2005 MERCEDES-BENZ SPRINTER engine

#8948 CHAIN SEPARATOR TOOL
#8949 THRUST PIECE
#8950 PRESSING SCREW
#8951 ASSEMBLY LINKS
9 - 18 ENGINEVA
ENGINE (Continued)

#8952 ASSEMBLY INSERTS
#9285 FUEL LINE WRENCH
# 9286 GLOW PLUG PLIERS
Fig. 8 #9295 COMPRESSION HOSE ADAPTOR
# 9310 ASSEMBLY INSERTS
#9311 PRESSING SCREW
VAENGINE 9 - 19
ENGINE (Continued)

AIR CLEANER ELEMENT
REMOVAL
(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.
9).
(3) Unclip the air cleaner housing lid (Fig. 9).
(4) Remove air cleaner element (Fig. 9).
INSTALLATION
(1) Position and seat the air cleaner element into
the lower housing (Fig. 9).
(2) Install the housing cover and snap retainers
into place (Fig. 9).
(3) Install air flow sensor into housing cover (Fig.
9).
(4) Install heat shield.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the Air Flow sensor(Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/MANIFOLD AIR
FLOW (MAF) SENSOR - REMOVAL).
(4) Unclip the top of the air cleaner housing and
remove (Fig. 10).(5) Take out air cleaner element (Fig. 10).
(6) Detach bottom part of the air cleaner housing
at the body (Fig. 10).
(7) Take air intake hose out of inner fender and
out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 10).
(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 10).
INSTALLATION
NOTE: Ensure that the seal betwwen the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 10).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 10).
(3) Install air cleaner element (Fig. 10).
(4) Install and clip air cleaner top to air cleaner
body (Fig. 10).
(5) Install Air Flow sensor (Fig. 10).
(6) Install heat shield.
Fig. 9 AIR CLEANER ELEMENT
1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSINGFig. 10 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR CLEANER HOUSING COVER
9 - 20 ENGINEVA

(7) Connect negative battery cable.
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 11).
Cylinder Head
BoltsThread
Diameter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE
NOTE: Only resurface cylinder head contact surface
if porous or damaged. IT IS NOT necessary to
rework minor variations in flatness in the longitudi-
nal direction.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 12).NOTE: The camshaft housing Must Not be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Machine cylinder head contact surface, if nec-
essary.
(8) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 12) CYLINDER
HEAD SPECIFICATIONS.
(9) Measure valve setback at points (2) indicated
(Fig. 12) CYLINDER HEAD SPECIFICATIONS.
NOTE: If measurement is less than dimension ª2º
no further correct valve clearance compensation is
possible; replace valve seat ring or cylinder head if
measurement is greater than specification.
CYLINDER HEAD SPECIFICATIONS
Description Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat RingsExhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
Fig. 11 MEASURING CYLINDER HEAD BOLTS
Fig. 12 CYLINDER HEAD MEASURMENTS
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
VAENGINE 9 - 21
AIR CLEANER HOUSING (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)

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.
(6) Remove low pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(7) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(8) 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.
(9) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 15).NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
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).
Fig. 15 CYLINDER HEAD FRONT COVER
1 - TOP GUIDE RAIL
2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN
5 - CYLINDER HEAD FRONT COVER6 - SEAL
7 - TIMING CHAIN TENSIONER
8 - LOW PRESSURE PUMP
9 - VACUUM PUMP
9 - 24 ENGINEVA
CYLINDER HEAD (Continued)

(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 15).
(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.
NOTE: If piston or connecting rods have been
replaced, measure piston protrusion.
NOTE: Check facing cylinder head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as guide (Fig. 14).
NOTE: Inspect all cylinder head bolts for defects
and stretching before installation (Refer to 9 -
ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
CYLINDER HEAD BOLT TORQUE SEQUENCE
The M12 cylinder head bolts must be torqued
in 3 stages.
(1) Install M12 cylinder head bolts finger tight
(Fig. 14).
(2) Torque bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.in.) (Fig. 16).
(3) Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
(4) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
16).
(5) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(3 stages). (Fig. 16).
(2) Install fuel return flow line between rail and
high pressure pump (Fig. 13).
(3) Connect the coolant hoses to the thermostat
housing (Fig. 13).(4) Connect the coolant pipe at the cylinder head
(Fig. 13).
(5) Reconnect transmission oil dip stick tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 13).
(6) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 13).
(7) 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. 13)
(8) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(9) Install and properly route the engine wiring
harness, making appropriate connections.
(10) Install high pressure fuel pump intermediate
gear (Fig. 13).
(11) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(12) Install the camshaft housing to cylinder head
(Fig. 13).
(13) Install the tappets (Fig. 13).
(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
Fig. 16 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 25
CYLINDER HEAD (Continued)