2005 MERCEDES-BENZ SPRINTER engine

CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the timing chain is followed exactly. Fail-
ure to do so will result in severe engine damage.
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
CAUTION: ENSURE THAT THE SPRING IS COR-
RECTLY INSTALLED ON THE TENSIONING CLAMP
AND SLIDE RAIL.
(1) Install rail on bearing pin (Fig. 67).
(2) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(3) Install oil pan bolts. Tighten M6 bolts to 9N´m
(80 lbs.in.) and M8 bolts to 20N´m (15 lbs. ft.).
(4) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Install the engine.
(6) Reconnect 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.
(7) Start the engine and inspect for leaks. care
must be take to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING).
INSTALLATION - INTERMEDIATE GEAR
NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.
(1) Install intermediate gear and bushing. Tighten
bolt to 40N´m (30 lbs.ft.)
(2) Install camshaft sprocket, noting dowel pin
alignment. Tighten bolt to 18 N´m (159 lbs. in.).
(3) Remove tie strap retaining timing chain to
sprocket.
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.(4) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install top slide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(6) Install cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(7) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
NOTE: Inspect basic position of camshaft and reset
if necessary.
(8) Remove camshaft locking pin.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(10) Install fuel high pressure lines and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(11) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(12) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(13) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
INSTALLATION - TIMING CHAIN TENSIONING
RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
(1) Install tensioning rail on bearing pin
(2) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
9 - 66 ENGINEVA
TIMING BELT/CHAIN AND SPROCKETS (Continued)

(3) Install oil pan and bolts. Tighten M6 bolts to
9N´m (80 lbs.in.) and M8 bolts to 20N´m (15 lbs. ft.).
(4) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) 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.
(6) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING).
ADJUSTMENTS
INSTALLATION - TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.CAUTION: Cover timing case recesses to prevent
foreign material from entering engine.
(1) Connect new timing chain and old timing chain
with the assembly link, the assembly plate and the
assembly locking element, and secure (Fig. 76).
NOTE: Always keep new timing chain meshed with
camshaft sprocket.
NOTE: Rotate engine at crankshaft only. DO NOT
crank engine and DO NOT rotate engine backward
(Fig. 76).
NOTE: Draw out the end of old timing chain evenly
as it becomes free, to the same extent that new tim-
ing chain is drawn in (Fig. 76).
(2) Draw in new timing chain by rotating the
crankshaft slowly in direction of rotation of engine
until the ends of the new timing chain meet and can
be connected (Fig. 76).
Fig. 76 TIMING CHAIN TEMPORARY LINK
1 - CYLINDER HEAD COVER
2 - TIMING CHAIN TEMPORARY LINK
3 - ALIGNMENT PINS
4 - TOP GUIDE RAIL
5 - CYLINDER HEAD FRONT COVER
6 - TIMING CHAIN TENSIONER SEAL7 - TIMING CHAIN TENSIONER
8 - VACUUM PUMP
9 - LOW PRESSURE FUEL PUMP
10 - LOW PRESSURE PUMP MOUNTING BOLTS
11 - VACUUM PUMP MOUNTING BOLTS
VAENGINE 9 - 67
TIMING BELT/CHAIN AND SPROCKETS (Continued)

NOTE: Assembly link is only an assembly aid and
NOT designed for engine running.
(3) Remove assembly locking element, assembly
outer plate and assembly link (Fig. 77).
(4) Attach new timing chain to camshaft sprocket
and retain.
(5) Insert new riveted link and new middle plate
into ends of timing chain (Fig. 78).
(6) Take off retaining devise at cylinder head.
(7) Remove camshaft sprocket from camshaft with
timing chain secured.
NOTE: When assembling riveting tool, piece F5 is
secured by a screw and D9 can move loosely on
thrust spindle
(8) Assemble riveting tool by inserting pieces F5
and D9 (Fig. 79).
NOTE: Ensure that the riveted link and riveting tool
are aligned.
(9) Press in new riveted link as far as the stop
(Fig. 80).
(10) Remove riveting tool to change inserts.
(11) Install insert F1 on riveting tool and secure
with screw (Fig. 81).
(12) Install insert D8 on riveting tool (Fig. 81).
NOTE: The outer plate is held magnetically by rivet-
ing tool.(13) Insert new outer plate into the moving assem-
bly insert.
(14) Position riveting tool so that spacer webs of
the guide are side by side.
(15) Ensure that riveted link and outer plate are
aligned (Fig. 82).
Fig. 77 REMOVING TEMPORARY LINK
1 - TEMPORARY LINK
2 - NEW TIMING CHAIN
3 - OLD TIMING CHAIN
Fig. 78 INSERT NEW RIVETED LINK
1 - SPECIAL TOOL #8931
2 - NEW TIMING CHAIN ENDS
3 - NEW MIDDLE PLATE
4 - NEW RIVETED LINK
Fig. 79 INSTALLING ASSEMBLY INSERTS INTO
RIVETING TOOL
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #8952
9 - 68 ENGINEVA
TIMING BELT/CHAIN AND SPROCKETS (Continued)

NOTE: When turning spindle of riveting tool, be
sure that pins of riveted link are inserted into holes
of outer plate (Fig. 82).
(16) Screw in spindle of riveting tool until firm
resistance is felt (Fig. 82).
(17) Remove riveting tool.
(18) Turn over moving assembly insert (D8) to the
riveting profile.(19) Position riveting tool exactly over middle of
pin.
(20) Tighten riveting tool spindle to end of travel.
(21) Repeat procedure for both riveting pins (Fig.
83).
(22) Inspect riveting, re-rivet if required (Fig. 84).
(23) Install camshaft sprocket with timing chain
retained onto camshaft. Tighten camshaft bolts to
18N´m (159 lbs.in.).
Fig. 80 PRESSING IN NEW RIVETED LINK
1 - SPECIAL TOOL #8947
2 - NEW RIVETED LINK
3 - SPECIAL TOOL #8952
Fig. 81 INSTALLING RIVETING INSERTS INTO
RIVETING TOOL
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #8949
Fig. 82 INSTALLING LINK OUTER PLATE
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #8949
Fig. 83 RIVETING LINKS OF THE RIVETED LINK
1 - SPECIAL TOOL #8947
2 - SPECIAL TOOL #8949
VAENGINE 9 - 69
TIMING BELT/CHAIN AND SPROCKETS (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

DIAGNOSIS AND TESTING - DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten/replace clamps/bolts at
leaking joints.
2. Rusted or expanded muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten/replace exhaust manifold
to cylinder head bolts.
7. Turbocharger mounting flange
cracked.7. Remove turbocharger and
inspect.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
Fig. 1 Exhaust System
1 - TURBOCHARGER
2 - HEAT SHIELD
3 - CLAMP
4 - EXHAUST PIPE
5 - FRONT INSULATOR
6 - NUT7 - WASHER
8 - INSULATOR
9 - BOLT
10 - MUFFLER/CATALYTIC CONVERTER ASSEMBLY
11 - TAILPIPE
11 - 2 EXHAUST SYSTEMVA
EXHAUST SYSTEM (Continued)