MERCEDES-BENZ SPRINTER 2006 Service Manual

volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Disconnect and isolate the remote battery neg-
ative cable terminal.
(3) One at a time, trace and disconnect the battery
cable retaining pushpins, fasteners and routing clips
until the cables are free from the vehicle.
(4) Feed the battery cable assembly out of the
vehicle.
INSTALLATION
(1) Position the battery cable in the vehicle.
(2) One at a time, install the battery cable retain-
ing pushpins, fasteners and routing clips until the
cable is installed exactly in the factory installed loca-
tion in the vehicle. Refer to the Wiring Diagram sec-
tion of the service manual for reference.
(3) Connect the battery negative cable terminal.
BATTERY TRAY
DESCRIPTION
The battery is mounted in a stamped steel battery
tray located in the left front corner of the engine
compartment. The battery tray is secured with bolts
to the left front wheelhouse inner steel panel. A hole
in the bottom of the battery tray is fitted with aformed drain tube. A second hole in the bottom of the
tray is fitted with a battery temperature sensor.
OPERATION
The battery tray provides a mounting location and
support for the vehicle battery. The battery tray sup-
port supports the battery tray and provides an
anchor point for the inboard battery hold down hard-
ware. The battery tray and the battery hold down
hardware combine to secure and stabilize the battery
in the engine compartment, which prevents battery
movement during vehicle operation. Unrestrained
battery movement during vehicle operation could
result in damage to the vehicle, the battery or both.
The battery tray drain tube directs spilled water or
electrolyte from a leaking battery to the ground
through another hole in the front extension of the
left front wheelhouse inner panel.
REMOVAL
(1) Remove the battery from the battery tray.
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(2) Remove the battery temperature sensor from
the battery tray. (Refer to 8 - ELECTRICAL/CHARG-
ING/BATTERY TEMPERATURE SENSOR -
REMOVAL).
(3) Remove the bolts that secure the battery tray
to the battery tray support.
(4) Remove the battery tray from the vehicle.
INSTALLATION
(1) Clean and inspect the battery tray. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM - CLEANING).
(2) Position the battery tray onto the battery tray
support.
(3) Install and tighten the bolts that secure the
battery tray to the battery tray support. Tighten the
screws to 11.8 N´m (105 in. lbs.).
(4) Install the battery temperature sensor onto the
battery tray. (Refer to 8 - ELECTRICAL/CHARGING/
BATTERY TEMPERATURE SENSOR - INSTALLA-
TION).
(5) Install the battery onto the battery tray. (Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
INSTALLATION).
Fig. 12 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
8F - 16 BATTERY SYSTEMVA

CHARGING SYSTEM
TABLE OF CONTENTS
page page
CHARGING SYSTEM
SPECIFICATIONS
TORQUE ± 2.7L DIESEL................17
SPECIAL TOOLS.......................18
GENERATOR
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................19
GENERATOR DECOUPLER PULLEY
DESCRIPTION.........................19OPERATION...........................19
DIAGNOSIS AND TESTING - GENERATOR
DECOUPLER.........................20
REMOVAL.............................20
INSTALLATION.........................22
VOLTAGE REGULATOR
DESCRIPTION.........................24
REMOVAL.............................24
INSTALLATION.........................26
CHARGING SYSTEM
SPECIFICATIONS
TORQUE ± 2.7L DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
B+ Terminal Nut (larger of
2 nuts)18 - 159
D+ Terminal Nut (smaller
of 2 nuts)5-44
Rear Generator Support
Bracket Bolts (to engine)28 - 250
Generator Decoupler 110 81 -
Generator/Turbocharger
Brace Bolt at Turbocharg-
er End30 22 -
Generator/Turbocharger
Brace Bolt at Engine End20 15 -
VACHARGING SYSTEM 8F - 17

SPECIAL TOOLS
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine using a
serpentine-type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea-
son, the entire assembly must be replaced.
On certain engines, the decoupler pulley may be
replaced separately.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The stator winding connections deliver the induced
AC current to 3 positive and 3 negative diodes for
rectification. From the diodes, rectified DC current isdelivered to the vehicle electrical system through the
generator battery terminal.
Although the generators appear the same exter-
nally, different generators with different output rat-
ings are used on this vehicle. Be certain that the
replacement generator has the same output rating
and part number as the original unit. Refer to Spec-
ifications and see Generator Ratings for amperage
ratings and part numbers.
Noise emitting from the generator may be caused
by: worn, loose or defective bearings; a loose or defec-
tive drive pulley (decoupler pulley); incorrect, worn,
damaged or misadjusted fan drive belt; loose mount-
ing bolts; a misaligned drive pulley or a defective sta-
tor or diode.
An instrument panel mounted, battery charge indi-
cator lamp is used. When the key is in the on posi-
tion, the lamp will be illuminated. This is done as a
bulb check. If this lamp remains illuminated while
the engine is running, a Diagnostic Trouble Code
(DTC) has been detected for the charging system.
REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.
(1) Disconnect and isolate negative battery cable.
(2) Remove generator drive belt. Refer to Cooling
System for procedure.
(3) Raise and support vehicle.
(4) Remove protective plastic cover from B+ stud
at top of generator.
(5) Remove nut securing battery output cable to
B+ terminal at top of generator.
(6) Unplug field terminal connector at rear of gen-
erator.
(7) Remove 4 generator mounting bolts (Torx-style
#12 bit) (Fig. 1).
(8) Remove generator from lower side of vehicle.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
8F - 18 CHARGING SYSTEMVA

INSTALLATION
(1) Raise and support vehicle.
(2) Position generator to engine.
(3) Install 4 generator mounting bolts (Fig. 1).
Refer to Torque Specifications.
(4) Connect field terminal connector at rear of gen-
erator.
(5) Install battery output cable and nut to B+ ter-
minal at top of generator. Refer to Torque Specifica-
tions.
(6) Install protective plastic cover to B+ stud at
top of generator.
(7) Lower vehicle.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. Thewater pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.
(8) Install generator drive belt. Refer to Cooling
System for procedure.
(9) Connect negative battery cable.
(10) Check charging system for proper operation.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The generator decoupler is used only with
certain engines.The decoupler is used in place of
the standard generator drive pulley (Fig. 2).
OPERATION
The generator decoupler is used only with
certain engines.The decoupler (Fig. 2) is a one-way
clutch designed to help reduce belt tension fluctua-
tion, vibration, reduce fatigue loads, improve belt life,
reduce hubloads on components, and reduce noise.
Dry operation is used (no grease or lubricants). The
decoupler is not temperature sensitive and also has a
low sensitivity to electrical load. The decoupler is a
non-serviceable item and is to be replaced as an
assembly.
Fig. 1 GENERATOR MOUNTING - 2.7L DIESEL
1 - GENERATOR
2 - DRIVE BELT
3 - MOUNTING BOLTS (4)
4 - GENERATOR WIRING HARNESS
Fig. 2 GENERATOR DECOUPLER PULLEY
VACHARGING SYSTEM 8F - 19

DIAGNOSIS AND TESTING - GENERATOR DECOUPLER
CONDITION POSSIBLE CAUSES CORRECTION
Does not drive generator
(generator not charging)Internal failure Replace decoupler
Noise coming from decou-
plerInternal failure Replace decoupler
REMOVAL
The generator decoupler is used only with
certain engines.
Two different type generator decoupler pulleys are
used. One can be identified by the use of machined
splines (Fig. 3). The other can be identified by a hex
opening (Fig. 4) and will not use splines.
Different special tools are required to service each
different decoupler. Refer to following procedure.
INA Decoupler
(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.
Refer to Generator Removal.
(3) Position Special Tool #8823 (VM.1048) into
decoupler (Fig. 5).
(4) Determine if end of generator shaft is hex
shaped (Fig. 6) or is splined (Fig. 7). If hex is used,
insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 8). If splined, insert a 5/16º 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 9).
(5) The generator shaft uses conventional right-
hand threads to attach decoupler. To break decoupler
loose from generator threads, rotate end of tool clock-
wise (Fig. 8) or, (Fig. 9).
(6) After breaking loose with tool, unthread decou-
pler by hand from generator.
Fig. 3 GENERATOR DECOUPLER PULLEY (INA)
1 - GENERATOR
2 - DECOUPLER (INA)
3 - MACHINED SPLINES
Fig. 4 GENERATOR DECOUPLER PULLEY (LITENS)
1 - DECOUPLER (LITENS)
2 - HEX OPENING
8F - 20 CHARGING SYSTEMVA

Fig. 5 #8823 TOOL AND INA DECOUPLER
1 - INA DECOUPLER
2 - TOOL #8823 (VM.1048)
Fig. 6 END OF GENERATOR SHAFT (HEX)
1 - GENERATOR SHAFT
2 - HEX
Fig. 7 END OF GENERATOR SHAFT (SPLINED)
1 - GENERATOR SHAFT
2 - SPLINES
Fig. 8 DECOUPLER REMOVAL (INA-HEX)
1 - DEEP 10 MM SOCKET
2 - TOOL #8823 (VM.1048)
VACHARGING SYSTEM 8F - 21

Litens Decoupler
(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.
Refer to Generator Removal.
(3) Position Special Tool #8433 (Fig. 10) into
decoupler. Align to hex end of generator shaft.
(4) The generator shaft uses conventional right-
hand threads to attach decoupler. To break decoupler
loose from generator threads, rotate end of tool clock-
wise (Fig. 11).
(5) After breaking loose with tool, unthread decou-
pler by hand from generator.
INSTALLATION
INA Decoupler
(1) Thread decoupler pulley onto generator shaft
by hand (right-hand threads).
(2) Position Special Tool #8823 (VM.1048) into
decoupler (Fig. 5).
(3) Determine if end of generator shaft is hex
shaped (Fig. 6) or is splined (Fig. 7). If hex is used,
insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 12). If splined, insert a 5/16º 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 13).
Fig. 9 DECOUPLER REMOVAL (INA-SPLINED)
1 - DRIVER
2 - TOOL #8823 (VM.1048)
3 - 17 MM WRENCH
Fig. 10 # 8433 TOOL AND LITENS DECOUPLER
Fig. 11 DECOUPLER REMOVAL (LITENS)
8F - 22 CHARGING SYSTEMVA

(4)Do not use an adjustable, ratcheting
ªclick typeº torque wrench. Most ªclick typeº
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench.Tighten in counter-clockwise
rotation (Fig. 12) or, (Fig. 13). Refer to torque speci-
fications.
(5) Install accessory drive belt, and generator.
Refer to Generator Installation.
(6) Connect negative battery cable.
Litens Decoupler
(1) Thread decoupler pulley onto generator shaft
by hand (right-hand threads).
(2) Position Special Tool 8433 (Fig. 10) into decou-
pler. Align tool to hex end of generator shaft.
(3)Do not use an adjustable, ratcheting
ªclick typeº torque wrench. Most ªclick typeº
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench.Tighten in counter-clockwise
rotation (Fig. 14). Refer to torque specifications.
(4) Install accessory drive belt, and generator.
Refer to Generator Installation.
(5) Connect negative battery cable.
Fig. 12 DECOUPLER INSTALLATION (INA-HEX)
1 - 10MM DEEP SOCKET
2 - TOOL # 8823 (VM.1048)
Fig. 13 DECOUPLER INSTALLATION (INA SPLINED)
1 - DRIVER
2 - TOOL # 8823 (VM.1048)
3 - BACKUP WRENCH
VACHARGING SYSTEM 8F - 23

VOLTAGE REGULATOR
DESCRIPTION
The electronic voltage regulator (1) (Fig. 15) is
attached to the rear of the generator. The regulator
may be serviced separately from the generator.
REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
(1) Disconnect and isolate negative battery cable.(2) Raise and support vehicle.
(3) Remove bolt (2) (Fig. 16) at turbocharger brace
(1) (Fig. 16).
(4) Loosen bolt (1) (Fig. 17) at brace (2) (Fig. 17).
Swivel the race (2) to the side.
(5) Remove + terminal nuts (3) and (4) (Fig. 17).
(6) Remove wires (5) and (6) (Fig. 17).
Fig. 14 DECOUPLER INSTALLATION (Litens)
Fig. 15 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
Fig. 16 BRACE BOLT
1 - Turbocharger Brace
2 - Brace Bolt
Fig. 17 REAR OF GENERATOR
1 - Brace Bolt
2 - Brace
3 - Nut
4 - Nut
5 - Wire
6 - Wire
8F - 24 CHARGING SYSTEMVA

(7) Remove plastic cover (1) (Fig. 18) by removing
screw (2) and nuts (3) and (4).
(8) Remove screws (1), (3), and (4) (Fig. 19).
(9) Remove voltage regulator (2) (Fig. 19).To pre-
vent damage to the carbon brushes, slowly pull
the voltage regulator straight out from genera-
tor without slanting or tipping.(10) Check condition of commutator rings (1) (Fig.
20). If rings are worn, replace generator assembly.
(11) Check condition of carbon brushes (1) (Fig.
21). If brushes are worn, replace generator assembly.
Fig. 18 PLASTIC COVER
1 - Plastic Cover
2 - Screw
3 - Nut
4 - Nut
Fig. 19 MOUNTING BOLTS
1 - Screw
2 - Voltage Regulator
3 - Screw
4 - Screw
Fig. 20 COMMUTATOR RINGS
1 - Commutator Rings
Fig. 21 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
VACHARGING SYSTEM 8F - 25