2005 MERCEDES-BENZ SPRINTER Service Repair Manual

FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: M6x90 bolts must be used with retaining
lock to prevent damage to rear end cover.
(2) Install retaining lock for crankshaft/starter
ring gear.
NOTE: Flywheel does not need balancing or should
it be interchanged.
(3) Remove flywheel with both inner and outer
washers (Fig. 31).
INSTALLATION
INSTALLATION
NOTE: A flex rod torque wrench must not be used
in order to avoid angle errors when tightening to
degrees.
(1) Align flywheel and inner and outer washers
with straight pin. Tighten bolts in two stages. 45N´m
(33 lbs. ft.) then 90É.
(2) Remove the retaining lock from the crankshaft/
starter ring gear.
(3) Install transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - W5J400 -
INSTALLATION).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. 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.
(5) Start the vehicle.
INSTALLATION
(1) Raise and support the vehicle.
(2) Remove the generator wiring harness duct at
the crankcase and set aside.
(3) Remove inspection cover (Fig. 32).
(4) Remove the bolts (Fig. 32).
(5) Insert the crankshaft lock #8932 into the
starter ring gear and install the retaining bolts.
Tighten the lock bolts to 9 N´m (80 lbs. in.) (Fig. 32).
Fig. 31 FLYWHEEL ASSEMBLY
1 - SPECIAL TOOL #8932 CRANKSHAFT LOCK
2 - RETAINING BOLTS
3 - ALIGNMENT PIN
4 - WASHER
5 - FLYWHEEL
6 - FLYWHEEL
7 - FLYWHEEL BOLT
VAENGINE 9 - 39

PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 33).
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS
NOTE: Connecting rods with blue discoloration,
cross scores or notches must be replaced. Com-
pensate for different weights by milling off the bal-
ancing weight.
(1) Inspect connecting rod for discoloring, cross
scores and notches.NOTE: Connecting rod and bearing cap are marked
in sets and attached with two sleeves.
(2) Bolt connecting rod bearing cap to connecting
rod. Tighten connecting rod bearing caps to initial
specification (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON & CONNECTING ROD - INSTALLATION).
NOTE: If the maximum permissible diameter is
exceeded, grind off contact surface of connecting
rod bearing cap by a Maximum of 0.02mm.
(3) Using a dial indicator, measure connecting rod
bearing basic bore, repair as necessary (Fig. 34).
NOTE: If excessive wear is present, press in new
connecting rod bushings.
(4) Measure connecting rod bushing inner diame-
ter (Fig. 34).
(5) Inspect wristpin bushing.
(6) Measure piston pin end play in connecting rod
bushing.
Fig. 32 CRANKSHAFT LOCK #8932
1 - RETAINING BOLTS 3 - CRANKSHAFT LOCK #8932
2 - INSPECTION COVER 4 - RETAINING BOLTS
9 - 40 ENGINEVA
FLYWHEEL (Continued)

(7) Measure peak to valley height of connecting
rod bushing on inside.
Fig. 33 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 34 MEASURING CONNECTING RODS
VAENGINE 9 - 41
PISTON & CONNECTING ROD (Continued)

CONNECTING ROD SPECIFICATIONS
Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Width of connecting rod
bearing bore at
connecting rod bushing
bore21.940 mm to 22 mm
Connecting rod bearing
shell basic bore51.600 mm to 51.614
mm
Allowable out-of-
roundness and taper of
basic bore.020 mm
Allowable twist of
connecting rod bearing
bore to connecting rod
bushing bore over a
length of 100 mm.100 mm
Allowable variation of
axial parallelism of
connecting rod bearing
bore to connecting rod
bushing bore over a
length of 100 mm.045 mm
Allowable difference in
weight of complete
connecting rod of an
engine2g
Connecting rod inner
bushing30.018 to 30.024 mm
Connecting rod outer
bushing32.575 mm to 32.600
mm
Connecting rod basic
bore32.500 mm to 32.525
mm
Piston pin play in
connecting rod.018 mm to .024 mm
Peak-to-Valley height
(Rz) of connecting rod
bushing on inside5
Connecting rod bolt
threadM8x1
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION
After replacing the pistons/connecting rods or
machining the engine block contact surface, it is then
necessary to measure the piston protrusion.
Measure protrusion between piston crown and cyl-
inder head contact surface without the head gasket
installed. The measurment must be carried out inthe direction of the piston pin in order to eliminate
piston rock.
(1) Measure piston protrusion at the two measur-
ing points (arrows) (Fig. 35).
Piston protrusion with new crankcase should be
0.38 - 0.62 mm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Push back on the chain tensioner and remove
the oil pump chain from the oil pump.
(6) Remove the oil pump.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side.
(7) Remove the connecting rod bearing cap.
Fig. 35 MEASURING PISTON PROTRUSION
1 - PISTON PROTRUSION MEASUREMENT
9 - 42 ENGINEVA
PISTON & CONNECTING ROD (Continued)

NOTE: Do Not mix up the top and bottom connect-
ing rod bearing shells.
(8) Mark the connecting rod bearing shell and the
connecting rod bearing cap to each other.
NOTE: If the pistons are used, the direction of
travel arrows and the marking of the pistons may
no longer be visible because of carbon deposits.
The carbon deposits on the pistons must be
removed.
NOTE: If the arrows indicating the driving direction
on the piston are no longer visible, they must be
marked again.
(9) Remove the connecting rod together with the
piston through the top of the engine.NOTE: DO NOT mix up the top and bottom connect-
ing rod bearing shells.
(10) Mark the connecting rod bearing shell and
connecting rod to each other.
CAUTION: Care must be taken not to damage the
piston.
(11) Remove the piston pin circle clip. (Fig. 36).
(12) Press the piston pin out of the piston and con-
necting rod bushing. (Fig. 36).
(13) Inspect the connecting rod for wear and dam-
age.
INSTALLATION
(1) Assign piston to the cylinder bore.
(2) Using the appropriate clean engine oil, oil pis-
ton pin and connecting rod bushing.
Fig. 36 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN CIRCLIP
2 - PISTON PIN
3 - PISTON ASSEMBLY
4 - CONNECTING ROD AND CAP ALIGNMENT MARKS5 - CONNECTING ROD CAP
6 - CONNECTING ROD BOLTS
7 - ENGINE BLOCK
VAENGINE 9 - 43
PISTON & CONNECTING ROD (Continued)

CAUTION: Assemble the piston and connecting rod
so that the arrow is pointing in the direction of
travel (in the opposite direction of power flow). The
marking on the connecting rod is pointing toward
the inlet side.
(3) Assemble piston and connecting rod (Fig. 37).
(4) Insert piston pin by hand (Fig. 37).
CAUTION: Care must be taken not to damage the
piston.
(5) Insert circle clip of piston pin into groove on
piston (Fig. 37).
(6) Using the appropriate clean engine oil, clean
the cylinder bores, connecting rod bearing journals,
connecting rod bearing shells and pistons.
CAUTION: Offset the piston ring gaps by 120É.
(7) Position a ring compressor over piston and
rings. Tighten ring compressor (Fig. 38).Ensure that
ring position does not change during this oper-
ation.
CAUTION: Rotate the crankshaft sufficiently so that
the connecting rod does not touch the connectingrod journal when the piston is pushed onto the cyl-
inder bore.
(8) Install piston with arrow pointing in the direc-
tion of travel (in the opposite direction to power flow)
(the marking on the connecting rod should be point-
ing toward the inlet side). (Fig. 38).
(9) Clean and inspect the connecting rod bolts.
CAUTION: Assure that the correct top and bottom
connecting rod bearings shells are used in accor-
dance with the markings.
CAUTION: The anti-twist locks of the connecting
rod bearing shells must be located in the slots of
the connecting rod bearing caps.
(10) Insert connecting rod bearing shell into con-
necting rod bearing cap.
CAUTION: The markings on the connecting rod and
connecting rod cap must be lined up.
(11) Install connecting rod bearing cap. Tighten
bolts in 3 stages, 5N´m (44 lbs in), 25N´m (221 lbs
in), 90É.
(12) Rotate crankshaft fully and check the clear-
ance.
(13) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(14) Install engine oil pan and oil pan drain plug
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
CAUTION: Install a cylinder head gasket of standard
thickness or a cylinder head gasket of repair thick-
ness depending on piston protrusion.
(15) Measure piston protrusion (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
(16) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(17) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(18) Fill the crankcase with correct engine oil, to
proper level. Refer to owners manual for specifica-
tions.
(19) Fill the cooing system with proper coolant, to
the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(20) 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.
Fig. 37 PISTON AND CONNECTING ROD ASSEMBLY
1 - CIRCLE CLIP
2 - PISTON PIN
3 - PISTON ASSEMBLY
4 - CONNECTING ROD ALIGNMENT MARKINGS
5 - CONNECTING ROD BOLTS
6 - CONNECTING ROD CAP
7 - CONNECTING ROD
9 - 44 ENGINEVA
PISTON & CONNECTING ROD (Continued)

WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).(21) Start the engine and inspect for leaks.
Fig. 38 PISTON AND CONNECTING ROD INSTALLATION
1 - PISTON RING COMPRESSOR
2 - WOOD HAMMER HANDLE
3 - CONNECTING ROD ALIGNMENT MARKINGS
4 - CONNECTING ROD BOLTS
5 - CONNECTING ROD CAP6 - CONNECTING ROD
7 - CIRCLE CLIP
8 - PISTON PIN
9 - PISTON ASSEMBLY
VAENGINE 9 - 45
PISTON & CONNECTING ROD (Continued)

PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Carefully clean the carbon from all ring
grooves. Oil drain openings in the oil ring groove and
pin boss must be clear. DO NOT remove metal from
the grooves or lands. This will change ring-to-groove
clearances and will damage the ring-to-land seating.
(2) Be sure the piston ring grooves are free of
nicks and burrs.
(3) Measure the ring side clearance with a feeler
gauge fitted snugly between the ring land and ring
(Fig. 39). Rotate the ring in the groove. It must move
freely around circumference of the groove.
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.012 - 0.016 mm
(0.0047 - 0.0063 in.)
Second Compression
Ring0.05 - 0.09 mm
(0.0019 - 0.0035 in.)
Oil Control Ring 0.03 - 0.07 mm
(0.0011 - 0.0027 in.)(4) Place ring in the cylinder bore and push down
with inverted piston to position near lower end of the
ring travel. Measure ring gap with a feeler gauge fit-
ting snugly between ring ends (Fig. 40).
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression
Ring0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
(5) The oil control rings are symmetrical, and can
be installed with either side up. It is not necessary to
use a tool to install the upper and lower rails. Insert
oil rail spacer first, then side rails.
(6) Using a ring expander, install compression
rings with manufactures designation pointing toward
piston crown (Fig. 41).
Ring Gap Orientation
²Position the gaps on the piston as shown (Fig.
42).
²Oil spacer - Gap on center line of piston skirt.
²Oil rails - gap 180É apart on centerline of piston
pin bore.
²No. 2 Compression ring - Gap 120É from top oil
rail gap.
Fig. 39 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 40 Ring
1 - FEELER GAUGE
9 - 46 ENGINEVA