drain bolt MERCEDES-BENZ SPRINTER 2006 Owner's Manual

FUEL DRAIN TUBES
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS
LOW - PRESSURE LINES
Fuel supply line restrictions can cause starting
problems and prevent engine from accelerating. The
starting problems include; low power and/or white
fog like exhaust.
Test all fuel supply lines for restrictions or block-
age. Flush or replace as necessary.
HIGH - PRESSURE LINES
CAUTION: High pressure lines cannot contact each
other or other components. Do not attempt to weld
high-pressure fuel lines or to repair lines that are
damaged. High pressure lines must be replaced at
each disassembly. Use only recommended lines
when replacement of high-pressure fuel line is nec-
essary.
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance,engine mis-fire and white smoke from exhaust (Refer
to 14 - FUEL SYSTEM - WARNING).
FUEL FILTER
DESCRIPTION
The fuel filter was designed for improved high alti-
tude operation and for better re-start after the fuel
tank has been completely emptied. The water drain
plug and water in fuel (WIF) sensor are located on
the top of the filter. Water is drained by using the in-
tank electric fuel pump to generate flow (attach a
hose to the drain plug). The filter has a pressure dif-
ferential of 200±300 mbar (2.9 psi.) when new. When
dirty, the pressure differential rises to 800 mbar (11.6
psi.) (Fig. 2).
REMOVAL
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: DO NOT bend, twist or cut the fuel hose
clamps. The fuel hose clamps through out the fuel
system are reusable when using special tool #9539.
Orginal clamps must be used when servicing the
fuel system.
(1) Disconnect negative battery cable.
(2) Disconnect the water in fuel (WIF) sensor har-
ness connector (Fig. 2).
(3) Release the fuel inlet and outlet hose clamps
using special tool #9539 at the fuel filter (Fig. 2).
(4) Remove fuel filter retaining bracket bolt and
remove fuel filter (Fig. 2).
(5) Separate the WIF sensor from the fuel filter
(Fig. 2)
FUEL LINE WRENCH-9285
FUEL LINE PLIERS-9539
14 - 10 FUEL DELIVERYVA

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.
CAUTION: DO NOT bend, twist or cut the fuel hose
clamps. The fuel hose clamps through out the fuel
system are reusable when using special tool #9539.
Orginal clamps must be used when servicing the
fuel system.
NOTE: Capture any fuel spillage and dispose of in
appropriately marked container.
(1) Fill new fuel filter with the new diesel fuel
(approximately 0.4 liters)
(2) Carefully seat WIF sensor and tighten bolt to
13 lbs. in. (1.5 N´m) (Fig. 2)
(3) Position fuel filter in bracket and tighten
retaining bolt to 53 lbs. in. (6 N´m) (Fig. 2)
(4) Install fuel lines and re-crimp clamps using
special tool #9539 (Fig. 2).
(5) Connect the WIF wiring harness connector
(Fig. 2).
(6) Connect negative battery cable.(7) Cycle ignition several times to build pressure.
(8) Start engine and inspect for leaks.
FUEL LINES
REMOVAL - HIGH PRESSURE LINES
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.
CAUTION: Counterhold with wrench at threaded
connections of injectors. DO NOT EXCEED the
tightening torque in order to avoid also slackings
the threaded connection.
CAUTION: DO NOT crimp or bend lines.
NOTE: After removing injection lines, seal connec-
tions and ensure cleanliness.
(2) Unscrew union nuts of injection lines.
(3) Remove injection lines (Fig. 3).
Fig. 2 FUEL FILTER
1 - FUEL SUPPLY LINE TO HIGH PRESSURE PUMP
2 - FUEL FILTER
3 - WIF SENSOR
4 - FUEL FILTER DRAIN
VAFUEL DELIVERY 14 - 11

INSTALLATION - HIGH PRESSURE LINES
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) Loosen the fuel rail mounting bolts to install
lines free of stress.
CAUTION: Inspect sealing cone at lines. Replace if
compression points exist. Ensure lines are exactly
located.
(2) Position and install fuel lines (Fig. 3). Tighten
to 22N´m (195 lbs. in.) using a wrench to counterhold
at threaded connection.
(3) Tighten fuel rail to 14N´m (124 lbs. in.).
(4) Connect negative battery cable.
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.(5) Start engine, run for a few minutes, turn
engine off and inspect for leaks (Refer to 14 - FUEL
SYSTEM - WARNING), (Refer to 14 - FUEL SYS-
TEM - DIAGNOSIS AND TESTING).
FUEL RAIL PRESSURE SEN-
SOR
DESCRIPTION
The fuel rail pressure sensor is attached to the
front of the fuel rail. The sensor supplies the current
fuel rail pressure to the ECM.
OPERATION
Non-constant fuel system pressure influences the
position of a diaphragm inside the sensor. This
results in a variation in the electrical resistance. The
fuel rail pressure sensor supplies the appropriate
voltage signal to the ECM.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor wiring harness connector
(Fig. 4).
NOTE: Place a shop towel underneath the sensor to
capture any fuel spillage.
(3) Unscrew the sensor and discard the seal.
Fig. 3 FUEL RAIL
1 - CAMSHAFT POSITION SENSOR
2 - FUEL INJECTOR
3 - FUEL INJECTOR VALLEY DRAIN
4 - FUEL RAIL PRESSURE CONTROL VALVE
5 - BANJO BOLT
6 - FUEL RAIL
7 - HIGH PRESSURE FUEL LINE
Fig. 4 FUEL RAIL PRESSURE SENSOR
1 - FUEL RAIL PRESSURE SENSOR
2 - FUEL RAIL
3 - COOLANT TEMPERATURE SENSOR
14 - 12 FUEL DELIVERYVA

FUEL RAIL
DESCRIPTION
The fuel rail acts like a high pressure store. It is
available to all injectors for drawing fuel which has
been compressed by the high pressure injection
pump. The rail pressure sensor, rail pressure control
valve, high pressure line, and the return flow line
are attached to the fuel rail.
OPERATION
The stored fuel volume inside the rail acts as a
damper for pressure fluctuations which result
because of pulsating supply and brief large extrac-
tions of fuel during injector firing. The rail primarily
influences the atomization of fuel at the injector noz-
zle, and the accuracy of injected quantity during
injection.
REMOVAL
(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 the engine cover.
(3) Disconnect the intake manifold air inlet duct
and position aside.
(4) Disconnect the fuel rail pressure and control
valve wiring harness connectors.
(5) Remove engine harness retaining bolts and
unclip the engine harness from the fuel rail.
(6) Remove injector high pressure lines (Fig. 19)
(7) Remove fuel rail retaining bolts (Fig. 19).
CAUTION: When slackening and tightening fuel
injection line union nuts, counter hold with wrench
at threaded connection. ON NO ACCOUNT exceed
the tightening torque at any time. Do NOT crimp or
bend lines.
NOTE: After removing lines, seal connections and
ensure cleanliness.(8) Detach fuel return flow line to high pressure
pump at rail
(9) Detach fuel return flow line at banjo bolt (Fig.
19)
(10) Remove fuel rail.
INSTALLATION
(Refer to 14 - FUEL SYSTEM - WARNING)
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.
(1) Loosely position fuel rail into proper position
on the cylinder head and hand tighten the fasteners.
(2) Connect the fuel pressure control valve harness
connector (Fig. 19).
(3) Connect the fuel return lines at the banjo bolt
(Fig. 19).
CAUTION: Inspect sealing cones at the lines.
Replace as necessary. Ensure that all fuel pressure
lines are exactly located in original position.
(4) Install the high pressure fuel lines and hand
tighten.
Fig. 19 FUEL RAIL
1 - CAMSHAFT POSITION SENSOR
2 - FUEL INJECTOR
3 - FUEL INJECTOR VALLEY DRAIN
4 - FUEL RAIL PRESSURE CONTROL VALVE
5 - BANJO BOLT
6 - FUEL RAIL
7 - HIGH PRESSURE FUEL LINE
14 - 22 FUEL DELIVERYVA

(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

CONDITION POSSIBLE CAUSES CORRECTION
NO UPSHIFT OF 1ST
GEAR AT TIMES1. Connector Ballast Unit. Output
Speed Sensor Loose, Incorrectly
Contacted.1. Check Connectors, Replace
Output Speed sensor If Neces-
sary.
2. Output Speed Sensor Defective 2. Replace Output Speed Sen-
sor.
LEAKAGE AT THE AREA
OF THE ELECTRICAL
PLUG TO THE CONDUC-
TOR PLATE1. Deformation O-Rings. 1. Replace O-Rings.
2. Deformation Adapter. 2.Replace Adaptor.
3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is
Not Centered In The Socket And
The O-ring Will Not Seal.3. Remove Nose Of Conductor
Plate.
4. Contacting At The Conductor
Plate Leaky. Oil In Harness, Some-
times In The Control Module.4. Replace Conductor Plate.
LEAKAGE AT THE AREA
OF BELL HOUSING/
TORQUE CONVERTER1. Bolts (Torx M6) Outer Disc Carri-
er B1.1. Clean Thread and Install the
Bolts Using Sealer.
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter
Housing.1. Clean Thread and Install the
Bolts Using Sealer.
2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.2. Install Drain Plug Correctly.
3. Weld Seam Of Torque Converter
Leaky.3. Replace Torque Converter.
4. Radial Sealing Ring Oil Pump
Defective.4. Replace Sealing Ring.
5. O-Ring Oil Pump Defective Or
Not Installed.5. Install O-Ring.
6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.6. Install Fit Bolt If Necessary.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
(1) Disconnect the negative (ground) battery cable.
CAUTION: Isolate ground lead to prevent accidental
contact.(2) Apply parking brake.
(3) Move gear selector lever to position ªNº.
(4) Remove oil drain plug (2) (Fig. 26) and drain
automatic transmission oil into a clean container.
21 - 42 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(5) Remove oil filler pipe.
(a) Remove bolts (2) (Fig. 27) to cylinder head.
(b) Remove bolt (3) (Fig. 27) to transmission
flange and bolt (2) to transmission housing.
(c) Pull lower connection of oil filler pipe (1) (Fig.
27) out of the fill hole in the side of the transmis-
sion housing.
(d) Guide oil filler pipe (1) (Fig. 27) up and
out.
(6) Remove exhaust heat shield (5) (Fig. 28).
(7) Remove retaining bracket (4) (Fig. 28).(8) Detach propeller shaft (1) (Fig. 28) at transmis-
sion (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL). Move propeller shaft to the right and tie
up.
(9) Remove the cooler lines at transmission.
(a) Remove bracket for the oil cooler feed and
return lines (1) (Fig. 29) from engine oil pan
flange. Detail shows right side of motor. Position is
mirrored for the left side of engine.
(b) Detach bracket of cable retainer (4) (Fig. 30)
from the threaded shank of a engine oil pan bolt
(5).
(c) Press cable retainer (4) (Fig. 30) down and
out.
(d) Remove the bolts holding the oil cooler lines
(6) (Fig. 31) to the left and right sides of transmis-
sion and hang the lines to the side.
Fig. 26 Drain Transmission
1 - SEAL
2 - DRAIN PLUG
Fig. 27 Fill Tube
1 - FILL TUBE
2 - BOLTS TO CYLINDER HEAD AND TRANSMISSION HOUS-
ING
3 - BOLT TO TRANSMISSION FLANGE
Fig. 28 Propeller Shaft and Heat Shield
1 - PROPELLER SHAFT
2 - BOLT
3 - BOLT
4 - RETAINING BRACKET
5 - HEAT SHIELD
6 - WASHER
7 - BOLT
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 43

(12) Remove the torque converter bolts.
(a) Remove the steering gear (1) (Fig. 34) from
the chassis crossmember.
(b) Lower the steering gear (1) (Fig. 34) down-
wards.
(c) Remove the plastic torque converter access
cover (1) (Fig. 35) at back of engine flange.
(d) Rotate engine by hand until bolts (2) (Fig.
35) are in front of opening. Rotate engine forwards
at crankshaft.
(e) To remove bolts, position a ratchet with long
extension and joint nut as shown (Fig. 36).
(f) Remove the two bolts (2) (Fig. 35) at each of
the three locations at circumference of driving
plate.
(13) Remove torque converter drain plug and drain
automatic transmission oil into a clean container. Re-
install the drain plug and torque the plug to 14 N´m
(130 in.lbs.).
(14) Support engine. Insert wooden block between
oil pan and front chassis crossmember beam.
(15) Remove vent hose bracket and tie back to one
side.
Fig. 33 Shift Cable at Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 34 Steering Gear
1 - STEERING GEAR
2 - BRACKET
Fig. 35 Torque Converter Access Cover
1 - TORQUE CONVERTER ACCESS COVER
2 - BOLT
Fig. 36 Torque Converter Bolts Access
1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE
4 - OPENING
5 - CHASSIS CROSSMEMBER
6 - STEERING GEAR
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 45

(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

(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