2005 MERCEDES-BENZ SPRINTER check engine

INSTALLATION
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Remov-
al/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines.
(6) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(7) Install and position both fuel tank support
straps to mounting studs.
(8) Install 2 fuel tank strap nuts. Refer to Torque
Specifications.
(9) Remove hydraulic jack.
(10) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump isnot usedin the fuel tank
module for diesel powered engines. Fuel is supplied
to the fuel injection pump by the fuel transfer (lift)
pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 9). The fuel tank module contains the
following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connection
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
(3) Disconnect both fuel lines from tank module
fittings.
Fig. 8 FUEL TANK ASSEMBLY
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
Fig. 9 FUEL TANK MODULE
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
VAFUEL DELIVERY 14 - 13
FUEL TANK (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 12
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....12
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............13
REMOVAL.............................13
INSTALLATION.........................13
SPECIFICATIONS - TORQUE CHART........14
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE........................14FLUID COOLER TUBE
REMOVAL.............................14
INSTALLATION.........................14
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE...........15
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE.......................15
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE....................15
INSTALLATION
INSTALLATION - PRESSURE HOSE.......15
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE...............15
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE...............15
PUMP
DESCRIPTION
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
19 - 12 PUMPVA

Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4)
Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4)
Remove the return hose from the pump (Fig. 1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5)
Fill the power steering fluid (Refer to 19 - STEER-
ING/PUMP/FLUID - STANDARD PROCEDURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
VAPUMP 19 - 13
PUMP (Continued)

SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pump To
Timing Case Cover/
Support21 15 185
High Pressure Flexible
Hose To Power Steering
Pump38 28 336
Power Steering Pulley To
Pump30 22 265
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE
(1) Remove the cap from the fluid reservoir.
Check cap seal for damage and replace if
needed.
(2) Fill the power steering pump with Mopar
ATF+4 Automatic Transmission fluid or equivalent.
Do not fill fluid beyond the MAX mark.
(3) Raise the vehicles front wheels off the ground.
(4) With the engine off turn the steering wheel
from right to left.Perform this step until all the
bubble formations can no longer be seen in the
power steering reservoir.
(5) Start the engine and turn the steering wheel
with the engine at idle speed then shut the engine off
and check for correct oil level and no bubble in the
system.
(6) Reinstall power steering cap tightly.
(7) Test the system for leaks and proper operation.
FLUID COOLER TUBE
REMOVAL
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(3) Remove the left headlight assembly.
(4) Disconnect the return lines from the cooler
tube.
(5) Remove the radiator clips (2).
(6) Remove the heat shield bolt for the turbo at
the core support.
(7) Remove the right headlight assembly.(8) Remove the core support bolts (4) and discon-
nect the hood latch cable.
(9) Remove the fan bracket bolts (4) to the radiator
(Fig. 2).
(10) Remove the two upper screws for the con-
denser (Fig. 2).
(11) Remove the condenser air dam shield.
(12) Remove the mounting screws for the cooler
tube (Fig. 2).
(13) Remove the cooler tube from the vehicle.
INSTALLATION
(1) Install the cooler tube to the vehicle.
(2) Install the cooler tube mounting screws (Fig.
2).
(3) Install the condenser air dam shield.
(4) Install the condenser upper mounting screws
(Fig. 2).
Fig. 2 FLUID COOLER TUBE
1 - MOUNTING SCREWS (4)
2 - FLUID COOLER
3 - ELECTRIC COOLING FAN
4 - A/C CONDENSOR
19 - 14 PUMPVA
PUMP (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on a NAG1
automatic transmission, check for Diagnostic Trou-
ble Codes with the DRBTscan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance.
²Improper adjustments.
²Hydraulic malfunctions.
²Mechanical malfunctions.
²Electronic malfunctions.
²Transfer case performance.
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce-
dure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using DRBt
scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
VEHICLE IS DISABLED
(1) Check fluid level and condition.(2) Check for broken or disconnected gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged driveplate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis-
sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
ble codes have been resolved.
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analy-
sis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, overrunning clutch, or line pressure problems.
A slipping clutch can often be determined by com-
paring which internal units are applied in the vari-
ous gear ranges. The Clutch Application chart
CLUTCH APPLICATION provides a basis for analyz-
ing road test results.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
NX X
R 3.16 X* X X X
* = The shift components required during coast.
VAAUTOMATIC TRANSMISSION - NAG1 21 - 23
AUTOMATIC TRANSMISSION - NAG1 (Continued)

DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION
CONDITION POSSIBLE CAUSES CORRECTION
MAXIMUM SPEED 30 km/h 1. Speed Control 30 Actuated. 1. Instruct Customer.
ENGINE DIES WHEN
TRANSMISSION IS
SHIFTED INTO GEAR,
ALSO NOISES IN N
AND/OR P1. PWM Valve Blocked. 1. Replace Valve.
2. Torque Converter Lock Up Control
Valve Locked.2. Enable Movement of Valve,
Remove Particle.
LEVER IN9P9POSITION
BLOCKED (BRAKE
ACTIVATED)1. No Vacuum Brake Booster After
Long Immobilization, Brake Pedal
Not Fully Applied/Hard Pedal.1. Check Vacuum/ Tightness of
Brake Booster.
2. No Stoplamp Switch Signal (no
DTC IN ECM).2. Check Contact to Stoplamp
Switch. Replace Switch if
Necessary.
GRUMBLING, DRONING,
JERKING WHEN TCC IS
ENGAGED1. Slip Speed TCC to Low. 1. Switch Off Torque Converter
Lock Up Using DRBT.If
Complaint Is Not Reproduced
Afterwards, Replace PWM
Valve, Set Adaption Values to
Zero.
HOWLING, HUMMING
ABOVE 4000 RPM IN
EACH GEAR1. Oil Filter Blocked. 1. Replace Oil Filter.
2. Oil Pump. 2. Replace Oil Pump.
WHINING, SINGING 1. Gear Set Noises in 1st, 2nd, 5th
Gear.1. Replace Transmission..
2. Intermediate Bearing Of The Drive
Shaft At 0 km/h, Only When Cold.2. Replace Intermediate
Bearing of the Drive Shaft.
9CLACK9NOISE FROM
CENTER SHIFT AREA
WHEN STOPPING OR
STARTING1. Park Lock Solenoid. 1. Replace Shift Lever
Assembly.
CRACKING NOISE WHEN
LOAD CYCLE1. Stick - Slip Between Joint Flange
and Collar Nut.1. Install Zinc Coated Collar Nut
Together With Washer.
CHATTERING IN CENTER
CONSOLE SHIFT WHILE
ACCELERATING1. Bushing Shift Shaft Has Too Much
Clearance.1. Replace Shifter Lever and
Cover Plate.
HARD 2-3 UPSHIFT WHEN
STEPPING OFF THE
ACCELERATOR PEDAL1. Response Characteristic Control
Loop.1. Install K2 Disc Spring.
UPSHIFT 2-3, 3-4
SLIPPING1. Spring of Regulating Valve
Pressure control Valve Broken.1. Replace Spring.
HARD 2-1 DOWNSHIFT
WHEN COMING TO A
STOP1. Transmission (2-1 downshift) Not
Adapted.1. Re-adapt Transmission.
2. TCM Software Data. 2. Flash TCM.
3. Free Wheeling Clutch F1
Defective.Replace Free Wheeling Clutch
F1.
21 - 24 AUTOMATIC TRANSMISSION - NAG1VA
AUTOMATIC TRANSMISSION - NAG1 (Continued)

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.
VAAUTOMATIC TRANSMISSION - NAG1 21 - 25
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)