2005 MERCEDES-BENZ SPRINTER timing belt

COOLING
TABLE OF CONTENTS
page page
COOLING
OPERATIONÐCOOLING SYSTEM...........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS.............................1DIAGNOSIS AND TESTING - COOLING
SYSTEM.............................2
ACCESSORY DRIVE.......................5
ENGINE................................9
COOLING
OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
VACOOLING 7 - 1

LEFT MOUNT
REMOVAL.............................49
INSTALLATION.........................49
RIGHT MOUNT
REMOVAL.............................49
INSTALLATION.........................49
OIL
REMOVAL - OIL SEPARATOR..............50
INSTALLATION - OIL SEPARATOR..........50
OIL COOLER & LINES
REMOVAL.............................50
INSTALLATION.........................50
OIL FILTER
REMOVAL.............................51
INSTALLATION.........................51
OIL JET
DESCRIPTION.........................51
REMOVAL.............................51
INSTALLATION.........................51
OIL PAN
REMOVAL.............................52
INSTALLATION.........................52
OIL PUMP
REMOVAL
REMOVAL...........................53
REMOVAL- OIL PUMP CHAIN............53
INSTALLATION
INSTALLATION.......................54
INSTALLATION - OIL PUMP CHAIN........54
OIL TEMPERATURE SENSOR
DESCRIPTION.........................56OPERATION...........................56
REMOVAL.............................57
INSTALLATION.........................57
INTAKE MANIFOLD
REMOVAL.............................57
INSTALLATION.........................58
EXHAUST MANIFOLD
REMOVAL.............................59
INSTALLATION.........................59
TIMING CHAIN COVER
REMOVAL.............................59
INSTALLATION.........................60
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE
RAILS..............................61
REMOVAL - INTERMEDIATE GEAR........61
REMOVAL - TIMING CHAIN TENSIONING
RAIL...............................63
REMOVAL - TIMING CHAIN..............63
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE
RAIL...............................66
INSTALLATION - INTERMEDIATE GEAR....66
INSTALLATION - TIMING CHAIN
TENSIONING RAIL....................66
ADJUSTMENTS
INSTALLATION - TIMING CHAIN..........67
TIMING CHAIN TENSIONER
REMOVAL.............................70
INSTALLATION.........................71
ENGINE
DESCRIPTION
This 2.7 Liter five-cylinder Common Rail Diesel
Injection (CDI) engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has for valve per cylinder and dual overhead
camshafts (Fig. 1).
Fig. 1 2.7L CDI Engine
9 - 2 ENGINEVA

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)

(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)

WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLE IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING 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.
(6) Remove low pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(7) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(8) Remove bolts attaching front cover.
NOTE: Lower portion of front cover is sealed with
RTV sealant. Carefully tug at front cover until it
loosens from cylinder head.
(9) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 15).NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
REMOVAL - CYLINDER HEAD GUIDE RAIL
(1) Disconnect negative battery cable.
CAUTION: Rotate engine at crankshaft only. DO
NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine back.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove engine cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
Fig. 15 CYLINDER HEAD FRONT COVER
1 - TOP GUIDE RAIL
2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN
5 - CYLINDER HEAD FRONT COVER6 - SEAL
7 - TIMING CHAIN TENSIONER
8 - LOW PRESSURE PUMP
9 - VACUUM PUMP
9 - 24 ENGINEVA
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)