2006 MERCEDES-BENZ SPRINTER ESP

CONDITION POSSIBLE CAUSES CORRECTION
NO UPSHIFT OF 1ST
GEAR AT TIMES1. Connector Ballast Unit. Output
Speed Sensor Loose, Incorrectly
Contacted.1. Check Connectors, Replace
Output Speed sensor If Neces-
sary.
2. Output Speed Sensor Defective 2. Replace Output Speed Sen-
sor.
LEAKAGE AT THE AREA
OF THE ELECTRICAL
PLUG TO THE CONDUC-
TOR PLATE1. Deformation O-Rings. 1. Replace O-Rings.
2. Deformation Adapter. 2.Replace Adaptor.
3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is
Not Centered In The Socket And
The O-ring Will Not Seal.3. Remove Nose Of Conductor
Plate.
4. Contacting At The Conductor
Plate Leaky. Oil In Harness, Some-
times In The Control Module.4. Replace Conductor Plate.
LEAKAGE AT THE AREA
OF BELL HOUSING/
TORQUE CONVERTER1. Bolts (Torx M6) Outer Disc Carri-
er B1.1. Clean Thread and Install the
Bolts Using Sealer.
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter
Housing.1. Clean Thread and Install the
Bolts Using Sealer.
2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.2. Install Drain Plug Correctly.
3. Weld Seam Of Torque Converter
Leaky.3. Replace Torque Converter.
4. Radial Sealing Ring Oil Pump
Defective.4. Replace Sealing Ring.
5. O-Ring Oil Pump Defective Or
Not Installed.5. Install O-Ring.
6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.6. Install Fit Bolt If Necessary.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
(1) Disconnect the negative (ground) battery cable.
CAUTION: Isolate ground lead to prevent accidental
contact.(2) Apply parking brake.
(3) Move gear selector lever to position ªNº.
(4) Remove oil drain plug (2) (Fig. 26) and drain
automatic transmission oil into a clean container.
21 - 42 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

Torque Converter Lockup Clutch Regulating Valve
The torque converter lock-up clutch regulating
valve (6) (Fig. 102) is located in the valve housing of
the electrohydraulic control module. The valve is
responsible for the hydraulic control of the torque
converter lockup clutch and distribution of the lubri-
cating oil.
Fig. 102 Torque Converter Lockup Clutch Regulating Valve
1 - TORQUE CONVERTER LOCK-UP CLUTCH
2 - TORQUE CONVERTER OUTPUT
3 - TORQUE CONVERTER INPUT
4 - LUBRICATION
5 - TORQUE CONVERTER LOCK-UP SOLENOID6 - TORQUE CONVERTER LOCK-UP CLUTCH REGULATING
VA LV E
7 - OIL COOLER
8 - LINE PRESSURE REGULATING VALVE
9 - OIL PUMP
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 107

Shift Pressure Shift Valve
When the multiple-disc brake B1 (3) is activated,
the working pressure (p-A) is applied to the end face
of the 1-2 / 4-5 shift pressure shift valve (4) (Fig. 117)
via the command valve (1). Its shift state is main-
tained during the shift phase by substituting the
shift element pressure acting on its end face (and
which is variable during the shift phase) with a cor-
responding constant pressure. When the multi-plate
clutch K1 (2) is activated, the end face of the shift
valve is unpressurized during the stationary and
shift phases, so the shift state is maintained during
the shift phase in this case too.Lubrication Pressure Regulating Valve
At the working pressure regulating valve surplus
oil is diverted to the lubrication pressure regulating
valve (1) (Fig. 118), from where the lubrication pres-
sure (p-Sm) is used in regulated amounts to supply
the transmission lubrication system including the
torque converter.
Fig. 117 Shift Pressure Shift Valve
1 - 1-2/4-5 COMMAND VALVE
2 - DRIVING CLUTCH K13 - HOLDING CLUTCH B1
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE
Fig. 118 Lubrication Pressure Regulating Valve
1 - LUBRICATION PRESSURE REGULATING VALVE
21 - 118 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

upper and lower side of the crescent (1) to the pres-
sure chamber (6) of the housing. The meshing of the
teeth prevents oil flowing from the delivery side to
the intake side. An external gear (3) is eccentrically
mounted in the pump housing. The external gear is
driven by the internal gear (4) which is connected to
the torque converter hub.
DISASSEMBLY
(1) Remove pump gears (1 and 2) (Fig. 186) from
pump housing.
(2) Remove the inner oil pump seal (1) (Fig. 187).
(3) Replace the outer oil pump O-ring (2) (Fig.
187).
INSPECTION
Before measuring any oil pump components, per-
form a thorough visual inspection of all the compo-nents. If any sign of scoring, scratches, or other
damage is seen, replace the oil pump as an assembly.
SIDE CLEARANCE
Side clearance is the difference between the thick-
ness of the pump gears and the depth of the pocket
in the pump housing. Side clearance can be mea-
sured by laying a flat plate across the mounting face
of the pump housing, and measuring the distance
between the plate and the gears.
Acceptable side clearance:
²Inner gear: 0.064 mm (0.0025 in) max
²Outer gear: 0.069 mm (0.0027 in) max
TIP CLEARANCE
Tip clearance is the difference between the tip
diameters of the gear teeth and the corresponding
diameters of the pocket in the pump housing.
Tip clearance for the inner gear can be checked by
moving the inner gear into tight mesh (2) (Fig. 188)
with the outer gear as shown. Clearance between the
ID of the crescent feature of the housing and the OD
of the teeth of the inner gear (3) should then me
measured at a point 37 mm from the corner of the
crescent (1) feature, as shown below.
Acceptable tip clearance for inner gear:
²0.85 mm (0.033 in) max
Fig. 186 Oil Pump Gears
1 - OUTER PUMP ROTOR
2 - INNER PUMP ROTOR
Fig. 187 Remove Oil Pump Seals
1 - INNER OIL SEAL
2 - OUTER OIL SEAL
Fig. 188 Oil Pump Measurement
1 - MEASURE 37MM FROM THE CORNER OF CRESCENT
2 - TIGHT MESH HERE
3 - MEASURE TIP CLEARANCE HERE
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 155

directly, which means that the solenoids must have
very high outputs to close the valves against the siz-
able flow areas and line pressures found in current
transmissions. Fast response time is also necessary
to ensure accurate control of the transmission.
The strength of the magnetic field is the primary
force that determines the speed of operation in a par-
ticular solenoid design. A stronger magnetic field will
cause the plunger to move at a greater speed than a
weaker one. There are basically two ways to increase
the force of the magnetic field:
1. Increase the amount of current applied to the
coil or
2. Increase the number of turns of wire in the coil.
The most common practice is to increase the num-
ber of turns by using thin wire that can completely
fill the available space within the solenoid housing.
The strength of the spring and the length of the
plunger also contribute to the response speed possi-
ble by a particular solenoid design.
A solenoid can also be described by the method by
which it is controlled. Some of the possibilities
include variable force, pulse-width modulated, con-
stant ON, or duty cycle. The variable force and pulse-
width modulated versions utilize similar methods to
control the current flow through the solenoid to posi-
tion the solenoid plunger at a desired position some-
where between full ON and full OFF. The constant
ON and duty cycled versions control the voltage
across the solenoid to allow either full flow or no flow
through the solenoid's valve.UPSHIFT / DOWNSHIFT SOLENOID VALVES
The solenoid valves (1) for upshifts and downshifts
(Fig. 229) are located in the shell of the electric con-
trol unit and pressed against the shift plate with a
spring.
The solenoid valves (1) initiate the upshift and
downshift procedures in the shift plate.
The solenoid valves (1) are sealed off from the
valve housing of the shift plate (5) by two O-rings (4,
6). The contact springs (8) at the solenoid valve
engage in a slot in the conductor tracks (7). The force
of the contact spring (8) ensures safe contacts.
Fig. 229 Upshift/Downshift Solenoid Valves
1 - UPSHIFT/DOWNSHIFT SOLENOID VALVE
2 - CONTACT SPRING
3 - CONDUCTOR TRACK
4 - O-RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - O-RING
7 - CONDUCTOR TRACK
8 - CONTACT SPRING
21 - 172 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

INSTRUMENT PANEL ASSEM-
BLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL)
(3) Remove glove compartment. (Refer to 23 -
BODY/INSTRUMENT PANEL/GLOVE BOX -
REMOVAL)
(4) Remove cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - REMOVAL)
(5) Remove instrument cluster. (Refer to 8 - ELEC-
TRICAL/INSTRUMENT CLUSTER - REMOVAL)(6) Remove passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
REMOVAL)
(7) Remove right and left speakers. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - REMOVAL)
(8) Remove center bezel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL CEN-
TER BEZEL - REMOVAL)
(9) Remove air conditioning push-button control
module. (Fig. 7)
(10) Twist cover lock 1/4 turn and remove Power
Distribution Center (PDC) cover. (Fig. 8)
(11) Remove nut and screws and remove steering
column shroud. (Fig. 9)
Fig. 7 HVAC CONTROL MODULE
1 - CONTROL CABLES
2 - ELECTRICAL CONNECTORS
3 - MODULE
4 - SCREWS
Fig. 8 POWER DISTRIBUTION CENTER COVER
1 - COVER LOCK
2 - COVER
VAINSTRUMENT PANEL 23 - 59

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Install the instrument panel.
NOTE: The guides on the bottom of the instrument
panel must engage in the cutouts on the left and
right next to the heater housing. (Fig. 21) (Fig. 22)(2) Route wire harness through the panel.
(3) Install and tighten 12 instrument panel screws.
(Fig. 20)
CAUTION: The position of the steering gear must
not be altered.
(4) Raise steering column into position and install
the bolts. (Fig. 19)
(5) Tighten steering column bolts to 25 N´m (18 ft.
lbs.).
(6) Install ignition transponder onto column lock.
(Fig. 18)
NOTE: The dome on the transponder must engage
into the groove on the ignition switch.
(7) Install brake pedal spring. (Fig. 17)
(8) Install vent hose. (Fig. 16)
Fig. 21 ALIGNMENT CUTOUT - 1
1 - CUTOUT
2 - HEATER HOUSING
Fig. 22 ALIGNMENT CUTOUT - 2
1 - CUTOUT
2 - HEATER HOUSING
VAINSTRUMENT PANEL 23 - 63

TOP COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
²WHEN REMOVING A DEPLOYED AIRBAG, RUB-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
²USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
²THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL)
(3) Remove passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
REMOVAL)
(4) Remove screws and remove passenger side air
nozzle cover. (Fig. 25)(5) Remove accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - REMOVAL)
(6) Remove a-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/A-PILLAR TRIM - REMOVAL)
(7) Remove speaker covers. (Fig. 26)
(8) Remove screw and bracket.
(9) Remove lower screws.
(10) Remove upper screws.
(11) Pull top cover toward rear and remove.
Fig. 25 PASSENGER SIDE AIR NOZZLE COVER
1 - FRONT SCREWS (2)
2 - BRACKET
3 - BRACKET SCREWS
4 - NOZZLE COVER
5 - INSTRUMENT PANEL
VAINSTRUMENT PANEL 23 - 67