2005 MERCEDES-BENZ SPRINTER Service Repair Manual

REMOVAL
REMOVAL
NOTE: Capture any fluid spillage and store in an
appropriately marked and suitable containers.
(1) Disconnect the negative battery cable.
(2) Remove the heat shield (Fig. 6).
(3) Separate the front exhaust pipe from the tur-
bocharger (Fig. 6)
(4) Separate the charge air and intake air hoses at
the turbocharger (Fig. 6).
(5) Remove the vacuum line from the turbocharger
vacuum unit (Fig. 6).
(6) Separate the oil supply at the cylinder head
and turbocharger (Fig. 6).
(7) Separate the oil return flow line at the turbo-
charger (Fig. 6).(8) Remove the turbocharger support bracket (Fig.
6).
(9) Remove turbocharger from exhaust manifold
(Fig. 6).
REMOVAL - VACUUM TRANSDUCER
(1) Disconnect the negative battery cable.
(2) Remove the air cleaner housing (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(3) Disconnect the electrical connector.
(4) Disconnect the vacuum hoses.
(5) Remove the vacuum transducer retaining bolts
and remove vacuum transducer.
Fig. 6 TURBOCHARGER
1 - TURBOCHARGER 8 - OIL RETURN LINE
2 - OIL SUPPLY LINE 9 - GASKET
3 - O-RING 10 - VACUUM UNIT
4 - FRONT EXHAUST PIPE 11 - CHARGE AIR HOSE
5 - BRACKET 12 - CLAMP
6 - O-RING 13 - AIR INTAKE HOSE
7 - GASKET 14 - HEAT SHIELD
VAEXHAUST SYSTEM 11 - 7
TURBOCHARGER (Continued)

INSTALLATION
INSTALLATION
(1) Clean all mating surfaces
(2) Install turbocharger to exhaust manifold.
Tighten bolts to 22 lbs. ft. (20 N´m) (Fig. 6).
NOTE: Slacken the bottom bolt of the turbocharger
support bracket to install bracket stress free.
(3) Install turbocharger support bracket. Tighten
bolts to 177 lbs. in. (20 N´m) at engine and 22 lbs. ft.
(30 N´m) at turbocharger (Fig. 6).
(4) Replace gaskets and install oil return line at
turbocharger. Tighten bolt to 80 lbs. in. (9 N´m) (Fig.
6).
NOTE: Counterhold the connection at the turbo-
charger when tightening the oil supply line bolt.
(5) Replace gaskets and install oil supply line at
turbocharger. Tighten bolt to 160 lbs. in. (18 N´m)
(Fig. 6).(6) Attach turbocharger vacuum line to vacuum
unit (Fig. 6).
(7) Attach air intake and charge air hoses (Fig. 6).
(8) Connect front exhaust pipe to turbocharger.
Tighten flange clamp to 22 lbs.ft. (30 N´m) (Fig. 6).
(9) Install heat shield (Fig. 6).
(10) Connect negative battery cable.
INSTALLATION - VACUUM TRANSDUCER
(1) Position vacuum transducer and install the
retaining bolts. Tighten bolts to 70 lbs.in (8 N´m).
(2) Connect vacuum hoses.
(3) Connect electrical connector
(4) Install air cleaner housing (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION)
(5) Connect negative battery cable.
11 - 8 EXHAUST SYSTEMVA
TURBOCHARGER (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT BUMPER - STEPS
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER - STEP
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 4
SPECIFICATIONS - TORQUE.............6
ENGINE CRADLE CROSSMEMBER
REMOVAL.............................6
INSTALLATION..........................8
REAR CROSSMEMBER - TRANSMISSION
REMOVAL.............................9
INSTALLATION..........................9
TRAILER HITCH
REMOVAL.............................9
INSTALLATION.........................10
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FRONT BUMPER - STEPS BOLTS 20 15 Ð
FRONT FASCIA SCREWS 23 17 Ð
REAR BUMPER STEP FRAME BOLTS/
NUTS38 17 Ð
REAR BUMPER STEP SUPPORT BOLTS 90 66 Ð
REAR FASCIA BOLTS 23 17 Ð
VAFRAME & BUMPERS 13 - 1

FRONT BUMPER - STEPS
REMOVAL
(1) Remove fascia. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT FASCIA -
REMOVAL)
(2) Remove the bolts and remove the steps. (Fig. 1)
INSTALLATION
(1) Install step and bolts.
(2) Tighten bolts to 20 N´m (15 ft. lbs.).
(3) Install fascia. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION)
FRONT FASCIA
REMOVAL
(1) Remove the screws and cover. (Fig. 2)
(2) Remove push pin fasteners.
(3) Remove fascia screws.
(4) Pull bumper forward off support brackets.
(5) Disconnect electrical connector.
INSTALLATION
(1) Connect outside temperature sensor electrical
connector.
(2) Slide fascia onto the support brackets.
(3) Install fascia screws and tighten to 23 N´m (17
ft. lbs.).
(4) Install push pin fasteners.
(5) Install cover and screws.
Fig. 1 BUMPER STEPS
1 - BOLTS (2 PER STEP)
2 - STEPS
Fig. 2 FRONT FASCIA
1 - ELECTRICAL CONNECTOR
2 - OUTSIDE TEMPERATURE SENSOR
3 - FASCIA SUPPORT BRACKET
4 - FASCIA
5 - SCREWS (2)
6 - COVER
7 - PUSH PIN FASTENERS
13 - 2 FRAME & BUMPERSVA

REAR BUMPER - STEP
REMOVAL
(1) Remove rear fascia. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)
(2) Remove frame bolts/nuts. (Fig. 3)
(3) Remove the remaining support bolts.
INSTALLATION
(1) Install bumper step and install support bolts.
(2) Tighten bolts to 38 N´m (28 ft. lbs.).
(3) Install frame bolts/nuts and tighten to 90 N´m
(66 ft. lbs.).
(4)
Install fascia. (Refer to 13 - FRAME & BUMPERS/
BUMPERS/REAR FASCIA - INSTALLATION)
REAR FASCIA
REMOVAL
(1) Remove screws and remove reflectors. (Fig. 4)
(2) Remove fascia bolts.
(3) Release bumper support brackets clips below
end panel.
(4) Press dowel pins out of and remove four plastic
rivets connecting fascia to rear step, if equipped.
(5) Separate the corners of the fascia from the sup-
port brackets and remove fascia.
INSTALLATION
(1) Install fascia and seat the corners over the sup-
port brackets.
(2) Seat bumper support brackets clips below end
panel firmly.
(3) Install the four plastic rivets to the bumper
step, if equipped.
(4) Install fascia bolts and tighten to 23 N´m (17
ft. lbs.).
(5) Install reflectors and reflector screws.Fig. 3 REAR BUMPER STEP
1 - FRAME BOLTS/NUTS (2)
2 - BOLTS (4)
3 - BUMPER STEP
4 - REAR FASCIA
Fig. 4 REAR FASCIA
1 - FASCIA
2 - BOLTS
3-TAB
4 - REFLECTOR
5 - SUPPORT BRACKET
VAFRAME & BUMPERS 13 - 3

FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Verti-
cal dimensions can be taken from the work surface to
the locations indicated were applicable.
INDEX
DESCRIPTION FIGURE
FRAME DIMENSIONS 5
13 - 4 FRAME & BUMPERSVA

Fig. 5 FRAME DIMENSIONS
VAFRAME & BUMPERS 13 - 5
FRAME (Continued)

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake line nuts 14 10 Ð
Brake pads wear
indicator caliper bolt10 7 89
Engine cradle bolts 125 92 Ð
Engine mount bolt
to engine bracket83 61 Ð
Engine mount nuts
to engine cradle45 33 Ð
Power steering line
nuts37 27 Ð
Steering gear
mounting bolts - 1st
stage25 18 Ð
Steering Gear
mounting bolts -
2nd stage45 33 Ð
Steering Gear
mounting bolts - 3rd
stage90ÉÐÐ
Steering gear
u-joint bolt24 18 Ð
Sway bar bushing
bolts30 22 Ð
Trailer hitch angle
bracket bolts/nuts50*
See
Warning37*
See
WarningÐ
Trailer hitch frame
bolts11 0 8 1 Ð
Transmission
crossmember nuts45 33 Ð
Transmission mount
bolts/nuts45 33 Ð
WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
ENGINE CRADLE
CROSSMEMBER
REMOVAL
(1) Install engine support tool 8534 or equivalent.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Remove engine mount nuts. (Fig. 6)
(4) Remove front spring. (Refer to 2 - SUSPEN-
SION/FRONT/SPRING - REMOVAL)
Fig. 6 ENGINE MOUNT
1 - ENGINE MOUNT
2 - SHIELD
3 - NUTS (2 PER MOUNT)
13 - 6 FRAME & BUMPERSVA
FRAME (Continued)