engine oil MERCEDES-BENZ SPRINTER 2006 Manual Online

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Connecting Rod Cap
to Connecting Rod (3
stage, 1&2 torque, 1
torque angle)5,25,90É - 44,221, 90É
Crankshaft
Bolt-Crankshaft Bearing
Cap (2 stage, 1 torque, 1
torque angle55,90É 40.5, 90É -
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)200,90É 147.5, 90É -
10.9m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)325,90É 240, 90É -
Bolt-Stretch Shank for
Flywheel or 2 Mass Fly-
wheel to Crankshaft (2
stage, 1 torque, 1 torque
angle)45,90É 33, 90É
Turbo Charger
Bolt-Oil Feed Line to Cyl-
inder Head9/22 - 80-194
Bolt-Oil Feed Line to Tur-
bo Charger30 22 -
Bolt-Turbo Charger Sup-
port30 22 -
Bolt-Turbo Charger Sup-
port to Crankcase20 - 177
Bolt-Oil Outlet Line to
Turbo Charger9-80
Connection-Flange of Ex-
haust Manifold to Turbo
Charger30 22 -
Connection-Turbo Charger
to Front Catalytic Con-
verter30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air Distribu-
tion Pipe16 - 141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe9-80
Bolt-Support to Charge
Air Distribution Pipe20 - 177
Bolt-Support to Engine
Bracket40 30 -
9 - 12 ENGINEVA

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Clamp-Charge Air Pipes/
Hoses3-27
Belt Tensioning Device
Bolt-Guide Pulley to Cool-
ant Pump35 26 -
Bolt-Guide Pulley to Tim-
ing Case Cover35 26 -
Bolt-V-Belt Tensioning De-
vice to Tensioning Pulley36 26.5 -
Bolt-V-Belt Tensioning De-
vice to Timing Case Cov-
er30 22 -
Exhaust Manifold
Nut-Exhaust Manifold at
Cylinder Head30 22 -
Position Sensor
Nut/Bolt-Camshaft Posi-
tion Sensor to Cylinder
Head Cover11 - 9 7
Nut/Bolt-Crankshaft Posi-
tion Sensor to Engine
Block8-70
Pre-Glow System
Cylinder Head to Glow
Plug12 - 106
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of Circuit
3014 - 124
Nut-Connection of Circuit
506-53
Alternator
Bolt-Generator to Timing
Case Cover20 15 -
Bolt-Generator to Cooler
Housing6-53
Bolt-Cooler Housing of
Generator to Crankcase20 - 177
Nut-B+ Circuit to Genera-
tor13-18 - 115-159
Nut-D+ Circuit to Genera-
tor5-44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to Crank-
case18
- 133
Bolt-Oil Pipe to Crank-
shaft Bearing Cap8-70
VAENGINE 9 - 13

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat Ex-
changer to Timing Cover
Case15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube
to Cylinder Head14 - 123
Bolt-Oil Level Sensor to
Oil Pan14 - 123
Coolant Pre-Heater
Coolant Pre-Heater in En-
gine Block35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant
Pump8-35 6 - 26 -
Bolt-Coolant Pump to
Timing Case Cover 6m/
8m14/20 10 - 15 -
Bolt-Thremostat Housing
to Cylinder Head9-80
Coolant Drain Plug to
Crankcase30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage,
torque, torque angle)20/90É 15, 90É -
Bolt-Engine Mount to En-
gine Bracket55 40.5 -
Bolt-Front Engine Mount
to Front Axle Carrier35 26 -
Bolt-Rear Engine Cross
Member to Body40 30 -
Bolt-Rear Engine Mount
to Rear Engine Cross
Member35 26 -
Bolt/Nut- Rear Engine
Mount to Transmission40 26 -
Bolt-Shrowd to Engine
Bracket10 - 88.5
Nut-Front Engine Mount
to Engine Bracket65 48 -
Nut-Engine Mount to Ve-
hicle Frame35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
9 - 14 ENGINEVA

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt- Fuel Filter to Charge
Air Distribution Pipe14 - 124
Exhaust System
Bolt- Catalytic Converter
Bracket to Crankcase20 - 177
Bolt - Turbocharger Oil
Supply Line at Turbo-
charger25 18 -
Bolt - Turbocharger Oil
Return Line at Turbo-
charger10 - 89
Clamp-Connection Be-
tween Front Exhaust Pipe
and Rear Exhaust System55 41 -
Clip-Front Catalytic Con-
verter to Engine Mount20 - 177
Exhaust Manifold to Cylin-
der Head29 21 -
Nut-EGR Valve 9 - 80
Nut-Bracket to Tail Pipe 55 40.5 -
Nut-Exhaust Bracket to
Threaded Plate of Center
Exhaust Pipe20 - 177
Support-Exhaust Bracket
on Transmission20 - 177
Refrigerant Compressor
Bolt-Refrigerant Compres-
sor to Timing Case Cover20 - 177
Bolt-Refrigerant Compres-
sor to Bracket20 - 177
Bolt-Refrigerant Lines to
Refrigerant Compressor20 - 177
Timing Chain, Chain Tensioner
Bolt-Camshaft Sprocket to
Exhaust Camshaft18 - 159
Bolt-Intermediate Gear of
High Pressure Pump to
Cylinder Head40 29.5 -
Timing Chain Tensioner to
Timing Case Cover80 59 -
Camshaft
Bolt-Camshaft Bearing
Cap to Cylinder Head9-80
Bolt-Driver to Inlet Cam-
shaft50 37 -
Common Rail Diesel Injection
Bolt-Banjo Bolt of Leak
Oil Line to Rail20 - 177
VAENGINE 9 - 15

SPECIAL TOOLS
SPECIAL TOOL CROSS REFERENCE CHART
MB
TOOL #MILLER
TOOL #DESCRIPTION
N/A 5069-2 FUEL GAUGE
611 589
04 63 008927 COMPRESSION TESTER
ADAPTER
611 589
03 15 008929 CAMSHAFT LOCKING
PINS
611 589
00 40 008930 COUNTERHOLDER
N/A 9525 TIMING CHAIN RETAINER
601 589
02 40 008932 CRANKSHAFT LOCK
603 589
00 40 008934 COUNTERHOLDER
N/A 8938A EXTRACTION CLAW
611 589
00 14 008936 FRONT CRANKSHAFT
SEAL INSTALLER
N/A 8938 EXTRACTION CLAW
613 589
00 33 008940 VIBRATION DAMPER RE-
MOVER
N/A 8941 SLIDE HAMMER
611 589
00 15 008942 OIL JET INSTALLER
611 589
01 14 008944 REAR MAIN SEAL IN-
STALLER
N/A 9312-1 CHAIN SEPARATOR / RIV-
ETING TOOL
9312-4 THRUST PIECE
N/A 9312-3 PRESSING SCREW
602 589
02 40 008951 ASSEMBLY LINKS
N/A 9312-5
THRU 12ASSEMBLY INSERTS
N/A 9285 FUEL LINE WRENCH
N/A 9286 GLOW PLUG PLIERS
N/A 9295 COMPRESSION HOSE
ADAPTER
111 5 8 9
25 61 009307 VALVE SERVICE TOOLS
N/A 8534-16 ENGINE SUPPORT FIX-
TURE ADAPTERS
N/A 9308 ENGINE LIFTING FIX-
TURE
N/A 9525 TIMING CHAIN GUIDE
N/A 9534 ADAPTOR
N/A 9539 FUEL LINE PLIERS
#8927 COMPRESSION TESTER ADAPTER
#8929 CAMSHAFT LOCKING PIN
VAENGINE 9 - 17

#8941 SLIDE HAMMER
#8942 OIL JET INSTALLER
#8944 REAR MAIN SEAL INSTALLER
#9307 VALVE SERVICE TOOLS
VAENGINE 9 - 19

(12) Remove the camshaft housing at the cylinder
head (Fig. 14).
(13) Remove the high pressure pump.
(14) Remove the front head cover plate.
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING
WHEN HANDLING FUEL.
(15) Remove the high pressure fuel pump interme-
diate gear (Fig. 14).
(16) Disconnect the engine side of the engine har-
ness and set aside.
(17) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
(18) Remove the turbocharger oil supply line at
the cylinder head and turbocharger (Fig. 14).
(19) Disconnect the turbocharger at the exhaust
manifold (Fig. 14).(20) Unbolt the transmission oil level indicator
tube fasteners from the cylinder head and engine
block (Fig. 14).
(21) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 14).
NOTE: Capture any fuel spillage when disconnect-
ing fuel lines.
(22) Disconnect the fuel line at the rear of the fuel
rail (Fig. 14).
Fig. 14 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 24 ENGINEVA

(23) Remove upper timing case to cylinder head
bolts (Fig. 15).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(24) Remove cylinder head bolts and inspect (Refer
to 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(25) Remove cylinder head (Fig. 15).
NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(26) Clean all mating surfaces and blow out bolt
thread holes.
REMOVAL - CYLINDER HEAD FRONT COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLE IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING FUEL.
RISK OF INJURY FROM SKIN AND EYE CONTACT
WITH FUEL. POUR FUELS ONLY INTO SUITABLE
AND APPROPRIATELY MARKED CONTAINERS.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL.
(5) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(6) Remove bolts attaching front cover.
NOTE: Lower portion of front cover is sealed with
RTV sealant. Carefully tug at front cover until it
loosens from cylinder head.
(7) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 16).
NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
Fig. 15 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL4 - GASKET
5 - BOLT TO TIMING COVER
VAENGINE 9 - 25

REMOVAL - CYLINDER HEAD GUIDE RAIL
(1) Disconnect negative battery cable.
CAUTION: Rotate engine at crankshaft only. DO
NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine back.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove engine cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 16).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly. If piston or connecting rods have been
replaced, measure piston protrusion. Inspect all cyl-
inder head bolts for defects and stretching before
installation (Refer to 9 - ENGINE/CYLINDER HEAD -
STANDARD PROCEDURE). Inspect facing cylinder
head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as a guide (Fig. 15).
CAUTION: The M12 cylinder head bolts must be
torqued in 3 stages.
NOTE: Add a small amount of clean engine oil to
the cylinder head bolt threads prior to installation.
Fig. 16 CYLINDER HEAD FRONT COVER
1 - TOP GUIDE RAIL
2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN5 - CYLINDER HEAD FRONT COVER
6 - SEAL
7 - TIMING CHAIN TENSIONER
8 - VACUUM PUMP
9 - 26 ENGINEVA

(2) Hand start clean head bolts and tighten per
the following procedure:
²Install M12 cylinder head bolts finger tight (Fig.
15).
²Tighten bolts in numeric order starting with
number 1 to 15 N´m (133 lbs.in.) (Fig. 17).
²Tighten bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.ft.) (Fig. 17).
²Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
17).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(4 stages). (Fig. 17).
(3) Install fuel return flow line between rail and
high pressure pump (Fig. 14).
(4) Connect the coolant hoses to the thermostat
housing (Fig. 14).
(5) Connect the coolant pipe at the cylinder head
(Fig. 14).
(6) Reconnect transmission oil level indicator tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 14).
(7) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 14).
(8) Install oil return flow line with new seals at
turbocharger. Tighten bolt of supply line to turbo-
charger to 18N´m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N´m (80 lbs. in.) (Fig. 14)
(9) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(10) Install and properly route the engine wiring
harness, making appropriate connections.
(11) Install high pressure fuel pump intermediate
gear (Fig. 14).(12) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(13) Install the camshaft housing with tappets to
cylinder head (Fig. 14).
(14) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(15) Install top guide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(16) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N´m (59 lbs.ft.).
(20) Remove retaining lock for crankshaft/starter
ring gear.
(21) Install air intake tube at turbocharger (Refer
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).
(22) Install the fasteners retaining the front
exhaust pipe to the support bracket at the read of
the engine.
(23) Install the upper support bracket fastener.
(24) Install the lower turbo support bracket bolt.
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.
(26) Refill cooling system with proper coolant mix-
ture to proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(27) Connect 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.
(28) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
Fig. 17 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 27