2005 MERCEDES-BENZ SPRINTER Service Repair Manual

²No. 1 Compression ring - Gap 120É from No. 2
compression ring gap.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Install retaining lock for crankshaft/ring gear
(Fig. 43).
(4) Remove crankshaft center bolt and washer
(Fig. 43).
NOTE: If hub of belt pulley/vibration damper is
tight, use puller # 8940 to remove. DO NOT tilt
puller when in use. Grooves of the puller must
mesh fully into the slots of the belt pulley.
(5) Remove the belt pulley/vibration damper (Fig.
43).
Fig. 41 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 42 Ring Gap Orientation
1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRTFig. 43 VIBRATION DAMPER/CRANKSHAFT PULLEY
1 - SPECIAL TOOL #8932
2 - RETAINING BOLTS
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY
4 - WASHER
5 - CRANKSHAFT BOLT
VAENGINE 9 - 47
PISTON RINGS (Continued)

NOTE: If grooves can be felt in the belt pulley/vibra-
tion damper during inspection, the pulley/damper
must be replaced.
(6) Inspect hub at belt pulley/vibration damper for
wear grooves.
(7) Replace front crankshaft seal.
INSTALLATION
NOTE: Align parallel key, fix in place with grease.
Turn to ensure the slot is aligned with parallel key
in crankshaft.
NOTE: Front crankshaft seal must be replaced
before installing the belt pulley/vibration damper.
(1) Position the belt pulley/vibration damper.
(2) Install crankshaft center bolt and washer.
Tighten bolt in two stages. M8.8 bolt to 200N´m (148
lbs. ft.) then 90É, M10.9 bolt to 325N´m (240 lbs. ft.)
then 90É.
(3) Remove the retaining lock for the crankshaft/
ring gear (Fig. 43).
NOTE: Inspect accessory drive belt for wear.
Replace as necessary.
(4) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Reconnect 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 CLOTHING.
(6) Start vehicle and inspect for leaks.
VACUUM PUMP
DESCRIPTION
The vacuum pump is operated by a slotted exten-
sion attached to the vacuum pump shaft. The vac-
uum pump shaft slotted extension fits into, and is
driven by, the exhaust camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum pump rotating components are inter-
nally lubricated.The vacuum pump is not serviceable and must be
replaced as a unit. Do not disassemble or attempt to
repair the pump.
OPERATION
Vacuum pump output is transmitted to the Heater,
Electronic, Vacuum, Air Conditioner (HEVAC) and
speed control, systems through a supply hose. The
hose is connected to an outlet port on the pump hous-
ing and uses an in-line check valve to retain system
vacuum when vehicle is not running.
Pump output ranges from a minimum of 8.5 to 25
inches vacuum.
The pump rotor and vanes are rotated by the pump
drive gear. The drive gear is operated by the exhaust
camshaft gear.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove vacuum line at vacuum pump (Fig.
44).
NOTE: Observe position of driver on rear of pump.
(3) Remove vacuum pump and seals (Fig. 44)
(4) Clean all sealing surfaces.
Fig. 44 VACUUM PUMP
1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING
4 - O-RING
5 - EXHAUST CAMSHAFT
6 - BOLTS
9 - 48 ENGINEVA
VIBRATION DAMPER (Continued)

INSTALLATION
(1) Clean all sealing surfaces.
(2) Position driver on rear of pump and install vac-
uum pump with new seals. Tighten bolts to 14N´m
(124 lbs. in.). (Fig. 44)
(3) Install vacuum line to vacuum pump (Fig. 44).
(4) 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.
(5) Start the engine and inspect for leaks.
LEFT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534±16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 45)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 45)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 45)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
45)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 45)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 45).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 45)
(7) Remove the engine support fixture and adap-
tors.
RIGHT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534-16 and raise the engine slightly.(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 46)
(4) Lower the vehicle.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 46)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 46)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
46)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 46)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 46).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 46)
Fig. 45 LEFT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - BRACKET
7 - GROUND CABLE
8 - WASHER
9 - BOLT
VAENGINE 9 - 49
VACUUM PUMP (Continued)

(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOTOPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 47).
(4) Remove the oil cooler from the timing case
cover (Fig. 47).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 47).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 47).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
Fig. 46 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
Fig. 47 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
9 - 50 ENGINEVA
RIGHT MOUNT (Continued)

OIL FILTER
REMOVAL
(1) Unscrew the oil filter cap (Fig. 48)
(2) Remove clean and inspect cap gasket, replace
as necessary.
(3) Remove oil filter (Fig. 48).
INSTALLATION
(1) Inspect oil filter cap gasket, if all right, lubri-
cate with clean engine oil.
(2) Install oil filter.
(3)
Screw oil filter cap to housing and tighten to
25N´m (18 lbs. ft.) (Fig. 48). Adjust oil level as necessary.
OIL JET
DESCRIPTION
There are five oil jets installed in the engine block
(Fig. 49). These oil jets are used to cool and lubricate
the piston assemblies.
REMOVAL
The engine must be removed from the vehicle and
completely dissassembled to replace the oil jets.
(1) Remove engine from vehicle.
(2) Completely dissassemble engine.
(3) Using an extraction claw and a slide hammer,
remove the oil jets from engine block.
INSTALLATION
(1) Install oil jet into special tool #8924.
(2) Align oil jet in location in engine block.
(3) Drive oil jets into block using special tool #8924
until oil jet is fully seated into engine block (Fig. 50).
(4) Reassemble engine.
(5) Install engine into vehicle.
Fig. 48 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
Fig. 49 OIL JET LOCATION
1 - ENGINE BLOCK
2 - OIL JET
Fig. 50 OIL JET INSTALLATION
1 - OIL JET INSTALLER #8942
2 - ENGINE BLOCK
3 - OIL JET
VAENGINE 9 - 51

OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534±16, to the engine lifting eye and
raise engine slightly.
(6) Remove engine mounts and raise engine.
(7) Disconnect the oil level sensor.
(8) Remove the transmission cooler lines from the
oil pan bolts and carefully position the lines aside
(9) Remove the oil pan bolts.
(10) Remove oil pan and gasket (Fig. 51).
INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 53).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, fill it with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Install the oil pan gasket and coat places indi-
cated with an arrow with sealant (Fig. 52).
(2) Install the oil pan. Tighten M6 bolts to 9N´m
(80 lbs. in.) and M8 bolts to 20N´m (15 lbs. ft.) (Fig.
53).
Fig. 51 OIL PAN
1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
9 - 52 ENGINEVA

(3) Tighten the bolt of the transmission bell hous-
ing to oil pan to 40N´m (30 lbs. ft.).(4) Install the wiring harness duct (Fig. 51).
(5) Install the transmission lines (Fig. 51).
(6) Connect the oil level sensor (Fig. 51).
(7) Lower the vehicle.
(8) Lower the engine until the engine mount and
engine supports make contact.
(9) Start and hand tighten the engine mount bolts.
(10) Lower the engine the rest of the way and
remove the engine support fixture.
(11) Tighten the engine mount bolts to 83 N´m (61
lbs. ft.).
(12) Install the sway bar and tighten bolts to 30
N´m (22 lbs. ft.).
(13) Refill crankcase with the proper engine oil to
the proper level. Refer to owners manual for specifi-
cation.
(14) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(15) Start the engine and inspect for leaks.
OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 51).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 51).
REMOVAL- OIL PUMP CHAIN
(1) Disconnect negative battery cable.
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
NOTE: Make sure the pin of the thrust spindle is
backed out into the thrust spindle before seating
the thrust spindle to the oil pump chain.
(4) Using special tool #8948 and thrust pin #9311,
position and fit chain seperating tool and thrust spin-
dle onto a link of the oil pump chain (Fig. 54).
(5) Screw the thrust pin in and seperate the oil
pump chain link.
Fig. 52 OIL PAN GASKET
Fig. 53 OIL PAN BOLTS
1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55
VAENGINE 9 - 53
OIL PAN (Continued)

(6) Remove pressed - out oil pump chain pin from
chain seperation tool.
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the oil pump chain is followed exactly.
Failure to do so will result in severe engine dam-
age.
INSTALLATION
INSTALLATION
NOTE: If the oil pump is dry, fill it with clean engine
oil before installation. Clean the oil pick±up tube
and strainer.
(1) Clean all sealing surfaces.
(2) Position the oil pump onto the drive chain and
reset tensioner.
(3) Install oil pump retaining bolts and tighten to
18 N´m (160 lbs. in.).
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Refill the crankcase to the appropriate level
with the proper engine oil (see owners manual).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOURHANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) Start the vehicle and inspect for leaks.
INSTALLATION - OIL PUMP CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
55).
(2) Slowly rotate crankshaft in a clockwise direc-
tion until it is possible to connect the ends of the new
and old oil pump chains.
(3) Remove assembly locking element, outer plate
and assembly link (Fig. 56).
CAUTION: Insert new riveted link from the rear.
(4) Connect ends of new oil pump chain with new
riveted link (Fig. 57).
NOTE: When assembling riveting tool, one piece is
secured by a screw and the other can move loosely
on the thrust spindle.
Fig. 54 OIL PUMP CHAIN LINK REMOVAL
1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
3 - SPECIAL TOOL #8948
Fig. 55 INSTALLING OIL PUMP CHAIN TEMPORARY
LINK
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OLD OIL PUMP CHAIN
3 - NEW OIL PUMP CHAIN
4 - TEMPORARY LINK
9 - 54 ENGINEVA
OIL PUMP (Continued)