2006 MERCEDES-BENZ SPRINTER Service Manual

bonnet navigation system fuses length trunk release transmission oil

Page 793 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual As the dragging brake overheats, efficiency is so
reduced that fade occurs. Since the opposite brake
unit is still functioning normally, its braking effect is
magnified. This causes pull to switch dir

As the dragging brake overheats, efficiency is so
reduced that fade occurs. Since the opposite brake
unit is still functioning normally, its braking effect is
magnified. This causes pull to switch direction in
favor of the normally functioning brake unit.
An additional point when diagnosing a change in
pull condition concerns brake cool down. Remember
that pull will return to the original direction, if the
dragging brake unit is allowed to cool down (and is
not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pull is usually caused by improperly
adjusted or seized parking brake cables, contami-
nated lining, bent or binding shoes and support
plates, or improperly assembled components. This is
particularly true when only one rear wheel is
involved. However, when both rear wheels are
affected, the master cylinder or proportioning valve
could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
This condition is generally caused by water soaked
lining. If the lining is only wet, it can be dried by
driving with the brakes very lightly applied for a
mile or two. However, if the lining is both soaked and
dirt contaminated, cleaning and/or replacement will
be necessary.
BRAKE LINING CONTAMINATION
Brake lining contamination is mostly a product of
leaking calipers or worn seals, driving through deep
water puddles, or lining that has become covered
with grease and grit during repair. Contaminated lin-
ing should be replaced to avoid further brake prob-
lems.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
produce a grab-like condition as the tire loses and
recovers traction. Flat-spotted tires can cause vibra-
tion and generate shudder during brake operation. A
tire with internal damage such as a severe bruise,
cut, or ply separation can cause pull and vibration.
BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfacesafter a few brake applications causing the noise to
subside.
BRAKE SQUEAK / SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material
embedded in the brake lining will also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brake pads in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors can become so scored that replacement is nec-
essary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP / CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use approved brake fluid (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES - DESCRIP-
TION). Use fresh, clean fluid from a sealed container
at all times.
(1) Remove reservoir filler caps and fill reservoir.
(2) If calipers, or wheel cylinders were overhauled,
open all caliper and wheel cylinder bleed screws.
Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more
before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
5 - 4 BRAKES - BASEVA

Page 794 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down closethe bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
whee

Page 795 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual DESCRIPTION N´m Ft. Lbs. In. Lbs.
Booster To Pedal Bracket 25 Ð 221
Brake Caliper Guide Pins
M8 Bolt25 Ð 221
Brake Caliper Guide Pins
M10 Bolt30 Ð 266
ALB Operating Linkage
Lever To The Rear Axle3

Page 796 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual DESCRIPTION SPECIFICATION
Rear Disc Brake Rotor
Max. Lateral Runout
Models 690.611/63/64,
903.1 mm (0.0007 in.)
Rear Disc Brake Rotor
Max. Axial Runout
Models 690.611/63/64,
9030.02 mm (0.0007 in.)
Re

Page 797 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency rep

BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.
To make a ISO flare use an ISO flaring tool kit.
(1) Cut off damaged tube with Tubing Cutter.
(2) Remove any burrs from the inside of the tube.
(3) Install tube nut on the tube.
(4) Position the tube in the flaring tool flush with
the top of the tool bar (Fig. 2). Then tighten the tool
bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube
(Fig. 2).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steeltube can be used for emergency repair when factory
replacement parts are not readily available.
(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on the tube.
(4) Insert tube in flaring tool.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter.
(7) Tighten the tool bar on the tube
(8) Insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar-
ing screw in recess of compression disc (Fig. 3).
(9) Tighten tool handle until plug gauge is
squarely seated on jaws of flaring tool. This will start
the inverted flare.
(10) Remove the plug gauge and complete the
inverted flare.
BRAKE PADS / SHOES
REMOVAL
REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 4).
Fig. 2 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 3 Inverted Flare Tools
5 - 8 BRAKES - BASEVA

Page 798 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.
(5) Remove the brake caliper guide bolt (Fig. 4).
(6) Remove the brake

Page 799 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual REMOVAL - REAR (15º WHEELS) (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION)

Page 800 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the brake pads (Fig. 4).
(2) Install the wear indicator cable and the wear
indicator (Fig. 4). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not instal

INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the brake pads (Fig. 4).
(2) Install the wear indicator cable and the wear
indicator (Fig. 4). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to the brake caliper
adapter (Fig. 4). Tighten the guide bolt to 25 N´m
(221 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - FRONT (DRW)
(1) Install the brake pads (Fig. 5).
(2) Install the wear indicator cable and the wear
indicator (Fig. 5). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to the brake caliper
adapter (Fig. 5). Tighten the guide bolt to 25 N´m
(221 in. lbs.)(M8 bolt) or Tighten the guide bolt to 30
N´m (265 in. lbs.)(M10 10.9 bolt).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the front wheels.
(7) Lower the vehicle.
INSTALLATION - REAR (16º WHEELS) (SRW)
(1) Install the brake pads (Fig. 6).
(2) Install the wear indicator cable and the wear
indicator (Fig. 6). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 6). Tighten the guide pins to 25 N´m
(221 in. lbs.) for M8 bolt or 30 N´m (266 in. lbs.) for
M10 bolt.
(4) Install the retaining spring (Fig. 6).
(5) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
INSTALLATION - REAR (16º WHEELS) (SRW)
(1) Install the brake pads (Fig. 7).
(2) Install the wear indicator cable and the wear
indicator (Fig. 7). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 7). Tighten the guide pin to 30 N´m
(266 in. lbs.) for M10 bolt.
(4) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
INSTALLATION - REAR (DRW)
(1) Install the brake pads (Fig. 8).
(2) Install the wear indicator cable and the wear
indicator (Fig. 8). Tighten to 10 N´m (89 in. lbs.).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
(3) Install the brake caliper to brake caliper
adapter (Fig. 8). Tighten the guide pins to 25 N´m
(221 in. lbs.) for M8 bolt or 30 N´m (266 in. lbs.) for
M10 10.9 bolt.
(4) Install the retaining spring (Fig. 8).
(5) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
Fig. 8 REAR DISC BRAKE PADS WITH DUAL REAR
WHEELS
1 - WEAR INDICATOR
2 - GUIDE PIN/BOLT
3 - DISC BRAKE CALIPER
4 - RETAINING SPRING
5 - DISC BRAKE PADS
6 - CALIPER ADAPTER
VABRAKES - BASE 5 - 11

Load next 8 pages

Page: < prev 1-10 ... 761-768 769-776 777-784 785-792 793-800 801-808 809-816 817-824 825-832 ... 2312 next >

battery location wiper blades service clock setting seats low oil pressure