battery MERCEDES-BENZ SPRINTER 2006 Service Manual

INSTALLATION
(1) Position the MAF sensor to air cleaner housing
and install the retaining screws (Fig. 24).
(2) Connect the air intake hose to the MAF sensor
and tighten clamp.
(3) connect the MAF wiring harness connector.
(4) Connect negative battery cable.
O2 SENSOR
DESCRIPTION
The wide band oxygen sensor measures the oxygen
content in the exhaust gas to monitor EGR. The sen-
sor is mounted in the exhaust pipe at a 30 degree
angle to prevent the collection of moisture between
the sensor housing and element. The sensor is
located close to the turbocharger for a quicker
response time.
The oxygen sensor has five wires (heater power
and ground, reference voltage, and 2 wires for a
pump cell). The oxygen sensor connects to a six wire
harness connector. A non serviceable trimming resis-
tor is built into the sensor connector. The resistance
is dependent on the over all length and type of sen-
sor.
OPERATION
The O2 sensor is a planar zirconium dioxide (ZrO2)
dual cell limiting current probe with a integralheater. The term wide ban, refers to the ability of the
O2 sensor to generate a clear signal over a wide air-
fuel ratio measuring range. As a dual sensor, it incor-
porates a second O2 chamber (oxygen pump cell),
which requires a separate voltage supply.
The sensor element combines a sensor cell (8) and
an oxygen pump cell (9). Both cells are made of zir-
conium-dioxide (ZrO2) and are coated with porous
platinum electrodes. The sensor cell operates just
like a typical O2 sensor. The oxygen pump cell trans-
port oxygen ions when voltage is applied.
A gas sample chamber (5) is sandwiched between
the oxygen pump cell and the sensor cell. A pump
electrode and sensor cell electrode are located in the
sample chamber. A sample passage (10) connects the
sample chamber to the surrounding exhaust gas. A
sensor cell electrode is located in the reference air
channel (6), which connects to the outside air (Fig.
25).
Fig. 24 MANIFOLD AIR FLOW SENSOR
1 - WIRING HARNESS
2 - AIR INTAKE HOSE
3 - CLAMP
4 - MAF SENSOR
5 - AIR CLEANER HOUSING
VAFUEL INJECTION 14 - 45

REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the exhaust heat shield (Fig. 27).
(3) Disconnect the O2 sensor harness connector
(Fig. 27)
(4) Remove the O2 sensor (Fig. 28).
INSTALLATION
(1) Install the oxygen sensor (Fig. 28).
(2) Install the heatshield and tighen fasteners to
9N´m (80 lbs. in.) (Fig. 27).
(3) Properly position the oxygen sensor wiring har-
ness and connect the electrical connector (Fig. 27)
(4) Connect the negative battery cable.
Fig. 27 HEAT SHIELD
1 - FASTENERS
2 - SHIELD
3 - O2 SENSOR HARNESS CONNECTOR
Fig. 28 OXYGEN SENSOR
1 - OXYGEN SENSOR
14 - 48 FUEL INJECTIONVA

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

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

(7) Press downward on the staking tool until the
staking pin (3) contacts the output shaft nut flange
(2) (Fig. 202).
(8) Strike the Driver handle C-4171 with a suit-
able hammer until the output shaft nut is securely
staked to the output shaft.
(9) Install the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION).
PARK LOCK CABLE
REMOVAL
(1) Disconnect battery.
(2) Move selector lever to position ªDº.
(3) Remove top section (3) (Fig. 203) of the center
section of instrument panel.
(4) Remove bottom section (2) (Fig. 204) of the cen-
ter section of instrument panel.
Fig. 202 Stake Output Shaft Nut
1 - STAKING TOOL 9078
2 - PROPELLER FLANGE
3 - STAKING PIN
Fig. 203 Remove Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
Fig. 204 Remove Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
21 - 160 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

(5) Connect the park lock cable coupling (1) (Fig.
210) to the shift lever assembly (SLA). Press locking
tab (2) together and push coupling (1) against the
spring force into the SLA, twist through 90É (right or
left) until locked.
(6) Install the bottom section (2) (Fig. 211) of the
center section of instrument panel.
(7) Install the top section (3) (Fig. 212) of the cen-
ter section of instrument panel.
(8) Connect battery.
Fig. 209 Tighten Park Lock Cable to Ignition Switch
1 - IGNITION SWITCH
2 - PARK LOCK CABLE
Fig. 210 Engage Park Lock Cable to SLA
1 - PARK LOCK CABLE COUPLING
2 - LOCK TAB
3 - BOLT
4 - SHIFT LEVER ASSEMBLY (SLA)
5 - CONNECTOR
Fig. 211 Install Bottom Section Of Center Instrument
Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
Fig. 212 Install Top Section Of Center Instrument
Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
21 - 162 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE...........................10
SPECIFICATIONS.......................11DOOR - FRONT..........................13
DOORS - REAR..........................23
DOORS - SLIDING........................35
EXTERIOR..............................48
HOOD.................................51
INSTRUMENT PANEL.....................55
INTERIOR..............................70
PAINT.................................77
SEATS.................................79
STATIONARY GLASS.....................84
WEATHERSTRIP/SEALS...................90
BODY STRUCTURE.......................91
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
VABODY 23 - 1

aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror canalso be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
23 - 2 BODYVA