reset MERCEDES-BENZ SPRINTER 2006 Workshop Manual

(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

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.
(6) Start the engine, allow to warm, turn engine
off and inspect for leaks. Care must be take to
observe the fuel system warning (Refer to 14 - FUEL
SYSTEM - WARNING).
INSTALLATION - INTERMEDIATE GEAR
NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.
(1) Install intermediate gear and bushing. Tighten
bolt to 40N´m (30 lbs.ft.)
(2) Install the intake camshaft (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
INSTALLATION).
(3) Install exhaust camshaft sprocket, noting
dowel pin alignment. Tighten bolt to 18 N´m (159 lbs.
in.).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(4) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install top slide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(6) Install cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(7) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
NOTE: Inspect basic position of camshaft and reset
if necessary (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
(8) Remove camshaft locking pin.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROMCONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(10) Install fuel high pressure lines and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(11) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(12) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(13) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
INSTALLATION - TIMING CHAIN TENSIONING
RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
(1) Install tensioning rail on bearing pin
(2) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(3) Install oil pan and 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.
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 engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING).
ADJUSTMENTS
INSTALLATION - TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
CAUTION: Cover timing case recesses to prevent
foreign material from entering engine.
VAENGINE 9 - 77

(4) Fill fuel tank with fresh diesel fuel.
(5) Drain and remove the fuel filter. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER /
WATER SEPARATOR - REMOVAL)
(6) Install a new fuel filter. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER
SEPARATOR - INSTALLATION)
(7) Check the engine control module for any diag-
nostic trouble codes (DTCs). Record and clear any
DTCs that are present.
(8) Start and run the engine. Run the engine for
up to 15 minutes to allow time for any DTCs to reset
and shut off the engine.
(9) Check the engine control module for any diag-
nostic trouble codes (DTCs). Record any DTCs that
are present. Refer to the appropriate engine electrical
diagnostics to diagnose any DTCs that were set.
CAUTION: With the high pressure fuel system in
this vehicle, any residual contaminated fuel will be
removed very quickly. Shut off the engine immedi-
ately if signs of engine damage are noted.The engine should then be evaluated to determine
if the contaminated fuel has caused any damage to
the fuel system and/or engine. Indicators that the
fuel system has been damaged include the following:
²Unstable fuel rail pressure. This can manifest
itself as instability of idle speeds, excessive under-
shoot/overshoot at engine start-up, or excessive
undershoot/overshoot when the engine operating con-
ditions change. A typical engine response to a large
rail pressure undershoot would be a decrease in
engine speed or engine stall.
²Excessive noise from the engine. This could indi-
cate poor rail pressure control or the inability of the
injection system to inject the proper amount of fuel.
²Excessive smoke (black or white). This could
indicate the inability of the fuel system to inject the
proper amount of fuel.
NOTE: If any of these conditions are exhibited after
cleaning the fuel system, proceed to the appropri-
ate engine electrical diagnostic information. Repair
the fuel system and/or engine as necessary.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FUEL TANK MOUNTING NUTS 15 - 17 11 - 13 -
FUEL TANK MODULE LOCKRING (LOCK-
NUT)60 44 -
PRESSURE CONTROL VALVE NUT TO
FUEL RAIL (2 STAGES)60, loosen 90É, re-
tighten to 8044, loosen 90É, re-
tighten to 59-
SPECIAL TOOLS
FUEL SYSTEM
SPECIAL TOOL CROSS REFERENCE CHART
MB
TOOL #MILLER
TOOL #DESCRIPTION
N/A 5069-2 FUEL GAUGE
N/A 6856 SPANNER WRENCH
N/A 9068 FUEL GAUGE ADAPTER
N/A 9285 FUEL LINE WRENCH
SPANNER WRENCH-6856
VAFUEL DELIVERY 14 - 9

(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

torque to 45 N´m (33 ft. lbs.) and a final additional
90É turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N´m (18 ft. lbs.).
(4) Install both the power steering hoses to the
steering gear (Fig. 2). Tighten the high pressure hose
to 37 N´m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
(6) Install the left outer tie rod end to the steering
gear.(7) Install both the outer tie rod ends to the steer-
ing knuckle (Fig. 2). Tighten to 130 N´m (96 ft. lbs.).
(8) Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
U-Joint To Steering Gear 24 18 212
High Pressure Hose To
Steering Gear37 27 328
Return Line To Steering
Gear37 27 328
Steering Gear To Frame
Initial Torque25 18 221
Steering Gear To Frame
Second Torque
Then additional 90É turn45 33 398
19 - 8 GEARVA

flexible adaptation to different vehicle and engine
variants.
EMERGENCY RUNNING FUNCTION
In order to ensure a safe driving state and to pre-
vent damage to the automatic transmission, the TCM
control module switches to limp-home mode in the
event of critical faults. A diagnostic trouble code
(DTC) assigned to the fault is stored in memory. All
solenoid and regulating valves are thus de-energized.
The net effect is:
²The last engaged gear remains engaged.
²The modulating pressure and shift pressures
rise to the maximum levels.
²The torque converter lockup clutch is deacti-
vated.
In order to preserve the operability of the vehicle
to some extent, the hydraulic control can be used to
engage 2nd gear or reverse using the following pro-
cedure:²Stop the vehicle.
²Move selector lever to ªPº.
²Switch off engine.
²Wait at least 10 seconds.
²Start engine.
²Move selector lever to D: 2nd gear.
²Move selector lever to R: Reverse gear.
The limp-home function remains active until the
DTC is rectified or the stored DTC is erased with the
appropriate scan tool. Sporadic faults can be reset
via ignition OFF/ON.
CLUTCH APPLICATION
Refer to CLUTCH APPLICATION for which shift
elements are applied in each gear position.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N N/A X X
R 3.16 X* X X X
R - Limp
In1.93 X X X
* = The shift components required during coast.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 5

3.2.5 TRANSMISSION OPERATION AND
SHIFT SCHEDULING
The transmission covered in this manual has
unique shift schedules depending on the tempera-
ture of the transmission oil. The transmission oil
temperature has a decisive effect on the shift qual-
ity of the transmission. The shift schedule is modi-
fied to extend the life of the transmission while
operating under extreme conditions and to improve
driver comfort by modifying shift schedules.
The transmission oil temperature is measured
with a Temperature Sensor on the NAG1 transmis-
sion. The Temperature Sensor is an integral com-
ponent of the Transmission Solenoid assembly. If
the Temperature Sensor is causing a problem, a
DTC will be set in the TCM.
The Transmission Temperature Sensor is wired in
series with the Park /Neutral (P/N) switch. The P/N
switch is also located in the transmission. The trans-
mission temperature is only read by the TCM when
the P/N switch closes while in the R, D position.
When the shifter lever is in the park or neutral
position, the P/N switch opens and the temperature
being displayed is Engine temperature.
AutoStick Feature (If equipped)
This feature allows the driver to manually shift the
transaxle when the shift lever is moved sideways to
the (+ / -) in position D to adjust the shift range.
3.2.6 TRANSMISSION ADAPTIVES -
INITIALIZE AND STORE
Initialize Adaptive -This TCM function should be
used when a new transmission has been placed in
the vehicle. This command will reset the TCM
adaptive to the factory setting.
Store Adaptive -This command should be used
after the vehicle has been test driven by the tech-
nician to store any learned adaptive changes that
occurred during the test drive. During normal op-
eration adaptive are updated every 10 minutes.
Using this command the latest adaptive will be
written to the TCM immediately.
3.3 DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC's) are codes stored
by the Transmission Control Module (TCM) and the
Shift Lever Assembly Module (SLA) to help diag-
nose Transmission and Shifter problems. They are
viewed using the DRBIIItscan tool.
Always begin by performing a visual inspection of
the wiring, connectors, cooler lines and the trans-
mission. Any obvious wiring problems or leaks
should be repaired prior to performing any diagnos-
tic test procedures. Some engine driveability prob-lems can be misinterpreted as a transmission prob-
lem. Ensure that the engine is running properly
and that no ECM DTC's are present that could
cause a transmission complaint.
If there is a communication K-ABS,Shifter or
K-TCM circuit problem, trouble codes will not be
accessible until the problem is fixed. The DRBIIIt
will display an appropriate message. The following
is a possible list of causes for a bus problem:
± open or short to ground/battery in K line
circuit.
± internal failure of any module or component
connected to the K line circuit
Each diagnostic trouble code is diagnosed by
following a specific testing sequence. The diagnostic
test procedures contain step-by-step instructions
for determining the cause of a transmission diag-
nostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not neces-
sary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.
If the TCM records a DTC that will adversely
affect the vehicles transmission, it will request (via
the communication bus) that the ECM illuminate
the Malfunction Indicator Lamp (MIL). All trans-
mission DTC's will be stored in the TCM.
3.3.1 ACTIVE (HARD) CODE
Any Diagnostic Trouble Code (DTC) that is set
whenever the system or component is monitored is
an Active code. This means that the problem is
there every time the TCM checks that system or
component. Some codes will set immediately at
start up and others will require a road test under
specific conditions to set the DTC. It must be
determined if a code is Active (repeatable) or Stored
(Intermittent) before attempting diagnosis.
3.3.2 STORED (INTERMITTENT) CODE
A diagnostic trouble code that is not there every
time the TCM checks the circuit or function is a
Stored (Intermittent) code. Problems that come and
go like this are the most difficult to diagnose, they
must be looked for under the specific conditions
that cause them. If the DTC is reset (after an
ignition cycle) the DTC will be set to Stored (Inter-
mittent) status. A DTC status can be9Active9or
9Stored9(Intermittent). Active is when the DTC is
present in the controller and the transmission is in
the particular mode of operation for that DTC.
Stored means that the DTC occurred at some point,
but is not currently present, or the conditions have
not been right to check for the presence of the
problem, when a DTC is classified as Stored (Inter-
mittent), no TCM reaction is required.
4
GENERAL INFORMATION

Emergency running function
If DTCs occur, safe-driving conditions must be re-
tained but full functionality of the transmission will
be limited to avoid damaging the automatic trans-
mission. In the event of certain DTCs the TCM
switches to emergency running. The TCM will store
the appropriate DTC codes and solenoids will be
de-energized (turned off)
The transmission effects will be:
²The last gear shifted remains in that position
²The modulating pressure and shift pressure in-
crease to maximum value
²The torque converter clutch is disengaged
(turned off)
Shifting manually after a DTC detection
NOTE: The vehicle can still be shifted
manually to 2nd or reverse gear.
To accomplish these shifts you must
Stop the vehicle
Turn the ignition off
Start the engine
Place the selector lever into D for 2nd gear
Place the selector lever into R for reverse gear
The emergency running function is retained until
the DTC is eliminated or the stored DTC code is
erased.
Stored (Intermittent) DTCs can be reset by cy-
cling the ignition switch
3.3.3 TROUBLE CODE ERASURE
Diagnostic Trouble Codes can be erased in two
ways. The first is to erase the DTC with the DRBIII
or scan tool. The second is if the DTC is no longer
present, the DTC is reset by the TCM (after an
ignition cycle), which will place the DTC in an
intermittent status (Stored DTC).
When there are no diagnostic trouble codes
stored in memory, the DRBIIItwill display
(NO DTC's DETECTED(
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser's guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill display
one of only two error messages:
± User-Requested WARM Boot
± User-Requested COLD Boot
If the DRBIIItshould display any other error
message, record the entire display and call the
S.T.A.R. Center.
3.5.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage. A mini-
mum of 11 volts is required to adequately power the
DRBIIIt.
If all connections are proper between the DRBI-
IItand the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIIIt
may be the result of faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate Body
Diagnostic manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
AND WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
5
GENERAL INFORMATION

Symptom:
INCORRECT CAN MESSAGE FROM ABS
POSSIBLE CAUSES
ABS - INTERNAL
SLA - INTERNAL
TEST ACTION APPLICABILITY
1 Turn the ignition off to the lock position.
Replace the ABS Control Module per the Service Information.
Ignition on, engine not running.
With the DRBIIIt, erase Transmission DTCs.
Start the engine and with the brakes firmly applied place the gear selector into Drive.
With the DRBIIIt, read Transmission DTCs.
Did the DTC, ABS CAN MESSAGES INCORRECT, reset?All
Ye s!Replace the Shift Lever Assembly per the Service Information.
No!Test complete.
18
SHIFT LEVER ASSEMBLY

TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the service information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTCs. Check and repair all engine DTCs prior to
performing transmission symptom diagnostics.
With the DRBIIIt, read and record all Transmission DTCs.
NOTE: Check connectors - Clean/repair as necessary. Poor pin to terminal
connections can set DTCs.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Most DTCs set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
NOTE: Check for any Technical Service Bulletins that may apply.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 Ignition on, engine not running.
With the DRBIIIt, erase DTCs.
With the DRBIIIt, perform the Solenoid Test.
With the DRBIIIt, read DTCs.
Did the DTC, 1-2/4-5 SOLENOID CIRCUIT, reset?All
Ye s!Go To 3
No!Go To 7
3 Turn the ignition off to the lock position.
Disconnect the Transmission Control Module C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the 1-2/4-5 Solenoid Control circuit from the TCM harness
connector to the Transmission Solenoid Assembly harness connector.
Is the resistance above 5.0 ohms?All
Ye s!Repair the 1-2/4-5 Solenoid Control circuit for an open.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off to the lock position.
Disconnect the Transmission Control Module C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the 1-2/4-5 Solenoid Control circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the 1-2/4-5 Solenoid Control circuit for a short to ground.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 5
25
TRANSMISSION - NAG1
1-2/4-5 SOLENOID CIRCUIT ÐContinued