2005 MERCEDES-BENZ SPRINTER brake pads
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(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)
Page 91 of 1232
(7) Remove the adjuster (Fig. 37).
(8) Remove the pressure springs (Fig. 37). by
depressing with your fingers and twisting.
(9) Remove the rear park brake shoes (Fig. 37).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
CLEANING - REAR DRUM IN HAT BRAKE
Clean the individual brake components, including
the support plate exterior, with a water dampened
cloth or with brake cleaner. Do not use any other
cleaning agents. Remove light rust and scale from
the brake shoe contact pads on the support plate
with fine sandpaper.
INSTALLATION
INSTALLATION - (SRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.(2) Install the lower retracting spring using special
tool 9280.
(3) Install the hold down springs using special tool
9281.
(4) Install the upper retracting spring using spe-
cial tool 9280.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.
(10) Lower the vehicle.
(11) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
INSTALLATION - (DRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
(1)Ensure that the cable lock moves easily
before installing shoes.Install the park brake
shoes.
(2) Install the lower retracting spring.
(3) Install the pressure hold down springs by
depressing with your fingers and twisting to lock in
place.
(4) Install the upper retracting spring.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheel flange ring. Tighten to
200 N´m (148 ft. lbs.).
(9) Install the rear wheels.
(10) Adjust the parking brakes.
(11) Lower the vehicle.
(12) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
ADJUSTMENTS
ADJUSTMENT
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Turn the adjusting wheel through the hole of
the wheel lug bolt until it is no longer possible to
rotate the rear wheel (Fig. 38).
Fig. 37 PARK BRAKE SHOES WITH DUAL REAR
WHEELS
1 - HOLD DOWN PIN
2 - PRESSURE SPRING
3 - ADJUSTER
4 - UPPER RETRACTING SPRING
5 - LOWER RETRACTING SPRING
6 - CABLE LOCK
7 - LOCKING PIN
8 - BRAKE CABLE
9 - PARK BRAKE SHOE
VABRAKES - BASE 5 - 27
SHOES (Continued)
Page 824 of 1232
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake line nuts 14 10 Ð
Brake pads wear
indicator caliper bolt10 7 89
Engine cradle bolts 125 92 Ð
Engine mount bolt
to engine bracket83 61 Ð
Engine mount nuts
to engine cradle45 33 Ð
Power steering line
nuts37 27 Ð
Steering gear
mounting bolts - 1st
stage25 18 Ð
Steering Gear
mounting bolts -
2nd stage45 33 Ð
Steering Gear
mounting bolts - 3rd
stage90ÉÐÐ
Steering gear
u-joint bolt24 18 Ð
Sway bar bushing
bolts30 22 Ð
Trailer hitch angle
bracket bolts/nuts50*
See
Warning37*
See
WarningÐ
Trailer hitch frame
bolts11 0 8 1 Ð
Transmission
crossmember nuts45 33 Ð
Transmission mount
bolts/nuts45 33 Ð
WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
ENGINE CRADLE
CROSSMEMBER
REMOVAL
(1) Install engine support tool 8534 or equivalent.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Remove engine mount nuts. (Fig. 6)
(4) Remove front spring. (Refer to 2 - SUSPEN-
SION/FRONT/SPRING - REMOVAL)
Fig. 6 ENGINE MOUNT
1 - ENGINE MOUNT
2 - SHIELD
3 - NUTS (2 PER MOUNT)
13 - 6 FRAME & BUMPERSVA
FRAME (Continued)
Page 1226 of 1232
SPEED SENSOR - INSTALLATION, REAR
WHEEL.............................5-31
SPEED SENSOR - REMOVAL, FRONT
WHEEL.............................5-30
SPEED SENSOR - REMOVAL, REAR
WHEEL.............................5-30
SPEED SENSORS - DESCRIPTION, INPUT . 21-119
SPEED SENSORS - OPERATION, INPUT . . 21-119
SPEEDOMETER - DESCRIPTION.........8J-23
SPEEDOMETER - OPERATION...........8J-23
SPEEDS - DESCRIPTION, TIRE
PRESSURE FOR HIGH..................22-6
SPLICE INFORMATION - DESCRIPTION,
CONNECTOR, GROUND..............8W-01-5
SPLICING - STANDARD PROCEDURE,
WIRE...........................8W-01-10
SPRING - DESCRIPTION................2-14
SPRING - INSTALLATION................2-8
SPRING - OPERATION..................2-14
SPRING - REMOVAL....................2-7
SPRING AND SHOCK - DIAGNOSIS AND
TESTING............................2-11
SPRING CLAMP PLATES - INSTALLATION . . . 2-8
SPRING CLAMP PLATES - REMOVAL.......2-8
SPRING SHACKLE - INSTALLATION.......2-15
SPRING SHACKLE - REMOVAL...........2-15
SPRING STOP PLATES - INSTALLATION.....2-9
SPRING STOP PLATES - REMOVAL........2-9
SPRINGS - INSTALLATION, VALVE..........9-32
SPRINGS - REMOVAL, VALVE............9-31
SQUEAK & RATTLE - STANDARD
PROCEDURE, BUZZ...................23-10
STABILIZER - INSTALLATION...........23-45
STABILIZER - REMOVAL...............23-45
STABILIZER BAR - DESCRIPTION..........2-9
STABILIZER BAR - INSTALLATION.....2-15,2-9
STABILIZER BAR - OPERATION............2-9
STABILIZER BAR - REMOVAL.........2-15,2-9
STABILIZER LINK - INSTALLATION.....2-16,2-9
STABILIZER LINK - REMOVAL........2-16,2-9
STARTER - DIESEL - TORQUE...........8F-29
STARTER MOTOR - DIAGNOSIS AND
TESTING...........................8F-29
STARTER MOTOR - DIESEL -
SPECIFICATIONS.....................8F-29
STARTER MOTOR - INSTALLATION.......8F-31
STARTER MOTOR - REMOVAL..........8F-30
STARTER MOTOR RELAY - DESCRIPTION . 8F-31
STARTER MOTOR RELAY -
INSTALLATION.......................8F-32
STARTER MOTOR RELAY - REMOVAL.....8F-31
STARTING - STANDARD PROCEDURE,
JUMP................................0-6
STARTING SYSTEM - DESCRIPTION......8F-24
STARTING SYSTEM - DIAGNOSIS AND
TESTING...........................8F-25
STARTING SYSTEM - OPERATION........8F-24
STEERING - DESCRIPTION..............19-1
STEERING - OPERATION................19-1
STEERING COLUMN OPENING COVER -
INSTALLATION.......................23-66
STEERING COLUMN OPENING COVER -
REMOVAL..........................23-66
STEERING FLUID - DESCRIPTION,
POWER..............................0-3
STEERING PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER.......19-12
STEERING PUMP FILL AND BLEED
PROCEDURE, STANDARD PROCEDURE
- POWER...........................19-14
STEERING SYSTEM - DIAGNOSIS AND
TESTING, POWER.....................19-2
STEERING SYSTEM - STANDARD
PROCEDURE, FLUSHING POWER........19-13
STEERING WHEEL - INSTALLATION.......19-7
STEERING WHEEL - REMOVAL...........19-7
STEP - INSTALLATION, REAR BUMPER....13-3
STEP - REMOVAL, REAR BUMPER........13-3
STEPS - INSTALLATION, FRONT BUMPER . . 13-2
STEPS - REMOVAL, FRONT BUMPER......13-2
STEPWELL SCUFF PADS - INSTALLATION
. 23-73
STEPWELL SCUFF PADS - REMOVAL
.....23-72
STOP LAMP BULB - INSTALLATION,
CENTER HIGH MOUNTED
...............8L-7
STOP LAMP BULB - REMOVAL, CENTER
HIGH MOUNTED
......................8L-7
STOP LAMP UN - INSTALLATION,
CENTER HIGH MOUNTED
...............8L-8STOP LAMP UN - REMOVAL, CENTER
HIGH MOUNTED......................8L-8
STOP PLATES - INSTALLATION, SPRING....2-9
STOP PLATES - REMOVAL, SPRING........2-9
STRIKER - INSTALLATION, LATCH.......23-18
STRIKER - INSTALLATION, REAR LATCH . . 23-41
STRIKER - REMOVAL, LATCH...........23-18
STRIKER - REMOVAL, REAR LATCH......23-41
STRUT - INSTALLATION................2-10
STRUT - REMOVAL....................2-10
SUCTION LINE - INSTALLATION.........24-66
SUCTION LINE - REMOVAL.............24-66
SUN VISOR - INSTALLATION...........23-73
SUN VISOR - REMOVAL...............23-73
SUPPLEMENTAL HEATER - DCHA -
DIAGNOSIS AND TESTING, DIESEL.......24-72
SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A.........8O-6
SUPPLEMENTAL RESTRAINT SYSTEM -
DIAGNOSIS AND TESTING..............8O-5
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE, HANDLING
NON-DEPLOYED......................8O-6
SUPPLY RESTRICTIONS - DIAGNOSIS
AND TESTING, FUEL...................14-5
SUPPORT BRACKET - INSTALLATION,
REAR VIEW MIRROR.................23-72
SURFACE - STANDARD PROCEDURE,
MEASURE CYLINDER HEAD.............9-21
SUSPENSION, SPECIAL TOOLS - FRONT . . 19-11
SUSPENSION, SPECIAL TOOLS - FRONT....2-2
SWITCH - DESCRIPTION, BLOWER
MOTOR.......................24-17,24-22
SWITCH - DESCRIPTION, DRIVER
HEATED SEAT ........................8G-2
SWITCH - DESCRIPTION, MASTER LOCK . . . 8N-2
SWITCH - DESCRIPTION, PASSENGER
HEATED SEAT ........................8G-5
SWITCH - DESCRIPTION, SEAT BELT.....8O-31
SWITCH - DESCRIPTION, WASHER
FLUID LEVEL.........................8R-7
SWITCH - DIAGNOSIS AND TESTING,
BLOWER MOTOR...............24-17,24-23
SWITCH - DIAGNOSIS AND TESTING,
DRIVER HEATED SEAT.................8G-2
SWITCH - DIAGNOSIS AND TESTING,
MASTER LOCK.......................8N-2
SWITCH - DIAGNOSIS AND TESTING,
PASSENGER HEATED SEAT..............8G-5
SWITCH - DIAGNOSIS AND TESTING,
POWER MIRROR.....................8N-3
SWITCH - DIAGNOSIS AND TESTING,
POWER WINDOW.....................8N-5
SWITCH - INSTALLATION...............8P-3
SWITCH - INSTALLATION, BLOWER
MOTOR............................24-23
SWITCH - INSTALLATION, BRAKE LAMP . . . 8L-6
SWITCH - INSTALLATION, DOOR JAMB . . . 8L-31
SWITCH - INSTALLATION, DRIVER
HEATED SEAT ........................8G-3
SWITCH - INSTALLATION, FOG LAMP....8L-12
SWITCH - INSTALLATION, HEADLAMP
LEVELING..........................8L-17
SWITCH - INSTALLATION, HORN.........8H-1
SWITCH - INSTALLATION, MASTER LOCK . . 8N-2
SWITCH - INSTALLATION, MULTI-
FUNCTION..........................8L-20
SWITCH - INSTALLATION, PARK BRAKE . . . 8L-20
SWITCH - INSTALLATION, PASSENGER
HEATED SEAT ........................8G-5
SWITCH - INSTALLATION, POWER
MIRROR............................8N-4
SWITCH - INSTALLATION, POWER
WINDOW............................8N-6
SWITCH - OPERATION, BLOWER MOTOR . 24-17,
24-22
SWITCH - OPERATION, DRIVER HEATED
SEAT ...............................8G-2
SWITCH - OPERATION, PASSENGER
HEATED SEAT ........................8G-5
SWITCH - OPERATION, SEAT BELT
.......8O-31
SWITCH - OPERATION, WASHER FLUID
LEVEL
..............................8R-8
SWITCH - REMOVAL
...................8P-3
SWITCH - REMOVAL, BLOWER MOTOR
. . 24-17,
24-23
SWITCH - REMOVAL, BRAKE LAMP
.......8L-6SWITCH - REMOVAL, DOOR JAMB.......8L-31
SWITCH - REMOVAL, DRIVER HEATED
SEAT ...............................8G-3
SWITCH - REMOVAL, FOG LAMP........8L-11
SWITCH - REMOVAL, HEADLAMP
LEVELING..........................8L-16
SWITCH - REMOVAL, HORN.............8H-1
SWITCH - REMOVAL, MASTER LOCK......8N-2
SWITCH - REMOVAL, MULTI-FUNCTION . . . 8L-19
SWITCH - REMOVAL, PARK BRAKE......8L-20
SWITCH - REMOVAL, PASSENGER
HEATED SEAT ........................8G-5
SWITCH - REMOVAL, POWER MIRROR....8N-3
SWITCH - REMOVAL, POWER WINDOW . . . 8N-6
SWITCH BEZEL - INSTALLATION,
ACCESSORY........................23-54
SWITCH BEZEL - REMOVAL, ACCESSORY . 23-54
SYMBOLS - DESCRIPTION,
INTERNATIONAL....................Intro.-2
SYMBOLS - DESCRIPTION,
INTERNATIONAL.......................0-9
TACHOMETER - DESCRIPTION..........8J-23
TACHOMETER - OPERATION............8J-24
TAIL LAMP UNIT - INSTALLATION.......8L-23
TAIL LAMP UNIT - REMOVAL...........8L-23
TAILPIPE - INSTALLATION...............11-3
TAILPIPE - REMOVAL..................11-3
TANK - DESCRIPTION, FUEL............14-12
TANK - INSTALLATION, FUEL...........14-13
TANK - REMOVAL, FUEL...............14-12
TANK MODULE - DESCRIPTION, FUEL....14-13
TANK MODULE - INSTALLATION, FUEL....14-14
TANK MODULE - REMOVAL, FUEL.......14-13
TCM ADAPTATION - STANDARD
PROCEDURE.........................8E-8
TEMP SENSOR - DESCRIPTION, ENGINE
COOLANT............................7-14
TEMP SENSOR - INSTALLATION, ENGINE
COOLANT............................7-15
TEMP SENSOR - REMOVAL, ENGINE
COOLANT............................7-14
TEMPERATURE CONTROL -
DESCRIPTION.......................24-29
TEMPERATURE CONTROL - DIAGNOSIS
AND TESTING.......................24-29
TEMPERATURE CONTROL -
INSTALLATION.......................24-29
TEMPERATURE CONTROL - OPERATION . . 24-29
TEMPERATURE CONTROL - REMOVAL....24-29
TEMPERATURE GAUGE - DESCRIPTION,
ENGINE............................8J-15
TEMPERATURE GAUGE - OPERATION,
ENGINE............................8J-15
TEMPERATURE INDICATOR -
DESCRIPTION, AMBIENT...............8J-11
TEMPERATURE INDICATOR -
OPERATION, AMBIENT.................8J-11
TEMPERATURE SENSOR - DESCRIPTION . . 24-30
TEMPERATURE SENSOR - DESCRIPTION,
AIR OUTLET........................24-14
TEMPERATURE SENSOR - DESCRIPTION,
AMBIENT...........................24-15
TEMPERATURE SENSOR - DESCRIPTION,
EVAPORATOR
..................24-17,24-25
TEMPERATURE SENSOR - DESCRIPTION,
FUEL
..............................14-29
TEMPERATURE SENSOR - DESCRIPTION,
IN-CAR
............................24-19
TEMPERATURE SENSOR - DESCRIPTION,
INLET AIR
..........................14-29
TEMPERATURE SENSOR - DESCRIPTION,
OIL
................................9-56
TEMPERATURE SENSOR - DESCRIPTION,
TRANSMISSION
.....................21-140
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING
.......................24-30
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING, EVAPORATOR
...........24-26
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING, IN-CAR
................24-19
TEMPERATURE SENSOR - INSTALLATION
. 24-30
TEMPERATURE SENSOR -
INSTALLATION, AIR OUTLET
............24-15
TEMPERATURE SENSOR -
INSTALLATION, AMBIENT
..............24-16
TEMPERATURE SENSOR -
INSTALLATION, EVAPORATOR
......24-18,24-26
16 INDEXVA
Description Group-Page Description Group-Page Description Group-Page