2005 MERCEDES-BENZ SPRINTER engine

CONDITION POSSIBLE CAUSES CORRECTION
HARD 3-2 DOWNSHIFT
WHEN DECELERATION
EVEN AFTER
READAPTION1. K3 Idles. 1. Install TCM And/Or
Electrohydraulic Control Unit.
NO RESP. DELAYED
UPSHIFT, NO DTC1. Different Tire Sizes Are Mounted
On The Front Axle.1. Mount Uniform Tire Sizes On
The Front Axle.
NO UPSHIFT 3-4, 4-5
AFTER FAST OFF
(ACCELERATOR)1. Upshift Prevention To Realize
Dynamical Drivestyle.1. Instruct Customer.
NO UPSHIFT OF 1ST
GEAR BELOW 5000 RPM1. Gear Recognition Switch. 1. Replace Gear Recognition
Switch.
NO UPSHIFT INTO 5TH
GEAR WHEN FULL
THROTTLE OR KICK
DOWN ACTIVATION1. The Upshift 4-5 At Full Throttle or
Kick Down Never Occurs Until
Reaching Cut Off Speed. Under
These Conditions, The High
Powered Vehicle Will Never Shift
Into 5th Gear Below 250 km/h.1. Instruct Customer.
NO KICK DOWN
SHIFTING1. Accelerator Pedal Value < 95%. 1. Check Engine Control. Adjust
As Necessary.
Engine Turns Up While 2-3
Upshift and/or Hard 3-2
Downshift1. Oil Level Too Low. 1. Check Oil Level. Add if
Necessary.
2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Free Wheeling Clutch F2
Defective.3. Replace Free Wheeling
Clutch F2, Hollow Shaft, and
Rear Sun Gear/Inner Disc
Carrier K3.
GRABBING 2-3 COASTING
UPSHIFT AND/OR BRAKE
DOWNSHIFT1. Oil Level Too Low. 1. Check Oil Level. Add if
Necessary.
2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Control shift or Command Valve
Blocked.3. Check Each Slide Valve For
Base Position and Ease Of
Movement, Remove Particle.
4. K3 Disc Burnt, Hot Spots or
Rubbed Down.4. Replace Inner and Outer
Disc Carrier K3 And Control
Valve.
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AUTOMATIC TRANSMISSION - NAG1 (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DELAYED ENGAGEMENT,
NO TRANSFER OF
POWER IN R AND/OR D,
ALSO AT TIMES1. Oil Level Too Low. 1. Check Oil Level. Add if
Necessary.
2. Recognition Switch - Selector
Lever Position.2. Replace Recognition Switch
Only When Intermediate
Position or Fault is Indicated.
3. Oil Filter Not Installed. 3. Install Oil Filter.
4. AEV, Delayed Pressure Build Up
On Piston B2/B3.4. Install New Shifting
Procedure (TCM,
electrohydraulic control unit or
repair set).
5. Wrong Combination TCM/
Electrohydraulic Control Unit.5. Check Combination
TCM/Electrohydraulic Control
Unit. Replace TCM Resp.
Electrohydraulic Control Unit, if
necessary.
NO UPSHIFT OF 1ST
GEAR AT TIMES1. Connector Ballast Unit. Output
Speed Sensor Loose, Incorrectly
Contacted.1. Check Connectors, Replace
Output Speed sensor If
Necessary.
2. Output Speed Sensor Defective 2. Replace Output Speed
Sensor.
LEAKAGE AT THE AREA
OF THE ELECTRICAL
PLUG TO THE
CONDUCTOR PLATE1. Deformation O-Rings. 1. Replace O-Rings.
2. Deformation Adapter. 2.Replace Adaptor.
3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is Not
Centered In The Socket And The
O-ring Will Not Seal.3. Remove Nose Of Conductor
Plate.
4. Contacting At The Conductor Plate
Leaky. Oil In Harness, Sometimes In
The Control Module.4. Replace Conductor Plate.
LEAKAGE AT THE AREA
OF BELL HOUSING/
TORQUE CONVERTER1. Bolts (Torx M6) Outer Disc Carrier
B1.1. Clean Thread and Install the
Bolts Using Sealer.
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter
Housing.1. Clean Thread and Install the
Bolts Using Sealer.
2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.2. Install Drain Plug Correctly.
3. Weld Seam Of Torque Converter
Leaky.3. Replace Torque Converter.
4. Radial Sealing Ring Oil Pump
Defective.4. Replace Sealing Ring.
5. O-Ring Oil Pump Defective Or Not
Installed.5. Install O-Ring.
6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.6. Install Fit Bolt If Necessary.
21 - 26 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(a) Remove bracket for the oil cooler feed and
return lines (1) (Fig. 23) from engine oil pan
flange. Detail shows right side of motor. Position is
mirrored for the left side of engine.
(b) Detach bracket of cable retainer (4) (Fig. 24)
from the threaded shank of a engine oil pan bolt
(5).
(c) Press cable retainer (4) (Fig. 24) down and
out.
(d) Remove the bolts holding the oil cooler lines
(6) (Fig. 25) to the left and right sides of transmis-
sion and hang the lines to the side.
(10) Disconnect the transmission electrical connec-
tor (2) (Fig. 26) from transmission and hang to the
side. Turn sealing ring (3) counterclockwise and dis-
connect plug connection (2).
(11) Detach shift cable at transmission.(a) Unlatch ball socket latch (Fig. 27) of cable.
(b) Unclip shift cable retainer from retainer
bracket. When pulling out cable, press together
hooks of shift cable retainer at the points shown
(arrows).
(c) Pull shift cable out of ball socket. Ball socket
can remain on transmission lever.
(12) Remove the torque converter bolts.
(a) Remove the steering gear (1) (Fig. 28) from
the chassis crossmember.
(b) Lower the steering gear (1) (Fig. 28) down-
wards.
(c) Remove the plastic torque converter access
cover (1) (Fig. 29) at back of engine flange.
Fig. 23 Remove Cooler Line Supports
1 - COOLER LINES
Fig. 24 Remove Cable Support
1 - CABLE
2 - BOLT
Fig. 25 Remove Driver's Side Cooler Line
1 - COOLER LINE
Fig. 26 Remove Transmission Electrical Connector
and Cooler Line
1 - COOLER LINE
2 - TRANSMISSION ELECTRICAL CONNECTOR
3 - SEALING RING
21 - 28 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(d) Rotate engine by hand until bolts (2) (Fig.
29) are in front of opening. Rotate engine forwards
at crankshaft.
(e) To remove bolts, position a ratchet with long
extension and joint nut as shown (Fig. 30).
(f) Remove3x2bolts (2) (Fig. 29) at circumfer-
ence of driving plate.
(13) Support engine. Insert wooden block between
oil pan and front chassis crossmember beam.
(14) Remove vent hose bracket and tie back to one
side.
(15) Disconnect ground strap and tie back to one
side.(16) Remove bolts (A) (Fig. 31) on underside of
transmission. Two bolts (A) on top of transmission
must remain in the housing.
(17) Place hydraulic transmission jack under
transmission and raise slightly. Secure transmission
on hydraulic jack with a strap or ask an assistant to
hold it.
Fig. 27 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 28 Lower Steering Gear
1 - STEERING GEAR
2 - BRACKET
Fig. 29 Remove Torque Converter Access Cover
1 - TORQUE CONVERTER ACCESS COVER
2 - BOLT
Fig. 30 Remove Torque Converter Bolts
1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE
4 - OPENING
5 - CHASSIS CROSSMEMBER
6 - STEERING GEAR
VAAUTOMATIC TRANSMISSION - NAG1 21 - 29
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(18) Remove rear engine cross member (4) (Fig.
31). First remove the nuts (5) at the outside ends of
the engine crossmember. Then remove the bolts (1) of
the transmission mount.
(19) Remove the last bolts (A, B) (Fig. 31) on the
top of the transmission.
(20) Remove the transmission towards the rear
and lower. Ensure that the converter remains in the
transmission housing when the transmission is
removed.
(21) Remove the torque converter.
DISASSEMBLY
(1) Remove the torque converter (1) (Fig. 32).
(2) Place transmission in a vertical position.
(3) Measure input shaft end play as follows (Fig.
33).
(a) Attach Adapter 8266-18 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.(e) Move the input shaft in and out. Record the
maximum travel for assembly reference.
(4) Loosen guide bushing (12) (Fig. 34) and remove
from transmission housing.
Fig. 31 Support Transmission and Remove Bolts
1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
5 - NUT, ENGINE CROSSMEMBER
6 - NUT, TRANSMISSION SUPPORT
Fig. 32 Remove Torque Converter
1 - TORQUE CONVERTER
2 - CONVERTER HOUSING
Fig. 33 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
21 - 30 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(3) Move the torque converter (1) (Fig. 59) to
shown position. Check position of torque converter
through housing opening (2) when installing trans-
mission.
(4) Move driving plate (1) (Fig. 60) to shown posi-
tion.
(5) Ensure the dowel pins are installed in their
correct position at the transmission housing flange.
(6) Place transmission onto a hydraulic transmis-
sion jack and raise the transmission into position.
Secure transmission on hydraulic jack with a strap
or ask an assistant to hold it.(7) Move the transmission into position on the
dowel pins and install two bolts (A, B) (Fig. 61) on
the top of the transmission. Torque the bolts to 38
N´m (28 ft.lbs.).
(8) Install the bolt to hose the vent hose bracket to
the transmission. Torque the bolt to 38 N´m (28
ft.lbs.).
(9) Install the bolt to hold the ground strap to the
transmission. Torque the bolt to 38 N´m (28 ft.lbs.).
(10) Install bolts (A) (Fig. 61) on underside of
transmission. Torque the bolts to 38 N´m (28 ft.lbs.).
(11) Install rear engine cross member (4) (Fig. 61).
First install the nuts (5) at the outside ends of the
engine crossmember. Then install the bolts (1) of the
transmission mount. Torque the bolts and nuts to 45
N´m (33 ft.lbs.).
(12) Remove the wooden block supporting the
engine and remove the hydraulic jack.
(13) Install the torque converter bolts.
(a) Install the first pair bolts (2) (Fig. 62) at cir-
cumference of driving plate snug only.
Fig. 59 Position Torque Converter as Shown
1 - TORQUE CONVERTER
2 - INSPECTION OPENING
Fig. 60 Position Driveplate as Shown
1 - DRIVEPLATE
Fig. 61 Support Transmission and Install Bolts
1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
5 - NUT, ENGINE CROSSMEMBER
6 - NUT, TRANSMISSION SUPPORT
21 - 42 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(b) To install bolts, position a ratchet with long
extension and joint nut as shown.
(c) Rotate engine by hand until the next pair of
bolts (2) are in front of opening. Rotate engine for-
wards at crankshaft. Install the next pair of bolts
snug only.
(d) Rotate engine by hand until the final pair of
bolts (2) are in front of opening. Rotate engine for-
wards at crankshaft. Install and torque the bolts to
50 N´m (37 ft.lbs.).
(e) Rotate engine by hand and tighten the first
two bolt pairs to 50 N´m (37 ft.lbs.).
(f) Install the plastic torque converter access
cover (1) (Fig. 63) to the back of the engine flange.
(g) Install the steering gear (1) (Fig. 64) onto the
chassis crossmember. Tighten both steering gear
bolts first to 25 N´m (18.5 ft.lbs.). Tighten both
steering gear bolts next to 45 N´m (33 ft.lbs.).
Tighten both steering gear bolts next an additional
90É.
Fig. 62 Install Torque Converter Bolts
1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE
4 - OPENING
5 - CHASSIS CROSSMEMBER
6 - STEERING GEAR
Fig. 63 Install Torque Converter Access Cover
1 - TORQUE CONVERTER ACCESS COVER
2 - BOLT
Fig. 64 Install Steering Gear
1 - STEERING GEAR
2 - BRACKET
VAAUTOMATIC TRANSMISSION - NAG1 21 - 43
AUTOMATIC TRANSMISSION - NAG1 (Continued)

(14) Install the transmission electrical connector
(2) (Fig. 65) from transmission and hang to the side.
Turn sealing ring (3) clockwise and connect plug con-
nection (2).
(15) Install the shift cable (Fig. 66) to the trans-
mission.
(a) Push shift cable onto the transmission shift
lever ball socket.
(b) Latch ball socket latch of cable.
(c) Clip shift cable retainer into retainer bracket.
(16) Install the cooler lines to the transmission.(a) Install the brackets for the oil cooler feed and
return lines (1) (Fig. 67) onto the engine oil pan
flange. Detail shows right side of motor. Position is
mirrored for the left side of engine.
(b) Attach the bracket for the cable retainer (4)
(Fig. 68) to the threaded shank of a engine oil pan
bolt (5).
(c) Install the bolts to hold the oil cooler lines (6)
to the left (Fig. 69) and right sides of transmission.
Torque the bolts to 34 N´m (254 ft.lbs.).
Fig. 65 Install Transmission Electrical Connector
and Cooler Line
1 - COOLER LINE
2 - TRANSMISSION ELECTRICAL CONNECTOR
3 - SEALING RING
Fig. 66 Install Shift Cable Onto Transmission
1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
Fig. 67 Install Cooler Line Supports
1 - COOLER LINES
Fig. 68 Install Cable Support
1 - CABLE
2 - BOLT
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AUTOMATIC TRANSMISSION - NAG1 (Continued)