lock MERCEDES-BENZ SPRINTER 2006 Service Manual

(5) Inspect standard size of crankshaft bearing
shells.
(6) Inspect crankshaft bearing cap.
(7) Mount crankshaft radially.
(8) Inspect crankshaft bearing play.
NOTE: Radial mounting of the main bearings of
standard size crankshaft is possible by assigning
the color-coded bearing shells.
ASSIGN CRANKSHAFT BEARING SHELLS
The oil pan rail of the cylinder block is marked
with chisel punches indicating what bearing shell are
used.
(9) Assign crankshaft bearing shells.
(10) Mount crankshaft axially.
(11) Inspect crankshaft bearing play.
REMOVAL
(1) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Remove end cover. (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
(4) Remove pistons (Refer to 9 - ENGINE/ENGINE
BLOCK/PISTON & CONNECTING ROD -
REMOVAL).
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 crankshaft bear-
ing caps fit.
(5) Unbolt crankshaft bearing caps (Fig. 32).
(6) Inspect crankshaft bearing caps and bolts for
wear and stretching.
(7) Remove crankshaft.
INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.
CAUTION: Oil grooves in the thrust washers must
point toward the thrust collars of the crankshaft.
CAUTION: Thrust washers in the bearing cap each
have two retaining lugs as a anti-twist lock.
Fig. 32 CRANKSHAFT ASSEMBLY
1 - BEARING HALVES IN ENGINE BLOCK
2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
7 - MAIN BEARING BOLTS
9 - 40 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

(3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller MUST mesh fully
into the slots of the belt pulley.
NOTE: Inspect the running surface of the belt pulley
for wear.
(4) Remove the belt pully/vibration damper.
CAUTION: Care must be taken to prevent severe
damage to the crankshaft and mounting whole for
the front crankshaft seal.
(5) Using a suitable prying tool, remove the front
crankshaft seal from the timing cover (Fig. 34).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the front crankshaft seal
evenly onto the timing cover.(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(3) Remove the retaining lock for the crankshaft/
ring gear.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Fill the crankcase with the correct engine oil to
the proper level.
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.
(7) Start the engine and inspect for leaks.
FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: M6x90 bolts must be used with retaining
lock to prevent damage to rear end cover.
(2) Install retaining lock for crankshaft/starter
ring gear.
NOTE: Flywheel does not need balancing or should
it be interchanged.
(3) Remove flywheel with inner washer (Fig. 35).
Fig. 34 FRONT SEAL REMOVAL/INSTALLATION
1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
3 - WASHER
4 - RETAINING BOLT
VAENGINE 9 - 43

INSTALLATION
INSTALLATION
NOTE: A flex rod torque wrench must not be used
in order to avoid angle errors when tightening to
degrees.
(1) Align flywheel and inner and outer washers
with straight pin. Tighten bolts in two stages. 45N´m
(33 lbs. ft.) then 90É (Fig. 35).
(2) Remove the retaining lock from the crankshaft/
starter ring gear.
(3) Install transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - W5J400 -
INSTALLATION).
(4) Connect 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 CLOTHES.
(5) Start the vehicle.
INSTALLATION - CRANKSHAFT LOCK
(1) Raise and support the vehicle.
(2) Remove the generator wiring harness duct at
the crankcase and set aside.(3) Remove inspection cover (Fig. 36).
(4) Remove the bolts (Fig. 36).
(5) Insert the crankshaft lock #8932 into the
starter ring gear and install the retaining bolts.
Tighten the lock bolts to 9 N´m (80 lbs. in.) (Fig. 36).
Fig. 35 FLYWHEEL ASSEMBLY
1 - SPECIAL TOOL #8932 CRANKSHAFT LOCK
2 - RETAINING BOLTS
3 - ALIGNMENT PIN
4 - WASHER
5 - FLYWHEEL
6 - FLYWHEEL BOLT
9 - 44 ENGINEVA

PISTON & CONNECTING ROD
DESCRIPTION
NOTE: No over sized pistons are available.
The pistons are of a free floating design and made
of optimized aluminum alloy with a graphite coated
bearing surface. The crown of the piston has been
designed to accommodate higher injection pressures.
Oil jets in the engine block lubricate and cool the pis-
ton and pin assembly. The connecting rods have a
pressed in place wrist pin bushing featuring specially
adjusted lubrication grooves which are lubricated by
the oil jets (Fig. 37). The steel connecting rods fea-
ture a small end of trapezoidal shape and a cracked
large end.
Fig. 36 CRANKSHAFT LOCK #8932
1 - RETAINING BOLTS 3 - CRANKSHAFT LOCK #8932
2 - INSPECTION COVER 4 - RETAINING BOLTS
VAENGINE 9 - 45

STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS
NOTE: Connecting rods with blue discoloration,
cross scores or notches must be replaced. Com-
pensate for different weights by milling off the bal-
ancing weight.
(1) Inspect connecting rod for discoloring, cross
scores and notches.
NOTE: Connecting rod and bearing cap are marked
in sets and attached with two sleeves.
(2) Bolt connecting rod bearing cap to connecting
rod. Tighten connecting rod bearing caps to initialspecification (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON & CONNECTING ROD - INSTALLATION).
(3) Using a dial indicator, measure connecting rod
bearing basic bore, repair as necessary (Fig. 38).
NOTE: If excessive wear is present, press in new
connecting rod bushings.
(4) Measure connecting rod bushing inner diame-
ter (Fig. 38).
(5) Inspect wristpin bushing.
(6) Measure piston pin end play in connecting rod
bushing.
(7) Measure peak to valley height of connecting
rod bushing on inside.CONNECTING ROD SPECIFICATIONS
Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Width of connecting rod
bearing bore at connect-
ing rod bushing bore21.940 mm to 22 mm
Connecting rod bearing
shell basic bore51.600 mm to 51.614
mm
Fig. 37 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 38 MEASURING CONNECTING RODS
9 - 46 ENGINEVA

Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Allowable out-of-round-
ness and taper of basic
bore.020 mm
Allowable twist of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.100 mm
Allowable variation of
axial parallelism of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.045 mm
Allowable difference in
weight of complete con-
necting rod of an engine2g
Connecting rod inner
bushing30.018 to 30.024 mm
Connecting rod outer
bushing32.575 mm to 32.600
mm
Connecting rod basic
bore32.500 mm to 32.525
mm
Piston pin play in con-
necting rod.018 mm to.024 mm
Peak-to-Valley height
(Rz) of connecting rod
bushing on inside5
Connecting rod bolt
threadM8x1
STANDARD PROCEDURE - MEASURING PIS-
TON PROTRUSION
After replacing the pistons/connecting rods or
machining the engine block contact surface, it is then
necessary to measure the piston protrusion.
Measure protrusion between piston crown and cyl-
inder head contact surface without the head gasket
installed. The measurment must be carried out in
the direction of the piston pin in order to eliminate
piston rock.
(1) Measure piston protrusion at the two measur-
ing points (arrows) (Fig. 39).
Piston protrusion with new crankcase should be
0.38 - 0.62 mm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Push back on the chain tensioner and remove
the oil pump chain from the oil pump.
(6) Remove the oil pump.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side.
(7) Remove the connecting rod bearing cap.
NOTE: Do Not mix up the top and bottom connect-
ing rod bearing shells.
(8) Mark the connecting rod bearing shell and the
connecting rod bearing cap to each other.
Fig. 39 MEASURING PISTON PROTRUSION
1 - PISTON PROTRUSION MEASUREMENT
VAENGINE 9 - 47

(10) Mark the connecting rod bearing shell and
connecting rod to each other.
CAUTION: Care must be taken not to damage the
piston.
(11) Remove the piston pin circle clip. (Fig. 40).
(12) Press the piston pin out of the piston and con-
necting rod bushing. (Fig. 40).
(13) Inspect the connecting rod for wear and dam-
age.
INSTALLATION
(1) Assign piston to the cylinder bore.
(2) Using the appropriate clean engine oil, oil pis-
ton pin and connecting rod bushing.CAUTION: Assemble the piston and connecting rod
so that the arrow is pointing in the direction of
travel (in the opposite direction of power flow). The
marking on the connecting rod is pointing toward
the inlet side.
(3) Assemble piston and connecting rod (Fig. 41).
(4) Insert piston pin by hand (Fig. 41).
CAUTION: Care must be taken not to damage the
piston.
(5) Insert circle clip of piston pin into groove on
piston (Fig. 41).
Fig. 40 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN CIRCLIP
2 - PISTON PIN
3 - PISTON ASSEMBLY
4 - CONNECTING ROD AND CAP ALIGNMENT MARKS
5 - CONNECTING ROD CAP
6 - CONNECTING ROD BOLTS
7 - ENGINE BLOCK
VAENGINE 9 - 49

(9) Clean and inspect the connecting rod bolts.
CAUTION: Assure that the correct top and bottom
connecting rod bearings shells are used in accor-
dance with the markings.
CAUTION: The anti-twist locks of the connecting
rod bearing shells must be located in the slots of
the connecting rod bearing caps.
(10) Insert connecting rod bearing shell into con-
necting rod bearing cap.
CAUTION: The markings on the connecting rod and
connecting rod cap must be lined up.
(11) Install connecting rod bearing cap. Tighten
bolts in 3 stages, 5N´m (44 lbs in), 25N´m (221 lbs
in), 90É.
(12) Rotate crankshaft fully and check the clear-
ance.(13) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(14) Install engine oil pan and oil pan drain plug
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
CAUTION: Install a cylinder head gasket of standard
thickness or a cylinder head gasket of repair thick-
ness depending on piston protrusion.
(15) Measure piston protrusion (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
(16) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(17) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(18) Fill the crankcase with correct engine oil, to
proper level. Refer to owners manual for specifica-
tions.
Fig. 42 PISTON AND CONNECTING ROD INSTALLATION
1 - PISTON RING COMPRESSOR
2 - WOOD HAMMER HANDLE
3 - CONNECTING ROD ALIGNMENT MARKINGS
4 - CONNECTING ROD BOLTS
5 - CONNECTING ROD CAP
6 - CONNECTING ROD
7 - CIRCLE CLIP
8 - PISTON PIN
9 - PISTON ASSEMBLY
VAENGINE 9 - 51

Ring Gap Orientation
²Position the gaps on the piston as shown (Fig.
46).
²Oil spacer - Gap on center line of piston skirt.
²Oil rails - gap 180É apart on centerline of piston
pin bore.
²No. 2 Compression ring - Gap 120É from top oil
rail gap.
²No. 1 Compression ring - Gap 120É from No. 2
compression ring gap.
VIBRATION DAMPER
REMOVAL
NOTE: If vehicle is equipped with the additional air
conditioner compressor, you must first remove the
coolant module and additional A/C belt then use
damper puller # 9544.
(1) Disconnect negative battery cable.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Install retaining lock for crankshaft/ring gear
(Fig. 47).
(4) Remove crankshaft center bolt and washer
(Fig. 47).
NOTE: If hub of belt pulley/vibration damper is
tight, use puller # 8940 to remove. DO NOT tilt
puller when in use. Grooves of the puller must
mesh fully into the slots of the belt pulley.
Fig. 45 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 46 Ring Gap Orientation
1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
VAENGINE 9 - 53