belt MERCEDES-BENZ SPRINTER 2006 Service Manual

(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

REMOVAL
(1) Disconnect negative battery cable.
(2) Remove vacuum line at vacuum pump (Fig.
48).
NOTE: Observe position of driver on rear of pump.
(3) Remove vacuum pump and seals (Fig. 48)
(4) Clean all sealing surfaces.
INSTALLATION
(1) Clean all sealing surfaces.
(2) Position driver on rear of pump and install vac-
uum pump with new seals. Tighten bolts to 14N´m
(124 lbs. in.). (Fig. 48)
(3) Install vacuum line to vacuum pump (Fig. 48).
(4) Connect 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.
(5) Start the engine and inspect for leaks.
LEFT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534±16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 49)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 49)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 49)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
49)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 49)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 49).
Fig. 48 VACUUM PUMP
1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING
4 - O-RING
5 - EXHAUST CAMSHAFT
6 - BOLTS
Fig. 49 LEFT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - BRACKET
7 - GROUND CABLE
8 - WASHER
9 - BOLT
VAENGINE 9 - 55

(4) Install the oil pan. Tighten M6 bolts to 9N´m
(80 lbs. in.) and M8 bolts to 20N´m (15 lbs. ft.) (Fig.
59).
(5) Tighten the bolt of the transmission bell hous-
ing to oil pan to 40N´m (30 lbs. ft.).
(6) Install the wiring harness duct (Fig. 57).
(7) Connect the oil level sensor (Fig. 57).
(8) Lower the vehicle.
(9) Lower the engine until the engine mount and
engine supports make contact.
(10) Start and hand tighten the engine mount
bolts.
(11) Lower the engine the rest of the way and
remove the engine support fixture.
(12) Tighten the engine mount bolts to 83 N´m (61
lbs. ft.).
(13) Install the sway bar and tighten bolts to 30
N´m (22 lbs. ft.).
(14) Refill crankcase with the proper engine oil to
the proper level (Refer to LUBRICATION & MAIN-
TENANCE/FLUID TYPES - SPECIFICATIONS).
(15) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(16) Start the engine and inspect for leaks.OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 57).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 57).
REMOVAL - OIL PUMP CHAIN
(1) Disconnect negative battery cable.
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
NOTE: Make sure the pin of the thrust spindle is
backed out into the thrust spindle before seating
the thrust spindle to the oil pump chain.
(4) Using special tool #9312±1 riveting tool, thrust
spindle #9312±4 and thrust pin pin #9312±3, position
and fit chain seperating tool and thrust spindle onto
a link of the oil pump chain (Fig. 60).
(5) Screw the thrust pin in and seperate the oil
pump chain link.
Fig. 59 OIL PAN BOLTS
1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55
Fig. 60 OIL PUMP CHAIN LINK REMOVAL
1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
3 - SPECIAL TOOL #9312-1
VAENGINE 9 - 61

(6) Remove pressed - out oil pump chain pin from
chain seperation tool.
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the oil pump chain is followed exactly.
Failure to do so will result in severe engine dam-
age.
INSTALLATION
INSTALLATION
NOTE: If the oil pump is dry, fill it with clean engine
oil before installation. Clean the oil pick±up tube
and strainer.
(1) Clean all sealing surfaces.
(2) Position the oil pump onto the drive chain and
reset tensioner.
(3) Install oil pump retaining bolts and tighten to
18 N´m (160 lbs. in.).
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Refill the crankcase to the appropriate level
with the proper engine oil (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) Start the vehicle and inspect for leaks.
INSTALLATION - OIL PUMP CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
61).(2) Slowly rotate crankshaft in a clockwise direc-
tion until it is possible to connect the ends of the new
and old oil pump chains.
(3) Remove assembly locking element, outer plate
and assembly link (Fig. 62).
Fig. 61 INSTALLING OIL PUMP CHAIN TEMPORARY
LINK
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OLD OIL PUMP CHAIN
3 - NEW OIL PUMP CHAIN
4 - TEMPORARY LINK
9 - 62 ENGINEVA

(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

NOTE: Care must be taken not to drop any repair
debris or pieces into the engine when separating
the timing chain links.
(6) Connect new timing chain with the oil holes
facing up, and old timing chain with the assembly
link, assembly plate and locking element, and secure
(Fig. 81).CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the timing chain is followed exactly. Fail-
ure to do so will result in severe engine damage.
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
CAUTION: ENSURE THAT THE SPRING IS COR-
RECTLY INSTALLED ON THE TENSIONING CLAMP
AND SLIDE RAIL.
(1) Install rail on bearing pin (Fig. 75).
(2) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(3) Install oil pan bolts. Tighten M6 bolts to 9N´m
(80 lbs.in.) and M8 bolts to 20N´m (15 lbs. ft.).
(4) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Reconnect negative battery cable.
Fig. 80 TIMING CHAIN SEPARATION
1 - LEFT TIMING CHAIN PORTION
2 - EXHAUST CAMSHAFT GEAR
3 - RIGHT TIMING CHAIN PORTION
4 - SPECIAL TOOL #9525
Fig. 81 TEMPORARY TIMING CHAIN LINK
1 - TEMPORARY TIMING CHAIN LINK
2 - LEFT TIMING CHAIN PORTION
3 - NEW TIMING CHAIN
4 - SPECIAL TOOL 9525
9 - 76 ENGINEVA