wheel MERCEDES-BENZ SPRINTER 2006 Service Manual

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Remote Keyless Entry Antenna NS
Relay Block Under Driver Seat 35, 36
Rollover Switch Assembly Instrument Panel N/S
Roof A/C Blower 1 Fuse Center Roof A/C Unit 41
Roof A/C Blower 2 Fuse Center Roof A/C Unit 41
Roof A/C Blower Stage 1 Relay Center Roof A/C Unit 40
Roof A/C Blower Stage 1 and 2 Relay Center Roof A/C Unit 40
Roof A/C Blower Stage 2 Relay Center Roof A/C Unit 40
Roof A/C Compressor Fuse Center Roof A/C Unit 41
Roof A/C Compressor Relay Center Roof A/C Unit 40
Roof A/C Control Module BK Instrument Panel N/S
Roof A/C Fan Fuse Center Roof A/C Unit 41
Roof A/C Fan Relay Center Roof A/C Unit 40
Roof A/C Fuse Center Roof A/C Unit 41
Roof A/C Switch Instrument Panel 20
Roof A/C Temperature Setting Control Center Stack 20
Roof Fan Motor BK In Headliner 30
Roof Fan Switch BK 27
Roof Thermotronic Control Module BK Center Roof A/C Unit 40
Seat Belt Switch BK Driver Seat Belt Lock 26
Seat Belt Tensioner-Driver YL Driver Seat-Back 34
Seat Belt Tensioner-Passenger YL Passenger Seat-Back 34, 36
Security System Module C1 BR Instrument Panel 3
Security System Module C2 GR Instrument Panel 3
Sentry Key Remote Entry Module
(SKREEM)GR Instrument Panel 3
Shifter Assembly BK Center Console 22
Siren BK Engine Compartment-Left 1
SKREEM Transponder BK NS
Speaker-Left Front Door Assembly C1 Engine Compartment-Left 44
Speaker-Left Front Door Assembly C2 In Left Front Door 44
Speaker-Left Rear Rear Of Vehicle On Left
Side45
Speaker-Right Front Door In Right Front Door 44
Speaker-Right Rear Rear Of Vehicle On Right
Side45
Speed Control Switch BK Steering Wheel Controls 17
Starter Motor On Engine 3
Starter Motor Relay (Fuse/Relay Block) In Fuse/Relay Block N/S
Steering Angle Sensor Steering Column 24, 32
Tail Lamp Assembly-Left BK Rear Of Vehicle On Left
Side53
Tail Lamp Assembly-Right BK Rear Of Vehicle On Right
Side53
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
TCS Switch (ASR) BK Center Of Instrument Panel 20
Temperature Sensor WT Center Roof A/C Unit 40
Thermotronic Control Module BK N/S
Thermotronic Diode Center Roof A/C Unit 39
Time Delay Relay Under Driver Seat N/S
Towing/Intrusion Sensor ON/OFF Switch BK Instrument Panel 20
Trailer Tow Connector Under Rear Of Vehicle N/S
Trailer Tow Control Module C1 BK Rear Of Vehicle N/S
Trailer Tow Control Module C2 BK Rear Of Vehicle N/S
Transmission Control Module C1 BK Engine Compartment 3
Transmission Control Module C2 BK Engine Compartment 3
Transmission Relay (Relay Block) In Fuse Block No.1 N/S
Transmission Solenoid Assembly BK Transmission 16
Turn Signal Lamp No.1-Left Front BK Front Of Vehicle On Left
SideN/S
Turn Signal Lamp No.1-Right Front BK Front Of Vehicle On Right
SideN/S
Turn Signal Lamp No.2-Left Front BK Front Of Vehicle On The
Left Side45
Turn Signal Lamp No.2-Right Front BK Front Of Vehicle On The
Right Side45
Turn Signal Relay (Fuse Block No.1) In Fuse Block No.1 N/S
Turn Signal/Anti-Theft Alarm Relay-Left (Re-
lay Block)BK Under Driver Seat N/S
Turn Signal/Anti-Theft Alarm Relay-Right
(Relay Block)BK Under Driver Seat N/S
Warm Air Auxiliary Heater Assembly C1 Instrument Panel 33
Warm Air Auxiliary Heater Assembly C2 Instrument Panel 33
Washer Pump Motor-Front WT Engine Compartment 25
Water Cycle Valve BK Underhood (To The Instru-
ment Panel)10
Water In Fuel Sensor Engine Compartment 14
Wheel Speed Sensor-Left Front Left Front Wheel 2
Wheel Speed Sensor-Left Rear Left Rear Wheel 2
Wheel Speed Sensor-Right Front Right Front Wheel 49
Wheel Speed Sensor-Right Rear Right Rear Wheel 49
Window Defogger Module - Rear BK Rear Of Vehicle N/S
Window Defogger Relay-Left Rear (Relay
Block)BK Under Driver Seat N/S
Window Defogger Relay-Right Rear (Relay
Block)BK Under Driver Seat N/S
Window Defogger Switch - Rear BK Instrument Panel 25
Window Defogger-Left Rear On Left Rear Window 53
Window Defogger-Right Rear On Right Rear Window 53
Wiper Motor-Front BK Underhood (To The Window) 8
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Wiper On/Off Relay (Fuse Block No. 1) In Fuse Block No.1 N/S
Wiper/Turn Signal/Engine Start Control Mod-
ule (In Fuse Block 1)In Fuse Block No.1 N/S
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Underhood-Left Front 52
G101 Underhood-Right Front 52
G102 Underhood-Right Front 52
G200 Engine Compartment-Left 8,10, 52
G201 Under Driver Seat 52
G202 Under Driver Seat 36, 52
G203 Dash 19, 52
G300 Right Rear-Body 52
G301 Right Rear-Body Top 52
G302 Engine Compartment-Left Front 52
G303 Left Front Instrument Panel 5
G304 Front Center Headliner 5
SPLICES
SPLICE NUMBER LOCATION FIG.
S100 Under Drivers Seat 18
S101 Instrument Panel 18
S102 Under Drivers Seat 18
S103 Under Drivers Seat 18
S104 Near Headlamp Assembly-Left 27
S105 Engine Compartment-Left 7
S106 Near Wheel 48
S108 Instrument Panel 18
S175 Engine Compartment-Left 18
S176 Engine Compartment-Left 18
S177 Engine Compartment-Left 18
S178 Engine Compartment-Left 18
S180 Left Plenum 27
S200 Engine Compartment-Left 1, 9
S201 Instrument Panel 21
S202 Instrument Panel 21
S203 Instrument Panel 18
S204 Near Brake Lamp Switch 18
S205 Instrument Panel 18
S206 Instrument Panel 18
S207 Near Time Delay Relay 18
S208 Near Time Delay Relay 18
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

SPLICE NUMBER LOCATION FIG.
S306 Near Locker Switch No.2 18
S307 Near Fuse/Relay Block 18
S308 Near Interior Lamp No.3 50
S309 Near Interior Lamp-Right 50
S310 Near Fuse Block No.2 18, 21
S311 Under Drivers Seat 18
S312 Near Wheel Speed Sensor-Left Rear 47
S313 Near Wheel Speed Sensor-Left Rear 47
S314 Near Wheel Speed Sensor-Right Rear 47
S315 Near Wheel Speed Sensor-Right Rear 47
S316 Near Headlamp Assembly-Left 18
S317 Under Drivers Seat 18
S318 Near Marker Lamp-Left Rear 7
S319 Near Tail Lamp Assembly-Left 7
S320 Under Body-Rear Center 7
S321 Near Power Window Switch-Passenger 23, 25
S322 Instrument Panel 18
S323 Near Brake Wear Sensor-Left Rear 47
S324 Near Interior Lamp No.3 N/S
S325 Near Map/Reading Lamp Switch 21
S326 Top Body- Front Center 42
S327 Near Security System Module 18
S328 Near Central Timer Module 18
S329 Near Central Timer Module 18
S330 Near Security System Module 18
S331 Near Security System Module 18
S332 Near Brake Wear Sensor-Left Rear 47
S333 Instrument Panel 18
S350 Near Trailer Tow Connector 18
S351 Near Trailer Tow Control Module 18
S352 Near Trailer Tow Control Module 18
S353 Near Dome Lamp 21
S354 Body-Upper Right Center 42, 50
S355 Near Window Defogger Module-Rear 18, 23
S356 Near Headlamp Assembly-Left 18
S357 Near Central Timer Module 23
S358 Near Trailer Tow Control Module 18
S359 Near Interior Light Switch-Passenger 9
S360 Near Interior Light Switch-Rear 9
S361 Near Time Delay Relay 18
S362 Near Circulation Pump Diode 18
S363 Near Heated Seat Module-Passenger 47
S364 Near CTEL Connector 21
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

Fig. 2 ENGINE COMPARTMENT AND WHEEL SPEED SENSORS
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................5
INSTALLATION
INSTALLATION - ENGINE COVER..........9
INSTALLATION........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS.....................11
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
AIR CLEANER HOUSING
REMOVAL.............................21
INSTALLATION.........................22
CYLINDER HEAD
DESCRIPTION.........................22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............22
REMOVAL
REMOVAL - CYLINDER HEAD............23
REMOVAL - CYLINDER HEAD FRONT
COVER.............................25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD........26
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE..................30
REMOVAL.............................30
INSTALLATION.........................32CYLINDER HEAD COVER(S)
REMOVAL.............................33
INSTALLATION.........................34
VALVE STEM SEALS
DESCRIPTION.........................34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............35
REMOVAL - VALVES...................36
INSTALLATION
INSTALLATION - VALVE SPRINGS........36
INSTALLATION - VALVES...............37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................38
CRANKSHAFT
DESCRIPTION.........................39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....39
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
FLYWHEEL
REMOVAL.............................43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - CRANKSHAFT LOCK.....44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................47
REMOVAL.............................47
INSTALLATION.........................49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................53
INSTALLATION.........................54
VAENGINE 9 - 1

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Connecting Rod Cap
to Connecting Rod (3
stage, 1&2 torque, 1
torque angle)5,25,90É - 44,221, 90É
Crankshaft
Bolt-Crankshaft Bearing
Cap (2 stage, 1 torque, 1
torque angle55,90É 40.5, 90É -
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)200,90É 147.5, 90É -
10.9m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)325,90É 240, 90É -
Bolt-Stretch Shank for
Flywheel or 2 Mass Fly-
wheel to Crankshaft (2
stage, 1 torque, 1 torque
angle)45,90É 33, 90É
Turbo Charger
Bolt-Oil Feed Line to Cyl-
inder Head9/22 - 80-194
Bolt-Oil Feed Line to Tur-
bo Charger30 22 -
Bolt-Turbo Charger Sup-
port30 22 -
Bolt-Turbo Charger Sup-
port to Crankcase20 - 177
Bolt-Oil Outlet Line to
Turbo Charger9-80
Connection-Flange of Ex-
haust Manifold to Turbo
Charger30 22 -
Connection-Turbo Charger
to Front Catalytic Con-
verter30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air Distribu-
tion Pipe16 - 141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe9-80
Bolt-Support to Charge
Air Distribution Pipe20 - 177
Bolt-Support to Engine
Bracket40 30 -
9 - 12 ENGINEVA

AIR CLEANER ELEMENT
REMOVAL
(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.
10).
(3) Unclip the air cleaner housing lid (Fig. 10).
(4) Remove air cleaner element (Fig. 10).
INSTALLATION
(1) Position and seat the air cleaner element into
the lower housing (Fig. 10).
(2) Install the housing cover and snap retainers
into place (Fig. 10).
(3) Install air flow sensor into housing cover and
connect. (Fig. 10).
(4) Connect the air cleaner restriction sensor (Fig.
10)..
(5) Install heat shield.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the air flow sensor (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/MANIFOLD AIR
FLOW (MAF) SENSOR - REMOVAL).
(4) Disconnect the air intake pressure sensor,
unclip the top of the air cleaner housing and remove
(Fig. 11).
(5) Take out air cleaner element (Fig. 11).
(6) Detach bottom part of the air cleaner housing
at the body (Fig. 11).
(7) Take air intake hose out of inner fender and
out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 11).
#9543 ADAPTOR
#9544 VIBRATION DAMPER PULLER
Fig. 10 AIR CLEANER ELEMENT
1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSING
VAENGINE 9 - 21

(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
INSTALLATION
NOTE: Ensure that the seal between the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 11).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 11).
(3) Install air cleaner element (Fig. 11).
(4) Install and clip air cleaner top to air cleaner
body and connect the air intake pressure sensor (Fig.
11).
(5) Install air flow sensor (Fig. 11).
(6) Install heat shield.
(7) Connect negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of high temperature
resistant aluminum alloy and features optimized spi-ral swirl intake ducts and a separate camshaft hous-
ing made of die cast aluminum. The combustion
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The
intake and exhaust valves have solid valve stems and
conical valve springs. The cylinder head is not ser-
viceable and must be replaced should a repair
become necessary.
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 12).
Cylinder Head
BoltsThread Diame-
ter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE CYLIN-
DER HEAD SURFACE
NOTE: DO NOT machine the cylinder head surface.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 13).
Fig. 11 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER
Fig. 12 Measuring Cylinder Head Bolts
9 - 22 ENGINEVA

CAUTION: Oil thread and head contact surfaces of
bolts that retain the crankshaft bearing caps;
tighten bolts from inside to outside, beginning at
the fit bearing. Rotate crankshaft to check clear-
ance.
(1) Install crankshaft.
CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way the crankshaft
bearing caps fit. If correctly installed, the lug, or
raised boss, on the crankshaft bearing cap is point-
ing to the left when viewed in the direction of travel
(intake side).
(2) Install the crankshaft bearing caps. Tighten
bolts in two stages. 55N´m (40.5 lbs. ft.), then 90É.
(3) Install the pistons (Refer to 9 - ENGINE/EN-
GINE BLOCK/PISTON & CONNECTING ROD -
INSTALLATION).
(4) Install the end cover (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
(5) Install the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to the owners manual for
specifications.
(8) Fill the cooling system with the proper coolant,
to the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(9) 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.
(10) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with the transmission removed
from the vehicle.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain the engine oil.NOTE: Loosen all of the oil pan bolts to assure that
the oil pan gasket is not damaged when removing
the rear main oil seal and end cover assembly.
NOTE: Inspect the oil pan gasket for damage. If the
oil pan gasket is damaged, remove the oil pan and
replace the oil pan gasket.
(4) Loosen the oil pan bolts.
(5) Remove the flywheel.
CAUTION: Care must be taken when removing the
rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.
(6) Remove the rear main seal/adaptor retaining
bolts and carefully pry the adaptor from the crank-
case at the adaptor shoulders (Fig. 33).
VAENGINE 9 - 41