2005 MERCEDES-BENZ SPRINTER drain bolt

DESCRIPTION N´m Ft. Lbs. In. Lbs.
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
Generator13-18 - 115-159
Nut-D+ Circuit to
Generator5-44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to
Crankcase18
- 133
Bolt-Oil Pipe to Crankshaft
Bearing Cap8-70
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat
Exchanger 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
Engine 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 -
VAENGINE 9 - 11
ENGINE (Continued)

REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.
(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crank-
case(Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(6) Lower vehicle.(7) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(9) Remove tappets (Fig. 13).
(10) Remove the camshaft housing at the cylinder
head (Fig. 13).
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.
(11) Remove the high pressure fuel pump interme-
diate gear (Fig. 13).
(12) Disconnect the engine side of the engine har-
ness and set aside.
(13) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
Fig. 13 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 - 22 ENGINEVA
CYLINDER HEAD (Continued)

(14) Disconnect the turbocharger oil supply line at
the cylinder head and turbocharger (Fig. 13).
(15) Disconnect the turbocharger at the exhaust
manifold (Fig. 13).
(16) Unbolt the transmission dipstick tube from
the cylinder head (Fig. 13).
(17) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 13).
NOTE: Capture any fuel spillage when disconnect-
ing fuel lines.
(18) Disconnect the fuel line at the rear of the fuel
rail (Fig. 13).
(19) Remove upper timing case to cylinder head
bolts (Fig. 14).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(20) Remove cylinder head bolts and inspect (Refer
to 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(21) Remove cylinder head (Fig. 14).NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(22) 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) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).
Fig. 14 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL4 - GASKET
5 - BOLT TO TIMING COVER
VAENGINE 9 - 23
CYLINDER HEAD (Continued)

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with the transmission removed
from the vehicle.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain the engine oil.
NOTE: Loosen all of the oil pan bolts to assure that
the oil pan gasket is not damaged when removing
the rear main oil seal and end cover assembly.
NOTE: Inspect the oil pan gasket for damage. If the
oil pan gasket is damaged, remove the oil pan and
replace the oil pan gasket.
(4) Loosen the oil pan bolts.
(5) Remove the flywheel.CAUTION: Care must be taken when removing the
rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.
(6) Remove the rear main seal/adaptor retaining
bolts and carefully pry the adaptor from the crank-
case at the adaptor shoulders (Fig. 29).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor
evenly onto the assembly sleeve. The rear main oil
seal lip MUST NOT roll over the edge of the tool.
(1) Position the rear main oil seal/adaptor with
assembly sleeve onto the crankshaft so that the
dowel sleeves fit into the guide holes (Fig. 29). Care
must be taken so that the oil pan gasket is not dam-
aged.
Fig. 29 REAR MAIN SEAL/ADAPTER
1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL 8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER
RETAINING BOLT
VAENGINE 9 - 37

(2) Install the rear main seal/adaptor to crankcase
bolts and tighten to 9´Nm (80 lbs.in) (Fig. 29).
(3) Tighten the M6 oil pan bolts to 9N´m (80 lbs
in) and the M8 bolts to 20 N´m (15 lbs ft).
(4) Install the fly wheel and tighten bolts in two
stages (Fig. 29). 45N´m (33 lbs. ft.) then 90É.
(5) Install the oil pan drain plug and tighten to
25N´m (18 lbs ft).
(6) Lower the vehicle.
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to owners manual for spec-
ifications.
(8) Connect the 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.
(9) Start the engine and inspect for leaks.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the accessory drive belt.
(3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller MUST mesh fully
into the slots of the belt pulley.
NOTE: Inspect the running surface of the belt pulley
for wear.
(4) Remove the belt pully/vibration damper.
CAUTION: Care must be taken to prevent severe
damage to the crankshaft and mounting whole for
the front crankshaft seal.
(5) Using a suitable prying tool, remove the front
crankshaft seal from the timing cover (Fig. 30).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the front crankshaft seal
evenly onto the timing cover.(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(3) Remove the retaining lock for the crankshaft/
ring gear.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Fill the crankcase with the correct engine oil to
the proper level.
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.
(7) Start the engine and inspect for leaks.
Fig. 30 FRONT SEAL REMOVAL/INSTALLATION
1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
3 - WASHER
4 - RETAINING BOLT
9 - 38 ENGINEVA
CRANKSHAFT OIL SEAL - REAR (Continued)

CAUTION: Assemble the piston and connecting rod
so that the arrow is pointing in the direction of
travel (in the opposite direction of power flow). The
marking on the connecting rod is pointing toward
the inlet side.
(3) Assemble piston and connecting rod (Fig. 37).
(4) Insert piston pin by hand (Fig. 37).
CAUTION: Care must be taken not to damage the
piston.
(5) Insert circle clip of piston pin into groove on
piston (Fig. 37).
(6) Using the appropriate clean engine oil, clean
the cylinder bores, connecting rod bearing journals,
connecting rod bearing shells and pistons.
CAUTION: Offset the piston ring gaps by 120É.
(7) Position a ring compressor over piston and
rings. Tighten ring compressor (Fig. 38).Ensure that
ring position does not change during this oper-
ation.
CAUTION: Rotate the crankshaft sufficiently so that
the connecting rod does not touch the connectingrod journal when the piston is pushed onto the cyl-
inder bore.
(8) Install piston with arrow pointing in the direc-
tion of travel (in the opposite direction to power flow)
(the marking on the connecting rod should be point-
ing toward the inlet side). (Fig. 38).
(9) Clean and inspect the connecting rod bolts.
CAUTION: Assure that the correct top and bottom
connecting rod bearings shells are used in accor-
dance with the markings.
CAUTION: The anti-twist locks of the connecting
rod bearing shells must be located in the slots of
the connecting rod bearing caps.
(10) Insert connecting rod bearing shell into con-
necting rod bearing cap.
CAUTION: The markings on the connecting rod and
connecting rod cap must be lined up.
(11) Install connecting rod bearing cap. Tighten
bolts in 3 stages, 5N´m (44 lbs in), 25N´m (221 lbs
in), 90É.
(12) Rotate crankshaft fully and check the clear-
ance.
(13) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(14) Install engine oil pan and oil pan drain plug
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
CAUTION: Install a cylinder head gasket of standard
thickness or a cylinder head gasket of repair thick-
ness depending on piston protrusion.
(15) Measure piston protrusion (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
(16) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(17) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(18) Fill the crankcase with correct engine oil, to
proper level. Refer to owners manual for specifica-
tions.
(19) Fill the cooing system with proper coolant, to
the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(20) 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.
Fig. 37 PISTON AND CONNECTING ROD ASSEMBLY
1 - CIRCLE CLIP
2 - PISTON PIN
3 - PISTON ASSEMBLY
4 - CONNECTING ROD ALIGNMENT MARKINGS
5 - CONNECTING ROD BOLTS
6 - CONNECTING ROD CAP
7 - CONNECTING ROD
9 - 44 ENGINEVA
PISTON & CONNECTING ROD (Continued)

(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOTOPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 47).
(4) Remove the oil cooler from the timing case
cover (Fig. 47).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 47).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 47).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
Fig. 46 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
Fig. 47 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
9 - 50 ENGINEVA
RIGHT MOUNT (Continued)

OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534±16, to the engine lifting eye and
raise engine slightly.
(6) Remove engine mounts and raise engine.
(7) Disconnect the oil level sensor.
(8) Remove the transmission cooler lines from the
oil pan bolts and carefully position the lines aside
(9) Remove the oil pan bolts.
(10) Remove oil pan and gasket (Fig. 51).
INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 53).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, fill it with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Install the oil pan gasket and coat places indi-
cated with an arrow with sealant (Fig. 52).
(2) Install the oil pan. Tighten M6 bolts to 9N´m
(80 lbs. in.) and M8 bolts to 20N´m (15 lbs. ft.) (Fig.
53).
Fig. 51 OIL PAN
1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
9 - 52 ENGINEVA