2005 MERCEDES-BENZ SPRINTER engine coolant

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Timing Case Cover to
Crankcase20 15 -
Plug-Coolant Drain to
Crankcase30 22 -
Oil Pan
6m-Bolt-Oil Pan to
Crankcase9-80
8m-Bolt-Oil Pan to
Crankcase20 15 -
Bolt-Oil Pan to End Cover 9 - 80
Bolt-Oil Pan to Timing
Case Cover9-80
Bolt-Oil Pan to
Transmission Bell Housing40 30 -
Plug-Oil Pan to Oil Drain 47 35 -
Connecting Rod
Bolt-Connecting Rod Cap
to Connecting Rod (3
stage, 1&2 torque, 3
torque angle)5,25,90É - 44,221
Crankshaft
Bolt-Crankshaft Bearing
Cap (2 stage, 1 torque, 2
torque angle55,90É 40.5 -
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 2 torque
angle)200,90É 147.5 -
10.9m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 2 torque
angle)325,90É 240 -
Bolt-Stretch Shank for
Flywheel or 2 Mass
Flywheel to Crankshaft (2
stage, 1 torque, 2 torque
angle)45,90É 33
Turbo Charger
Bolt-Oil Feed Line to
Cylinder Head9/22 - 80-194
Bolt-Oil Feed Line to
Turbo Charger30 22 -
Bolt-Turbo Charger
Support30 22 -
Bolt-Turbo Charger
Support to Crankcase20 - 177
VAENGINE 9 - 9
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt-Oil Outlet Line to
Turbo Charger9-80
Connection-Flange of
Exhaust Manifold to Turbo
Charger30 22 -
Connection-Turbo Charger
to Front Catalytic
Converter30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air
Distribution Pipe16 - 141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe9-80
Bolt-Support to Charge Air
Distribution Pipe20 - 177
Bolt-Support to Engine
Bracket40 30 -
Clamp-Charge Air
Pipes/Hoses3-27
Belt Tensioning Device
Bolt-Guide Pulley to
Coolant Pump35 26 -
Bolt-Guide Pulley to
Timing Case Cover35 26 -
Bolt-V-Belt Tensioning
Device to Tensioning
Pulley36 26.5 -
Bolt-V-Belt Tensioning
Device to Timing Case
Cover30 22 -
Exhaust Manifold
Nut-Exhaust Manifold at
Cylinder Head30 22 -
Position Sensor
Nut/Bolt-Camshaft
Position Sensor to
Cylinder Head Cover11 - 9 7
Nut/Bolt-Crankshaft
Position Sensor to Engine
Block8-70
Pre-Glow System
Cylinder Head to Glow
Plug12 - 106
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of Circuit
3014 - 124
9 - 10 ENGINEVA
ENGINE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut-Connection of Circuit
506-53
Alternator
Bolt-Generator to Timing
Case Cover20 15 -
Bolt-Generator to Cooler
Housing6-53
Bolt-Cooler Housing of
Generator to Crankcase20 - 177
Nut-B+ Circuit to
Generator13-18 - 115-159
Nut-D+ Circuit to
Generator5-44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to
Crankcase18
- 133
Bolt-Oil Pipe to Crankshaft
Bearing Cap8-70
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat
Exchanger to Timing
Cover Case15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube
to Cylinder Head14 - 123
Bolt-Oil Level Sensor to
Oil Pan14 - 123
Coolant Pre-Heater
Coolant Pre-Heater in
Engine Block35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant
Pump8-35 6 - 26 -
Bolt-Coolant Pump to
Timing Case Cover 6m/8m14/20 10 - 15 -
Bolt-Thremostat Housing
to Cylinder Head9-80
Coolant Drain Plug to
Crankcase30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage,
torque, torque angle)20/90É 15 -
VAENGINE 9 - 11
ENGINE (Continued)

REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.
(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crank-
case(Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(6) Lower vehicle.(7) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(9) Remove tappets (Fig. 13).
(10) Remove the camshaft housing at the cylinder
head (Fig. 13).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING
WHEN HANDLING FUEL.
(11) Remove the high pressure fuel pump interme-
diate gear (Fig. 13).
(12) Disconnect the engine side of the engine har-
ness and set aside.
(13) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
Fig. 13 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 22 ENGINEVA
CYLINDER HEAD (Continued)

(14) Disconnect the turbocharger oil supply line at
the cylinder head and turbocharger (Fig. 13).
(15) Disconnect the turbocharger at the exhaust
manifold (Fig. 13).
(16) Unbolt the transmission dipstick tube from
the cylinder head (Fig. 13).
(17) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 13).
NOTE: Capture any fuel spillage when disconnect-
ing fuel lines.
(18) Disconnect the fuel line at the rear of the fuel
rail (Fig. 13).
(19) Remove upper timing case to cylinder head
bolts (Fig. 14).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(20) Remove cylinder head bolts and inspect (Refer
to 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(21) Remove cylinder head (Fig. 14).NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(22) Clean all mating surfaces and blow out bolt
thread holes.
REMOVAL - CYLINDER HEAD FRONT COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).
Fig. 14 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL4 - GASKET
5 - BOLT TO TIMING COVER
VAENGINE 9 - 23
CYLINDER HEAD (Continued)

(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 15).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly.
NOTE: If piston or connecting rods have been
replaced, measure piston protrusion.
NOTE: Check facing cylinder head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as guide (Fig. 14).
NOTE: Inspect all cylinder head bolts for defects
and stretching before installation (Refer to 9 -
ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
CYLINDER HEAD BOLT TORQUE SEQUENCE
The M12 cylinder head bolts must be torqued
in 3 stages.
(1) Install M12 cylinder head bolts finger tight
(Fig. 14).
(2) Torque bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.in.) (Fig. 16).
(3) Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
(4) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
16).
(5) Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(3 stages). (Fig. 16).
(2) Install fuel return flow line between rail and
high pressure pump (Fig. 13).
(3) Connect the coolant hoses to the thermostat
housing (Fig. 13).(4) Connect the coolant pipe at the cylinder head
(Fig. 13).
(5) Reconnect transmission oil dip stick tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 13).
(6) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 13).
(7) Install oil return flow line with new seals at
turbocharger. Tighten bolt of supply line to turbo-
charger to 18N´m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N´m (80 lbs. in.) (Fig. 13)
(8) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(9) Install and properly route the engine wiring
harness, making appropriate connections.
(10) Install high pressure fuel pump intermediate
gear (Fig. 13).
(11) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(12) Install the camshaft housing to cylinder head
(Fig. 13).
(13) Install the tappets (Fig. 13).
(14) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(15) Install top guide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(16) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
Fig. 16 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 25
CYLINDER HEAD (Continued)

BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N´m (59 lbs.ft.).
(20) Remove retaining lock for crankshaft/starter
ring gear.
(21) Install air intake tube at turbocharger (Refer
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).
(22) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.
(23) Refill cooling system with proper coolant mix-
ture to proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(24) Connect 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.
(25) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
INSTALLATION - CYLINDER HEAD FRONT
COVER
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
NOTE: Dowel pins are used as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
(1) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 17).
NOTE: Install front cover of cylinder head within 10
minutes after applying sealant. Do not spread seal-
ing bead.
(2) Raise locking pawl of top guide rail and guide
front cover onto guide pins.
(3) Install bolts attaching front cover (Fig. 15)
Tighten bolts to 14N´m (124 lbs. in.).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
REMOVE SOURCES OF IGNITION FROM THE AREA.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELSONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS.
(4) Instal low pressure pump (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - INSTALLATION).
(5) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).
NOTE: Timing chain tensioner must be installed
with a new gasket.
(6) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(7) Refill cooling system with proper mixture to
proper level (Refer to 7 - COOLING/ENGINE/COOL-
ANT - STANDARD PROCEDURE).
(8) Connect 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.
(9) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)
INSTALLATION - CYLINDER HEAD GUIDE RAIL
(1) Carefully position the top guide rail onto the
guide pins.
Fig. 17 CYLINDER HEAD COVER SEALING
SURFACE
1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD
9 - 26 ENGINEVA
CYLINDER HEAD (Continued)

CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way crankshaft bear-
ing caps fit.
(5) Unbolt crankshaft bearing caps (Fig. 28).
(6) Inspect crankshaft bearing caps and bolts for
wear and stretching.
(7) Remove crankshaft.
INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.CAUTION: Oil grooves in the thrust washers must
point toward the thrust collars of the crankshaft.
CAUTION: Thrust washers in the bearing cap each
have two retaining lugs as a anti-twist lock.
CAUTION: Oil thread and head contact surfaces of
bolts that retain the crankshaft bearing caps;
tighten bolts from inside to outside, beginning at
the fit bearing. Rotate crankshaft to check clear-
ance.
(1) Install crankshaft.
CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way the crankshaft
bearing caps fit.
(2) Install the crankshaft bearing caps. Tighten
bolts in two stages. 55N´m (40.5 lbs. ft.), then 90É.
(3) Install the pistons (Refer to 9 - ENGINE/EN-
GINE BLOCK/PISTON & CONNECTING ROD -
INSTALLATION).
(4) Install the end cover (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
(5) Install the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to the owners manual for
specifications.
(8) Fill the cooling system with the proper coolant,
to the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(9) Connect the 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.
(10) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
Fig. 28 CRANKSHAFT ASSEMBLY
1 - BEARING HALVES IN ENGINE BLOCK
2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
7 - MAIN BEARING BOLTS
9 - 36 ENGINEVA
CRANKSHAFT (Continued)