2005 MERCEDES-BENZ SPRINTER Cool

Oil level and oil quality are separate of each other.
The information is first of all compensated in the
ECM before being transmitted over the CAN bus.
Faults at the oil sensor are detected by the ECM
and entered into fault memory. The voltage for the
oil sensor (approx.5V) is supplied by the ECM.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain engine oil into a suitable, and appropri-
ately marked container.
(4) Remove engine mount to chassis nuts.
(5) Lower vehicle and install engine support.
(6) Raise engine until the weight of the engine no
longer rests on the engine mounts.
(7) Raise and support the vehicle.
(8) Detach the front stabilizer bar at the front axle
and rotate it downward.
(9) Unplug the oil level sensor (Fig. 62).
(10) Remove the oil level sensor retaining screw,
oil level sensor and discard the gasket (Fig. 62).
INSTALLATION
(1) Seat O-ring on oil level sensor and lubricate
O-ring with clean engine oil (Fig. 62).
(2) Install the oil level sensor into the oil pan and
tighten screw to 124 lbs. in.(14N´m) (Fig. 62).(3) Connect oil level sensor wiring harness connec-
tor (Fig. 62).
(4) Rotate front stabilizer bar upward and secure
to axle beam. Tighten to 22 lbs.ft. (30 N´m)
(5) Lower the vehicle.
(6) Lower the engine into the mounts.
(7) Remove engine support fixture.
(8) Raise and support the vehicle.
(9) Tighten both engine mount to chassis nuts.
(10) Install and tighten oil drain plug.
(11) Lower vehicle and install the appropriate
engine oil.
INTAKE MANIFOLD
REMOVAL
WARNING: NO FIRE, SPARKS OR SMOKING.
STORE FUELS ONLY INTO SUITABLE AND APPRO-
PRIATELY MARKED CONTAINERS, AND WEAR
PROTECTIVE CLOTHING. (Refer to 14 - FUEL SYS-
TEM - WARNING).
WARNING: DO NOT OPEN THE COOLING SYSTEM
UNLESS THE COOLANT TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN RADIATOR CAP SLOWLY TO
RELEASE PRESSURE. STORE COOLANT ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS, WEAR PROTECTIVE CLOTHING AND
EYE PROTECTION.
(1) Disconnect the negative battery cable.
(2) Drain coolant from the radiator.
(3) Remove the engine cover.
(4) Disconnect the engine wiring harness from
inside the vehicle and carefully guide the harness
into the engine compartment.
(5) Disconnect the charge air hose at the intake
manifold (Fig. 63).
(6) Disconnect the EGR wiring harness connector
(Fig. 63).
(7) Remove the bolt retaining the engine wiring
harness to the intake manifold (Fig. 63).
(8) Disconnect the coolant hose at the connection
junction through the intake manifold support bracket
(Fig. 63).
NOTE: Collect and store any fluid spillage when
disconnecting components.
(9) Disconnect both fuel lines at the fuel filter (Fig.
63).
(10) Remove the lower intake manifold support
bracket (Fig. 63).
Fig. 62 OIL LEVEL SENSOR
1 - OIL PAN
2 - O-RING
3 - WIRING HARNESS
4 - BOLT
5 - OIL LEVEL SENSOR
VAENGINE 9 - 57
OIL TEMPERATURE SENSOR (Continued)

(11) Remove the right intake manifold support
brackets (Fig. 63).
(12) Disconnect the fuel pressure sensor electrical
connector (Fig. 63).
(13) Raise and support the vehicle.
(14) Remove the coolant hose at the rear of the
intake manifold (Fig. 63).
(15) Remove the rear intake manifold mounting
bolts while accessible from below (Fig. 63).
(16) Lower the vehicle.
(17) Remove the remaining intake manifold bolts,
lift the intake manifold up and out while guiding the
engine wiring harness and fuel lines through the
openings in the intake manifold, then remove the
gasket.
NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.INSTALLATION
NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.
(1) Clean both mating surfaces and install a new
intake manifold gasket with the intake manifold.
Guide the engine wiring harness and fuel lines
through the intake manifold openings. Tighten man-
ifold bolts to 16 N´m (142 lbs. in.) in a cross direc-
tional pattern beginning with the middle bolts and
tightening outward to the ends.
(2) Raise and support the vehicle.
(3) Install the rear intake manifold bolts and
tighen to 16 N´m (142 lbs. in.) (Fig. 63).
(4) Install the rear coolant hose to the intake man-
ifold and tighten clamp (Fig. 63).
(5) Lower the vehicle.
(6) Connect the fuel pressure sensor electrical con-
nector (Fig. 63).
Fig. 63 INTAKE MANIFOLD
1 - INTAKE MANIFOLD 10 - FUEL LINE
2 - REAR COOLANT HOSE 11 - BOLT
3 - BOLT 12 - FUEL PRESSURE SENSOR
4 - ENGINE HARNESS DUCTING 13 - HARNESS CONNECTOR
5 - ENGINE HARNESS 14 - HARNESS CONNECTOR
6 - CONNECTING JUNCTION 15 - CHARGE AIR HOSE
7 - SUPPORT BRACKET 16 - BRACKET
8 - COOLANT HOSE FROM HEATER 17 - GASKET
9 - FUEL LINE 18 - SUPPORT BRACKETS
9 - 58 ENGINEVA
INTAKE MANIFOLD (Continued)

(7) Install the right intake manifold support brack-
ets. Tighten the bolts to 14 N´m (124 lbs. in.) (Fig.
63).
(8) Install the lower intake manifold support
bracket. Tighten bolts to 20 N´m (177 lbs. in.) (Fig.
63).
(9) Connect both fuel lines to fuel filter assembly
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL FILTER - INSTALLATION).
(10) Connect the coolant hose at the connection
junction above the lower intake manifold support
bracket (Fig. 63).
(11) Secure the engine wiring harness and cable
duct to the intake manifold (Fig. 63).
(12) Connect the EGR wiring harness connector
(Fig. 63).
(13) Connect the charge air hose to the intake
manifold (Fig. 63).
(14) Carefully route the engine wiring harness
through and into the passenger compartment and
reconnect.
(15) Install the engine cover.
(16) Fill the cooling system.
(17) Connect the negative battery cable.
(18) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warnin-
g.(Refer to 14 - FUEL SYSTEM - WARNING).
EXHAUST MANIFOLD
REMOVAL
(1) Remove the turbocharger (Refer to 11 -
EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
TURBOCHARGER - REMOVAL).
(2) Remove the self locking exhaust manifold nuts
(Fig. 64).
(3) Remove exhaust manifold and clean mating
surfaces (Fig. 64).
INSTALLATION
NOTE: Exhaust manifold surface must be flat within
0.006 in. per foot (0.15mm per 300mm) of manifold
length.
(1) Inspect exhaust manifold gasket surface for
flatness with a straight edge (Fig. 64).
(2) Inspect exhaust manifold for cracks or distor-
tion (Fig. 64).
(3) Install new exhaust manifold gasket (Fig. 64).
(4) Position the exhaust manifold over to studs
and tighten retaining nuts to 22 lbs. ft. (30 N´m (Fig.
64)).
(5) Install turbocharger (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSTALLATION).
TIMING CHAIN COVER
REMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS TEMPERATURE IS BELOW 90ÉC (194ÉF).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(2) Position piston of cylinder 1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
Fig. 64 EXHAUST MANIFOLD
1 - EXHAUST MANIFOLD
2 - GASKET
3 - STUD
4 - NUT
VAENGINE 9 - 59
INTAKE MANIFOLD (Continued)

(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).
(8) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(9) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(12) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(13) Remove accessory drive belt pulley and vibra-
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).
(14) Remove the power steering pump.
NOTE: NO NOT open the air conditioning system.
(15) Unplug AC compressor electrical connector
and unbolt AC compressor. Relocate in lower engine
compartmentwith outopening the system.
(16) Remove the generator with wiring attached
and relocate somewhere in the engine compartment.
(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 65).
(20) Remove the cylinder head to timing cover
bolts (Fig. 65).
(21) Remove the timing cover bolts and cover (Fig.
65).
(22) Remove remaining ancillary components
attached to the timing case cover (Fig. 65).
NOTE: Inspect condition of hoses and clamps,
replace as necessary.
(23) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 65).
INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace the front crankshaft seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 66).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N´m (177 lbs in) (Fig. 65).
(6) Install the M8 bolts of cylinder head on timing
case cover. Tighten bolts to 20 N´m (177 lbs in) (Fig.
65).
(7) Install timing chain tensioner with new seal-
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
Fig. 65 TIMING CHAIN COVER
1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER
9 - 60 ENGINEVA
TIMING CHAIN COVER (Continued)

(8) Position and install the oil pan. Tighten M6
bolts to 9 N´m (80 lbs in) and M8 bolts to 20 N´m
(177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
M8.8 bolt in two stages, 200N´m (147 lbs ft.) then
90É, M10.9 bolt 325N´m (240 lbs ft) then 90É.
(10) Remove the engine support fixture.
(11) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditioning compressor.
(13) Install the power steering pump.
(14) Install water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sealant to lower portion of, and install,
front cover to cylinder block. Tighten bolts to 20N´m
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
- INSTALLATION).
(18) Remove retaining lock for crankshaft/starter
ring gear.
(19) Tighten the oil drain plug to 30N´m (265 lbs
in).
(20) Install a new oil filter. tighten screw cap for
filter to 25N´m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).(23) Install air intake hose.
(24) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(25) Fill the crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(26) 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.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
(27) Start engine and inspect for leaks. care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE RAILS
NOTE: If it necessary to replace the tensioning rail,
slide rail or tensioning arm, they are always
replaced together.
(1) Disconnect negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
(4) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Pull the tensioning rail off of the bearing pins
(Fig. 67).
(6) Release the spring at the slide rail and take it
off of the tensioning arm (Fig. 67).
REMOVAL - INTERMEDIATE GEAR
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
Fig. 66 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VAENGINE 9 - 61
TIMING CHAIN COVER (Continued)

(24) Remove camshaft sprocket to timing chain tie
straps.
(25) Install guide rail and tighten low pressure
fuel pump drive to 50N´m (37 lbs. ft.).
(26) Install low pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(27) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(28) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).
(29) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(30) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(31) Connect 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.
(32) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
TIMING CHAIN TENSIONER
REMOVAL
(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 counter clock-
wise.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove intake air scoop.
(4) Remove accessory drive belt and idler pulley
above generator (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
(5) Remove timing chain tensioner (Fig. 85).
Fig. 84 RIVET INSPECTION
Fig. 85 TIMING CHAIN TENSIONER
1 - TIMING CHAIN TENSIONER
2 - TIMING CHAIN TENSIONER SEAL
9 - 70 ENGINEVA
TIMING BELT/CHAIN AND SPROCKETS (Continued)

INSTALLATION
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
(1) Install timing chain tensioner with new gasket.
Tighten to 80N´m (59 lbs.ft.).
(2) Install idler pulley and accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).(3) Install intake air scoop.
(4) 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.
(5) Start the engine and inspect for leaks.
VAENGINE 9 - 71
TIMING CHAIN TENSIONER (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION - 2.7L DIESEL...............1
DIAGNOSIS AND TESTING - DIESEL ENGINE . . 2
CATALYTIC CONVERTER
REMOVAL.............................3
INSTALLATION..........................3
EXHAUST PIPE
REMOVAL.............................3
INSTALLATION..........................3
TAILPIPE
REMOVAL.............................3
INSTALLATION..........................3
TURBOCHARGER SYSTEM
DESCRIPTION..........................3
OPERATION............................4
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION..........................4OPERATION............................4
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS...............4
REMOVAL.............................5
CLEANING.............................5
INSPECTION...........................5
INSTALLATION..........................5
TURBOCHARGER
DESCRIPTION..........................6
OPERATION............................6
REMOVAL
REMOVAL............................7
REMOVAL - VACUUM TRANSDUCER.......7
INSTALLATION
INSTALLATION........................8
INSTALLATION - VACUUM TRANSDUCER . . . 8
EXHAUST SYSTEM
DESCRIPTION - 2.7L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe (Fig. 1).The exhaust system must be properly aligned and
secured to prevent stress, leakage and body contact.
The exhaust components should be kept a minimum
of 25.4 mm (1.0 in.) away from the body and frame.
If the system contacts any body panel, it may amplify
objectionable noises from the engine or body.
VAEXHAUST SYSTEM 11 - 1