2005 MERCEDES-BENZ SPRINTER brake fluid

FLUID RESERVOIR
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible (Fig. 14).
(2) Disconnect the electrical connector for the
brake fluid level indicator (Fig. 14).
(3) Remove the fluid reservoir (Fig. 14).Seal off
the ends and bore holes with plugs.
INSTALLATION
(1) Install the fluid reservoir and fill with fluid
(Fig. 14).
(2) Bleed the brake system.
(3) Check the brake system for any leaks.
(4) Reconnect the electrical connector to the brake
fluid level indicator (Fig. 14).
ALB LEVER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the retaining clip for the ALB lever
(Fig. 15).
(3) Remove the bolt for the lever at the axle (Fig.
15).
(4) Remove the lever.
INSTALLATION
(1) Install the lever to the vehicle.
(2) Install the lower mounting bolt to the axle (Fig.
15).(3) Install the lever to the shock bolt and then
install the clip (Fig. 15).
(4) Check the side deflection of the ALB lever with
a straight edge from Point-A to Point-B as the
graphic shows. Max deflection play of the actuator
rod should be no more than 15 mm (.60 in) (Fig. 15).
(5) Lower the vehicle.
ALB CONTROLLER
REMOVAL
(1) Install the brake pedal rod to hold the brake
pressure.
(2) Raise and support the vehicle.
(3) Remove the brake lines to the (automatic load-
dependant brake pressure control) ALB controller.
(4) Remove the adjusting nut and the spring from
the ALB controller.
(5) Remove the mounting bolts.
(6) Remove the ALB controller.
INSTALLATION
(1) Install the ALB controller to the vehicle.
(2) Install the mounting bolts for the controller.
(3) Install the brake lines. Tighten the lines to 16
N´m (142 in. lbs.)
(4) Install the adjusting rod, nut and spring to the
ALB controller.
(5) Lower the vehicle.
(6) Remove the brake pedal hold down rod.
(7) Fill and bleed the brake system (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
Fig. 14 FLUID RESERVOIR
1 - SUCTION GUN
2 - BRAKE FLUID CAP
3 - BRAKE FLUID LEVEL INDICATOR
4 - MASTER CYLINDER
5 - FLUID RESERVOIR
Fig. 15 ALB LEVER DEFLECTION
1 - CLIP
2 - SPRING
3 - LEVER
4 - STRIAGHT EDGE
5 - NUT
6 - POINT -A
7 - POINT - B
8 - SUSPENSION POINT
VABRAKES - BASE 5 - 15

POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 17).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 18).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 19).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return under
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible (Fig. 20).
Fig. 17 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 18 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 19 Master Cylinder Bleeding±Typical
1 - BLEEDING TUBES
2 - RESERVOIR
VABRAKES - BASE 5 - 17
MASTER CYLINDER (Continued)

(2) Remove the fluid reservoir (Fig. 20) or (Fig.
21)(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/FLUID RESERVOIR - REMOVAL).
(3) Remove the brake linesSeal off the ends and
bore holes with plugs.(Fig. 20) or (Fig. 21)
(4) Remove the master cylinder mounting nuts
(Fig. 20) or (Fig. 21).Check brake booster for
damage due to leaking master cylinder. It is not
possible to repair the master cylinder.INSTALLATION
(1) Install the master cylinder to the brake booster
(Fig. 20). Tighten to 28 N´m (248 in. lbs.).
(2) Install the brake lines (Fig. 20). Tighten to 14
N´m (124 in. lbs.).
(3) Install the fluid reservoir (Fig. 20) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/FLUID RES-
ERVOIR - INSTALLATION).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
PEDAL
REMOVAL
(1) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(2) Remove the retainer and pin for the master
cylinder push rod (Fig. 22).
(3) Remove the retainer and pin for the brake
pedal pivot bolt (Fig. 22).
(4) Unhook the spring and remove the brake pedal
(Fig. 22).
(5) Disconnect the plug connector on the stop lamp
switch (Fig. 22).
(6) Remove the bolts and remove the pedal bearing
bracket (Fig. 22).
Fig. 20 MASTER CYLINDER
1 - SUCTION GUN
2 - BRAKE FLUID CAP
3 - BRAKE FLUID LEVEL INDICATOR
4 - O-RING
5 - NUT
6 - BRAKE LINE
7 - MASTER CYLINDER
8 - FLUID RESERVOIR
Fig. 21 MASTER CYLINDER (DRW)
1 - POWER BRAKE BOOSTER
2 - RESERVOIR
3 - BRAKE LINES
4 - PRESSURE PORTS
5 - MASTER CYLINDER
Fig. 22 BRAKE PEDAL
1 - MOUNTING BOLT
2 - PEDAL BEARING BRACKET
3 - STOP LAMP SWITCH
4 - CLIP
5 - PIVOT BOLT
6 - RETURN SPRING
7 - PEDAL
8 - PUSH ROD BOLT
9 - PUSH ROD
10 - CLIP
11 - BOLT
12 - WASHER
5 - 18 BRAKES - BASEVA
MASTER CYLINDER (Continued)

INSTALLATION
(1) Install the bolts for the pedal bearing bracket
(Fig. 22). Tighten to 23 N´m (204 in. lbs.)
(2) Reconnect the plug connector for the stop lamp
switch (Fig. 22).
(3) Install the brake pedal and hook the spring
(Fig. 22).
(4) Install the retainer and pin for the brake pedal
(Fig. 22).
(5) Install the retainer and pin for the master cyl-
inder push rod (Fig. 22).
(6) Install the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION).
POWER BRAKE BOOSTER
DESCRIPTION
All models use a tandem diaphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster unit consists of a single housing
divided into two by a tandem diaphragm. The outer
edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible.
(2) Disconnect the brake level switch electrical
connector.
(3) Remove the brake lines from the master cylin-
derSeal off the ends and bore holes with plugs.
(4) Remove the master cylinder from the booster.
(5) Remove the booster vacuum hose and check
valve (Fig. 23).
(6) Remove the pedal push rod clip (Fig. 23).
(7) Remove the booster mounting nuts (Fig. 23).
(8) Remove the booster from the vehicle.
INSTALLATION
(1) Install the brake booster to the vehicle.(2) Install the booster mounting nuts (Fig. 23).
Tighten to 25 N´m (221 in.lbs.).
(3) Install the push rod pin & clip (Fig. 23).
(4) Install the brake booster vacuum line and
check valve (Fig. 23).
(5) Install the master cylinder to the brake
booster. Tighten to 28 N´m (248 in.lbs.).
(6) Install the brake lines to the master cylinder.
Tighten to 14 N´m (124 in.lbs.).
(7) Install the brake level switch electrical connec-
tor.
(8) Bleed the base brake system (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
ROTORS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 24).
(4) Remove the caliper adapter (Fig. 24).
(5) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(6) Remove the locking bolt for the disc brake rotor
(Fig. 24).
(7) Remove the two lug nuts.
(8) Remove the disc brake rotor (Fig. 24).
Fig. 23 POWER BRAKE BOOSTER
1 - VACUUM LINE & CHECK VALVE
2 - BRAKE BOOSTER
3 - GASKET
4 - MOUNTING NUTS (4)
5 - PUSH ROD PIN
6 - SECURING CLIP
VABRAKES - BASE 5 - 19
PEDAL (Continued)

(4) Remove the disc brake caliper adapter (Fig.
27).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the wheel flange ring (Fig. 27).
(8) Remove the locking bolt for the disc brake rotor
(Fig. 27).
(9) Remove the two lug nuts.
(10) Release the parking brake.
(11) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 27).
(12) Remove the rear disc brake rotor.
INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 24).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 24).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 24).
(5) Press and release the brake pedal several times
until pressure has built up.(6) Check fluid in reservoir and correct if neces-
sary.
(7) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(8) Lower the vehicle.
INSTALLATION - REAR (SRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 25).
(2) Apply the parking brake.
(3) Install the locking bolt for the rotor (Fig. 25).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 25).
Tighten to 90 N´m (66 ft. lbs.) (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DISC BRAKE CALI-
PER ADAPTER - INSTALLATION).
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 25).
(6) Release the parking brake.
(7) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(8) Press and release the brake pedal several times
until pressure has built up.
(9) Check fluid in reservoir and correct if neces-
sary.
(10) Install the rear wheels.
(11) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place.
(2) Install the locking bolt for the rotor (Fig. 26).
Tighten to 23 N´m (204 in. lbs.).
(3) Install the disc brake caliper adapter (Fig. 26).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the wheel flange ring. Tighten to 180
N´m (133 ft. lbs.)
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 26).
(6) Press and release the brake pedal several times
until pressure has built up.
(7) Check fluid in reservoir and correct if neces-
sary.
(8) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(9) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the disc brake rotor to the hub and
install two lug studs to hold rotor in place (Fig. 27).
(2) Apply the parking brake.
Fig. 27 REAR DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - RETAINING SPRING
7 - DISC BRAKE PADS
8 - WHEEL FLANGE RING MOUNITNG BOLT
9 - WHEEL FLANGE RING
10 - DISC BRAKE ROTOR
VABRAKES - BASE 5 - 21
ROTORS (Continued)

(3) Install the locking bolt for the rotor (Fig. 27).
Tighten to 23 N´m (204 in. lbs.).
(4) Install the disc brake caliper adapter (Fig. 27).
Tighten to 170 N´m (125 ft. lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(5) Install the wheel flange ring (Fig. 27) Tighten
to 200 N´m (148 ft. lbs.).
(6) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 27).
(7) Release the parking brake.
(8) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(9) Press and release the brake pedal several times
until pressure has built up.
(10) Check fluid in reservoir and correct if neces-
sary.
(11) Install the rear wheels.
(12) Lower the vehicle.
SUPPORT PLATE
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(3) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).(4) Remove the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(5) Remove the park brake cable from he support
plate.
(6) Remove the rear axle bearing (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - REMOVAL).
(7) Remove brake support plate.
INSTALLATION - REAR
(1) Press the brake support plate with the axle
bearing onto the axle shaft (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE/AXLE BEARINGS
- INSTALLATION).
(2) Install the park brake cable to the support
plate.
(3) Install the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION).
(4) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(5) Install the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(6) Adjust the rear park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(7) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Pressure Transformer Unit
For Brake Cables To
Frame Crossmember25 Ð 221
Hand Brake Lever To Seat
Frame25 Ð 221
5 - 22 BRAKES - BASEVA
ROTORS (Continued)

INSTALLATION
(1) Install the hydraulic control unit into the rub-
ber mounts (Fig. 5).
(2) Reconnect the brake lines to the hydraulic con-
trol unit (Fig. 5).Do not mix up the brake lines.
Tighten the lines to 16 N´m (142 in. lbs.)
(3) Reconnect the multiplug to the control module
(Fig. 5).(4) Reconnect the ground cable on the battery.
(5) Bleed the brake system.
(6) Check the fluid in the reservoir and correct if
necessary.
(7) Perform function test.
5 - 32 BRAKES - ABSVA
HCU (HYDRAULIC CONTROL UNIT) (Continued)

COOLING
TABLE OF CONTENTS
page page
COOLING
OPERATIONÐCOOLING SYSTEM...........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS.............................1DIAGNOSIS AND TESTING - COOLING
SYSTEM.............................2
ACCESSORY DRIVE.......................5
ENGINE................................9
COOLING
OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
VACOOLING 7 - 1