2005 MERCEDES-BENZ SPRINTER lock

LEVER
REMOVAL
(1) Disconnect the front brake cable from the pul-
ley unit.
(2) Remove the front brake cable from the hand
brake lever (Fig. 29).
(3) Remove the circle cover (Fig. 35).
(4) Remove the bolts on the hand brake lever (Fig.
35).
(5) Pull the cover off the hand brake lever (Fig.
35).
(6) Disconnect the hand brake check switch and
wiring harness from the hand brake lever (Fig. 35).
(7) Remove the hand brake lever (Fig. 35).
INSTALLATION
(1) Install the hand brake lever (Fig. 35).
(2) Reconnect the hand brake check switch and the
wiring harness to the hand brake lever (Fig. 35).
(3) Install the cover to the hand brake lever (Fig.
35).
(4) Install the bolts on the hand brake lever.
Tighten to 25 N´m (221 in. lbs.) (Fig. 35).
(5) Install the circle cover (Fig. 35).
(6) Install the front brake cable to the hand brake
lever.
(7) Connect the front brake cable to the pulley unit
(Fig. 35).
SHOES
REMOVAL
REMOVAL - (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the disc brake rotor.
(4) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(5) Remove the retracting springs using special
tool 9280 (Fig. 36).
(6) Remove the adjuster (Fig. 36).
(7) Remove the pressure springs using special tool
9281 (Fig. 36).
(8) Remove the rear park brake shoes (Fig. 36).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
REMOVAL - (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the wheel flange ring.
(4) Remove the disc brake rotor.
(5) Disconnect the front park brake cable from the
pulley unit.Do not remove the rear park brake
cables.
(6) Remove the retracting springs (Fig. 37).
Fig. 35 HAND BRAKE LEVER
1 - LOCKING PIN
2 - COVER
3 - HAND BRAKE LEVER
4 - HAND BRAKE CHECK SWITCH
5 - WIRING HARNESS
6 - BOLT
7 - HAND BRAKE CABLE
8 - BOLT
9 - RETAINING CLIP
10 - CIRCLE COVER
Fig. 36 PARK BRAKE SHOES
1 - PARK BRAKE SHOES
2 - PRESSURE SPRING
3 - RETRACTING SPRING (SHORT HOOK EYE)
4 - RETRACTING SPRING (LONG HOOK EYE)
5 - CABLE LOCK
6 - ADJUSTER
5 - 26 BRAKES - BASEVA

(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)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
SPECIFICATIONS - TORQUE CHART........29
ELECTRICAL
DESCRIPTION.........................29
OPERATION...........................29
FRONT WHEEL SPEED SENSOR
REMOVAL.............................30
INSTALLATION.........................30
REAR WHEEL SPEED SENSOR
REMOVAL.............................30INSTALLATION.........................31
TONE WHEEL
REMOVAL.............................31
INSTALLATION.........................31
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................31
REMOVAL.............................31
INSTALLATION.........................32
BRAKES - ABS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake Lines To Hydraulic
unit16 Ð 12
ELECTRICAL
DESCRIPTION
NOTE: Wheel speed sensor should be installed all
the way into the clamping bushings, the wheel
speed sensor will self adjust when the vehicle is
moved.
The ABS brake system uses 4 wheel speed sensors.
A sensor is mounted to each front hub/bearings in
the front. A rear sensor is mounted to each rear sup-
port plate.
OPERATION
The Wheel Speed Sensor consists of a magnet sur-
rounded by windings from a single strand of wire.
The sensor sends a small AC signal to the CAB. This
signal is generated by magnetic induction. The mag-
netic induction is created when a toothed sensor ring
(exciter ring or tone wheel) passes the stationary
magnetic WSS.When the ring gear is rotated, the exciter ring
passes the tip of the WSS. As the exciter ring tooth
approaches the tip of the WSS, the magnetic lines of
force expand, causing the magnetic field to cut across
the sensor's windings. This, in turn causes current to
flow through the WSS circuit (Fig. 1) in one direc-
tion. When the exciter ring tooth moves away from
the sensor tip, the magnetic lines of force collapse
cutting the winding in the opposite direction. This
causes the current to flow in the opposite direction.
Every time a tooth of the exciter ring passes the tip
of the WSS, an AC signal is generated. Each AC sig-
nal (positive to negative signal or sinewave) is inter-
preted by the CAB. It then compares the frequency of
the sinewave to a time value to calculate vehicle
speed. The CAB continues to monitor the frequency
to determine a deceleration rate that would indicate
a possible wheel-locking tendency.
The signal strength of any magnetic induction sen-
sor is directly affected by:
²Magnetic field strength; the stronger the mag-
netic field, the stronger the signal
VABRAKES - ABS 5 - 29

CONDITION POSSIBLE CAUSES CORRECTION
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)
TEMPERATURE GAUGE READING
INCONSISTENT ( ERRATIC,
CYCLES OR FLUCTUATES)1. Heavy duty cooling system,
extream cold ambient (outside)
temperature or heater blower motor
in high position.1. None. System operating normaly.
2. Temperature gauge or gauge
sensor defective.2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water
pump.6. Check for leak. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM
AND /OR COOLANT INTO
RESERVOIR BOTTLE.
(TEMPERATURE GAUGE MAY
READ HIGH)1. Radiator cap defective. 1. Replace radiator cap.
2. Radiator neck surface damaged. 2. Replace radiator.
HOSE OR HOSES COLLAPSE
WHEN ENGINE IS COOLING.1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reservior/overflow system.1. Replace radiator cap, check vent
hose between radiator and reservoir
bottle for blockage also check
reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
2. Thermal viscous fan drive. 2. None. Normal condition.
3. Fan blades striking surrounding
objects.3. Locate contact point and repair
as necessary.
4. Thermal viscous fan drive
bearing.4. Replace viscous fan drive
assembly.
5. Obstructed air flow through
radiator.5. Remove obstruction.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)1. Radiator and/or A/C condenser
air flow obstructed.1. Remove obstruction and/or clean.
VACOOLING 7 - 3
COOLING (Continued)

REMOVAL
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
(1) A 3/8 inch square hole is provided in the auto-
matic belt tensioner. Attach a 3/8 inch drive-long
handle ratchet to this hole (Fig. 2).
(2) Rotate ratchet and tensioner assembly counter-
clockwise (as viewed from front) until tension has
been relieved from belt (Fig. 2).
(3) Remove belt from water pump pulley first.
(4) Remove belt from vehicle.
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be the correct length and routed cor-
rectly. If not, engine may overheat due to water
pump rotating in wrong direction.
(1) Position drive belt over all pulleysexcept
water pump pulley (Fig. 3).
(2) Attach a 3/8 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner counterclock-
wise. Place belt over water pump pulley. Let ten-
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
Fig. 2 DRIVE BELT TENSIONER
1 - ACCESSORY DRIVE BELT TENSIONER
2 - RATCHET WRENCH
Fig. 3 ACCESSORY DRIVE BELT ROUTING
1 - A/C COMPRESSOR
2 - POWER STEERING
3 - DRIVE BELT TENSIONER
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - GENERATOR
7 - IDLER PULLEY
7 - 8 ACCESSORY DRIVEVA
DRIVE BELTS (Continued)

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION..........................9
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS......................10
STANDARD PROCEDURE
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................11
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM....................12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM....................12
COOLANT LEVEL SENSOR
REMOVAL.............................13
INSTALLATION.........................13
RADIATOR FAN
REMOVAL.............................13
INSTALLATION.........................13
ENGINE BLOCK HEATER
REMOVAL.............................14
INSTALLATION.........................14
ENGINE COOLANT TEMP SENSOR
DESCRIPTION.........................14REMOVAL.............................14
INSTALLATION.........................15
ENGINE COOLANT THERMOSTAT
REMOVAL.............................15
INSTALLATION.........................16
FAN DRIVE VISCOUS CLUTCH
REMOVAL.............................16
INSTALLATION.........................16
RADIATOR
REMOVAL.............................16
INSTALLATION.........................17
RADIATOR PRESSURE CAP
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP......................19
WATER PUMP
REMOVAL.............................19
INSTALLATION.........................20
COOLANT
DESCRIPTION
Coolant flows through the engine water jackets and
cylinder heads absorbing heat produced by the engine
during operation. The coolant carries heat to the radia-
tor and heater core. Here it is transferred to ambient
air passing through the radiator and heater core fins.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, year-round in all climates.If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause forma-
tion of additive deposits in the system, as the corrosion
inhibitive additives in ethylene-glycol require the pres-
ence of water to dissolve. The deposits act as insulation,
causing temperatures to rise to as high as 149 deg. C
(300 deg. F). This temperature is hot enough to melt
plastic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22 deg. C (-8 deg. F ).
Propylene-glycol FormulationsÐShould Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.
It's overall effec-
tive temperature range is smaller than that of ethylene-
glycol. The freeze point of 50/50 propylene-glycol and
water is -32 deg. C (-26 deg. F). 5 deg. C higher than
ethylene-glycol's freeze point. The boiling point (protec-
tion against summer boil-over) of propylene-glycol is 125
deg. C (257 deg.F)at96.5 kPa (14 psi), compared to
128 deg. C (263 deg. F) for ethylene-glycol. Use of pro-
pylene-glycol can result in boil-over or freeze-up in
Chrysler vehicles, which are designed for ethylene-gly-
col. Propylene glycol also has poorer heat transfer char-
VAENGINE 7 - 9

Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on coolant
container until thermostat opens. Attach a Pressure
Tester to container. If pressure builds up quickly it
indicates a combustion leak exists. This is usually
the result of a cylinder head gasket leak or crack in
engine. Repair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean and suitably marked
container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN
WITH SYSTEM HOT AND UNDER PRESSURE. SERI-
OUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat removal.
Remove accessory drive belt.
Add coolant to pressure container to bring level to
within 6.3 mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
STANDARD PROCEDURE
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
VAENGINE 7 - 11
COOLANT (Continued)

CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUG OR LOOSEN THE RADIATOR
DRAIN PLUG WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT remove coolant recovery pressure con-
tainer cap first. With engine cold, raise vehicle on a
hoist and locate radiator draincock.
NOTE: Radiator draincock is located on the left/
lower side of radiator.
(2)
Attach one end of a hose to the draincock (Fig. 3).
Put the other end into a clean and appropriately
marked container. Open draincock and drain coolant
from radiator. This will empty the coolant recovery pres-
sure container first. The coolant does not have to be
removed from the container unless the system is being
refilled with a fresh mixture. When container is empty,
remove cap and continue draining cooling system.
To drain the engine of coolant, loosen the cylinder
block drain plug located on the side of cylinder block
(Fig. 3).
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM
(1) Tighten the radiator drain and the cylinder
block drain plug(s) (if removed). Tighten the engine
drain plug to 22 lbs. ft. (30 N´m)
(2) Fill system using a 50/50 mixture of ethylene-
glycol antifreeze and low mineral content water. Fill
radiator to top and add sufficient coolant to the cool-
ant recovery pressure container to raise level to
COLD MINIMUM mark.
(3) With heater control unit in the HEAT position,
operate engine with container cap in place.
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the pressure container.
(5) Add coolant to pressure container as necessary.
Only add coolant to the container when the
engine is cold. Coolant level in a warm engine
will be higher due to thermal expansion.To
purge the cooling system of all air, this heat up/cool
down cycle (adding coolant to cold engine) must be
performed three times. Add necessary coolant to raise
container level to the COLD MINIMUM mark after
each cool down period.
Fig. 3 DRAINING COOLANT SYSTEM
1 - DRAIN HOSE 3 - RADIATOR DRAIN PLUG
2 - ENGINE DRAIN PLUG 4 - DRAIN HOSE
7 - 12 ENGINEVA
COOLANT (Continued)