2005 MERCEDES-BENZ SPRINTER Fluid

BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball
joints/tie rod ends).3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
VASTEERING 19 - 3
STEERING (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION..........................8
REMOVAL.............................8INSTALLATION..........................8
SPECIFICATIONS - TORQUE CHART.........9
GEAR
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part
of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa-
rate the tie rods from the steering knuckles (Fig. 2)
using special tool C-3894±A.
(6) Remove the left outer tie rod end from the
steering gear.(7) Remove both spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).
(8) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from
the steering gear (Fig. 2).
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.
INSTALLATION
(1) Install the gear to the vehicle.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR REMOVAL / INSTALL
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
19 - 8 GEARVA

NOTE: Steering gear must be torqued in a three
step procedure below.
(2) Install the steering gear bolts (Fig. 2). Tighten
to an initial torque of 25 N´m (18 ft. lbs.) Then
torque to 45 N´m (33 ft. lbs.) and a final additional
90É turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N´m (18 ft. lbs.).
(4) Install both the power steering hoses to the
steering gear (Fig. 2). Tighten the high pressure hose
to 37 N´m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).(6) Install the left outer tie rod end to the steering
gear.
(7) Install both the outer tie rod ends to the steer-
ing knuckle (Fig. 2). Tighten to 130 N´m (96 ft. lbs.).
(8) Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
U-Joint To Steering Gear 24 18 212
High Pressure Hose To
Steering Gear37 27 328
Return Line To Steering
Gear37 27 328
Steering Gear To Frame
Initial Torque25 18 221
Steering Gear To Frame
Second Torque
Then additional 90É turn45 33 398
VAGEAR 19 - 9
GEAR (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)

(5) Install the fan bracket bolts to the radiator
(Fig. 2).
(6) Install the core support bolts and reconnect the
hood latch cable.
(7) Install the right headlight assembly.
(8) Install the bolt for the turbo shield at the core
support.
(9) Install the radiator clips.
(10) Install the return lines to the cooler tube.
(11) Install the left headlight assembly.
(12) Install the grille assembly (Refer to 23 -
BODY/EXTERIOR/GRILLE - INSTALLATION).
(13) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Disconnect the pressure hose at the pump.
(3) Disconnect the pressure hose at the steering
gear.
(4) Remove the pressure hose mounting bracket
from the gear.
(5) Remove the pressure hose from the vehicle.
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Disconnect the return line at the pump.
(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(4) Remove the left headlight assembly.
(5) Disconnect the return line at the cooler tube.
(6) Remove the return line from the vehicle.
REMOVAL - RETURN HOSE FROM GEAR TO
COOLER TUBE
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Disconnect the return hose from the gear.(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(4) Remove the left headlight assembly.
(5) Disconnect the return line at the cooler tube.
(6) Remove the return line from the vehicle.
INSTALLATION
INSTALLATION - PRESSURE HOSE
(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the steering
gear. Tighten to 37 N´m (27 ft.lbs.).
(3) Install the pressure hose mounting bracket to
the steering gear.
(4) Reconnect the pressure hose at the power
steering pump. Tighten to 38 N´m (28 ft.lbs.).
(5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
INSTALLATION - RETURN LINE FROM PUMP
TO COOLER TUBE
(1) Install the return line to the vehicle.
(2) Reconnect the return line at the cooler tube.
(3) Install the left headlight assembly.
(4) Install the grille assembly (Refer to 23 - BODY/
EXTERIOR/GRILLE - INSTALLATION).
(5) Reconnect the return line at the power steering
pump.
(6) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
INSTALLATION - RETURN HOSE FROM GEAR
TO COOLER TUBE
(1) Install the return line to the vehicle.
(2) Reconnect the return line at the cooler tube.
(3) Install the left headlight assembly.
(4) Install the grille assembly (Refer to 23 - BODY/
EXTERIOR/GRILLE - INSTALLATION).
(5) Reconnect the return line at the power steering
gear.
(6) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD
PROCEDURE).
VAPUMP 19 - 15
FLUID COOLER TUBE (Continued)

TRANSMISSION
AUTOMATIC TRANSMISSION - NAG1
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - NAG1
DESCRIPTION..........................2
OPERATION............................4
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION......................23
DIAGNOSIS AND TESTING - PRELIMINARY . 23
DIAGNOSIS AND TESTING - ROAD
TESTING............................23
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION......................24
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR......................27
REMOVAL.............................27
DISASSEMBLY.........................30
ASSEMBLY............................34
INSTALLATION.........................41
SCHEMATICS AND DIAGRAMS............47
SPECIFICATIONS - NAG1 AUTOMATIC
TRANSMISSION......................68
SPECIAL TOOLS - NAG1 AUTOMATIC
TRANSMISSION......................69
DRIVING CLUTCHES
DESCRIPTION.........................72
OPERATION...........................72
DRIVING CLUTCH K1
DISASSEMBLY.........................74
ASSEMBLY............................75
DRIVING CLUTCH K2
DISASSEMBLY.........................76
ASSEMBLY............................78
DRIVING CLUTCH K3
DISASSEMBLY.........................80
ASSEMBLY............................80
ELECTROHYDRAULIC UNIT
DESCRIPTION.........................82
OPERATION...........................87
REMOVAL.............................92
DISASSEMBLY.........................92
ASSEMBLY............................95
INSTALLATION........................100
FLUID AND FILTER
DESCRIPTION........................101
OPERATION..........................101DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............102
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................102
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................102
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECK OIL
LEVEL.............................102
STANDARD PROCEDURE - TRANSMISSION
FILL...............................103
STANDARD PROCEDURE - FLUID/FILTER
SERVICE...........................104
FREEWHEELING CLUTCH
DESCRIPTION........................105
OPERATION..........................105
DISASSEMBLY........................106
ASSEMBLY...........................107
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................109
REMOVAL............................109
INSTALLATION........................109
HOLDING CLUTCHES
DESCRIPTION........................111
OPERATION..........................112
HOLDING CLUTCH B1
DISASSEMBLY........................112
ASSEMBLY...........................113
HOLDING CLUTCH B2
DISASSEMBLY........................115
ASSEMBLY...........................116
INPUT SPEED SENSORS
DESCRIPTION........................119
OPERATION..........................119
OIL PUMP
DESCRIPTION........................120
OPERATION..........................120
DISASSEMBLY........................120
ASSEMBLY...........................121
OUTPUT SHAFT BEARING
REMOVAL............................122
INSTALLATION........................122
VATRANSMISSION 21 - 1