydraulic Unit
1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING
Fig. 41 Remove Rear Output Shaft Retaining Ring
1 - RETAINING RING
2 - OUTPUT SHAFT BEARING
Fig. 42 Position Remover 9082 On Bearing
1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - OUTPUT SHAFT BEARING
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 47

(6) Place intermediate plate (3) on converter hous-
ing (2) and align.
NOTE: The intermediate plate can generally be used
several times. The plate must not be coated with
sealant
(7) Install the holding clutch B1 (5) (Fig. 51) onto
the converter housing and intermediate plate.
Installed position of clutch B1 in relation to converter
housing is specified by a plain dowel pin in clutch B1
(arrow).
(8) Install the bolts to hold clutch B1 (5) (Fig. 51)
to the converter housing.
(9) Securely tighten multiple-disc holding clutch
B1 (5) on converter housing (2) to 10 N´m (88.5
in.lbs.).
(10) Install new torque converter hub seal (1) (Fig.
52) into the oil pump using Seal Installer 8902A.
(11) Install new oil pump outer o-ring seal onto oil
pump (Fig. 52).
Fig. 51 Install Holding Clutch B1 and Oil Pump
1 - BOLTS - M6X32 4 - BOLTS - M8X35
2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1
3 - INTERMEDIATE PLATE 6 - OIL PUMP
Fig. 52 Install New Oil Pump Seals
1 - INNER OIL SEAL
2 - OUTER OIL SEAL
21 - 54 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(12) Install oil pump (6) and securely tighten.
Tighten the oil pump bolts to 20 N´m (177 in.lbs.).
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 55

installed. Retaining rings are available in thick-
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and
2.2 mm (0.087 in.).
(31) Rotate the transmission so that the bellhous-
ing is pointed upward and ensuring that the output
shaft is allowed to move freely.
(32) Measure input shaft end-play (Fig. 58).
NOTE: If end-play is incorrect, transmission is
incorrectly assembled, or the geartrain end-play
shim is incorrect. The geartrain end-play shim is
selective.
(a) Attach Adapter 8266-18 (2) to Handle 8266-8
(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. End play should be 0.3-0.5 mm (0.012-0.020
in.). Adjust as necessary.(33) Install the output shaft washer onto the out-
put shaft.
(34) Install a new transmission rear seal into the
transmission case with Seal Installer 8902A (1) (Fig.
59).
(35) Place the transmission in PARK to prepare for
the installation of the output shaft nut.
(36) Install the propeller shaft flange onto the out-
put shaft and install an new flange nut. Tighten the
flange nut to 200 N´m (147.5 ft.lbs.).
(37) Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(38) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 60).
Fig. 58 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
Fig. 59 Install Output Shaft Seal
1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE
Fig. 60 Align Staking Tool 9078
1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH
21 - 58 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(39) Press downward on the staking tool (1) until
the staking pin (3) contacts the output shaft nut
flange (2) (Fig. 61).
(40) Strike the Driver handle C-4171 with a suit-
able hammer until the output shaft nut is securely
staked to the output shaft.
(41) Install electrohydraulic unit (2). Tighten the
bolts to 8 N´m (71 in.lbs.).
(42) Install oil filter (4) (Fig. 62).
(43) Install oil pan (5) (Fig. 62). Tighten the bolts
to 8 N´m (71 in.lbs.).
(44) Install guide bushing (12) (Fig. 62).
Fig. 61 Stake Output Shaft Nut
1 - STAKING TOOL 9078
2 - PROPELLER FLANGE
3 - STAKING PIN
Fig. 62 Install Electrohydraulic Unit
1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 59