2006 MERCEDES-BENZ SPRINTER CD changer

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat Ex-
changer 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 En-
gine 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, 90É -
Bolt-Engine Mount to En-
gine Bracket55 40.5 -
Bolt-Front Engine Mount
to Front Axle Carrier35 26 -
Bolt-Rear Engine Cross
Member to Body40 30 -
Bolt-Rear Engine Mount
to Rear Engine Cross
Member35 26 -
Bolt/Nut- Rear Engine
Mount to Transmission40 26 -
Bolt-Shrowd to Engine
Bracket10 - 88.5
Nut-Front Engine Mount
to Engine Bracket65 48 -
Nut-Engine Mount to Ve-
hicle Frame35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
9 - 14 ENGINEVA

(8) Install the exhaust hanger fasteners at the
muffler.
(9) Tighten the exhaust hanger bracket to engine
block.
(10) Install the turbocharger support bracket.
(11) Lower the vehicle.
(12) Install the air cleaner duct to the turbo-
charger (Fig. 71).
(13) Install the exhaust heat shield.
(14) Connect the negative battery cable.
TIMING CHAIN COVER
REMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS TEMPERATURE IS BELOW 90ÉC (194ÉF).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(2) Position piston of cylinder 1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).
(8) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(9) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(12) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(13) Remove accessory drive belt pulley and vibra-
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).
(14) Remove the power steering pump.NOTE: NO NOT open the air conditioning system.
(15) Unplug AC compressor electrical connector
and unbolt AC compressor. Relocate in lower engine
compartmentwith outopening the system.
(16) Remove the generator with wiring attached
and relocate somewhere in the engine compartment.
(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 73).
(20) Remove the cylinder head to timing cover
bolts (Fig. 73).
(21) Remove the timing cover bolts and cover (Fig.
73).
(22) Remove remaining ancillary components
attached to the timing case cover (Fig. 73).
NOTE: Inspect condition of hoses and clamps,
replace as necessary.
(23) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 73).
Fig. 73 TIMING CHAIN COVER
1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER
9 - 70 ENGINEVA

INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.
(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace the front crankshaft seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 74).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N´m (177 lbs in) (Fig. 73).(6) Install the M8 bolts of cylinder head on timing
case cover. Tighten bolts to 20 N´m (177 lbs in) (Fig.
73).
(7) Install timing chain tensioner with new seal
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
(8) Position and install the oil pan. Tighten M6
bolts to 9 N´m (80 lbs in) and M8 bolts to 20 N´m
(177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
M8.8 bolt in two stages, 200N´m (147 lbs ft.) then
90É, M10.9 bolt 325N´m (240 lbs ft) then 90É.
(10) Remove the engine support fixture.
(11) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditioning compressor.
(13) Install the power steering pump.
(14) Install water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sealant to lower portion of, and install,
front cover to cylinder block. Tighten bolts to 20N´m
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
- INSTALLATION).
(18) Remove retaining lock for crankshaft/starter
ring gear.
(19) Tighten the oil drain plug to 30N´m (265 lbs
in).
(20) Install a new oil filter. tighten screw cap for
filter to 25N´m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).
(23) Install air intake hose.
(24) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(25) Fill the crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(26) Connect the 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.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
Fig. 74 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VAENGINE 9 - 71

²Reduction in exhaust emissions as a result of an
improvement in the air supply of the engine.
²Increased power output as a result of the higher
charge pressure combined with a reduced exhaust
backpressure and thus improved charge cycle.
OPERATION
The exhaust gases of the engine are directed
through the exhaust manifold into the turbine hous-
ing onto the turbine wheel (Fig. 2). The flow energy
of the exhaust gases cause the turbine wheel to
rotate. Consequently, the compressor wheel, which is
connected through the turbine shaft with the turbine
wheel, is driven at the same speed. The fresh air
inducted by the compressor wheel is compressed and
passed to the engine (Fig. 2).
The charge pressure is controlled by varying the
position of the guide vanes (Fig. 2). The guide stud of
the control linkage of the boost pressure actuator
turns the adjusting ring in the turbine housing (Fig.
2). As a result, all the guide vanes whose guide studs
likewise mesh into the adjusting ring, are also
turned (Fig. 2).
At low speeds, the flow cross-section is reduced by
closing the guide vanes (Fig. 2). Consequently the
speed at which the exhaust gas impacts on the tur-
bine wheel is increased, as a result of which the
speed of the turbocharger and thus the charge pres-
sure rises.
At high engine speeds the guide vanes are increas-
ingly opened and the flow cross-section is thus
enlarged, as a result of which the speed of the turbo-
charger reduces and the charge pressure drops.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge air system consists of the charge air
cooler and charge air cooler piping.
The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi-
ciency and power.
Fig. 2 TURBOCHARGER COMPONENTS
1 - COMPRESSOR HOUSING
2 - GUIDE VANE
3 - GUIDE STUD OF GUIDE VANE
4 - GUIDE STUD OF CONTROL LINKAGE
5 - CONTROL LINKAGE
6 - ADJUSTING RING
7 - TURBINE HOUSING
8 - BOOST PRESSURE CONTROL UNIT
1A - EXHAUST GASES TO TURBINE WHEEL
2A - TURBO INLET (FRESH AIR)
3A - TURBO OUTLET (COMPRESSED AIR)
4A - EXHAUST OUTLET
11 - 4 EXHAUST SYSTEMVA

Some vehicles are equipped with an additional
Denso 10S17 A/C compressor mounted to the engine
which is used for the optional rear A/C system and
various add-on A/C systems (Fig. 3).A heater booster is used to aid in warming the
engine coolant. The heater booster system can be
switched on while the vehicle is being driven to help
the engine reach its normal operating temperature
quickly and will help aid in heating up the air within
the passenger compartment quickly when requested
by the operator (Fig. 4).
OPERATION
Outside air enters the vehicle through the hood
opening at the base of the windshield, and passes
through the ventilation housing located in the engine
compartment into the heater housing located behind
the instrument panel. Air flow velocity is adjusted
with the blower motor speed selector thumbwheel on
the A/C-heater control. The air intake openings must
be kept free of snow, ice, leaves, and other obstruc-
tions for the HVAC system to receive a sufficient vol-
ume of outside air.
The automatic temperature control (ATC) system
controls interior temperature by taking actual values
from the temperature sensors and the CAN bus and
comparing them to the nominal value of the temper-
ature control switch. The electric pulsed heater valve
is then energized depending on the requested quan-
tity of heat and an electrically-operated water pump
gives a nearly constant water flow for exact temper-
ature regulation. If the solenoid is not energized, the
coolant circuit to the heat exchanger is fully open. To
control the temperature the solenoid valve is pulsed
by the ATC in periods of four seconds.
The mode control knob on the A/C-heater control is
used to direct the conditioned air flow to the selected
air outlets. The mode control knob operates the mode
doors by cables connected to the mode doors.
Fig. 2 Heater Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
Fig. 3 Denso 10S17 A/C Compressor
Fig. 4 Heater Booster
24 - 2 HEATING & AIR CONDITIONINGVA

²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) If equipped with an add-on rear A/C system,
install the lower A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION - DENSO 10S17).
(3) Lower the vehicle.
(4) Remove the tape or plugs from the opened suc-
tion line fitting and the discharge line fitting and the
compressor ports.
(5) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(6) Connect the A/C suction and discharge lines to
the A/C compressor.
(7) Install the bolts that secure the A/C suction
and discharge lines to the A/C compressor. Tighten
the bolts to 23 N´m (17 ft. lbs.).
(8) Connect the wire harness connector to the A/C
compressor clutch coil.
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Replace the receiver/drier if the A/C compres-
sor is being replaced due to an internal failure (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER/DRIER - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
DENSO 10S17A/CCOMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine com-
partment and loosely install the three compressorretaining bolts. Tighten the bolts using the following
sequence to 20 N´m (14 ft. lbs.).
²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened
underbody suction and discharge line fittings and
compressor ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(4) Connect the underbody suction and discharge
lines to the A/C compressor.
(5) Install the bolts that secure the underbody suc-
tion and discharge lines to the A/C compressor.
Tighten the bolts to 21 N´m (15 ft. lbs.).
(6) Connect the wire harness connector to the A/C
compressor clutch coil.
(7) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
INSTALLATION).
(8) Lower the vehicle.
(9) Replace the receiver/drier if the A/C compressor
is being replaced due to an internal failure (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
CEIVER/DRIER - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(12) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A / C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
VAPLUMBING 24 - 69

INSTALLATION
(1) Install the electric coolant pump and mounting
bracket onto the body studs.
(2) Install the two bracket retaining nuts. Tighten
the nuts to 5 N´m (45 in. lbs.).
(3) Using a twisting motion gently install both
hoses onto the electric coolant pump.
(4) Tighten both hose clamps securely.
(5) Connect the wire harness connector to the elec-
tric coolant pump.
(6) Reconnect the negative battery cable.
(7) Fill the engine cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE - COOLING SYSTEM FILL).
HEATER CORE
DESCRIPTION
The heater core is mounted into the HVAC hous-
ing, located behind the instrument panel (Fig. 14).
The heater core is a heat exchanger made of rows of
tubes and fins. The heater core tubes are attached to
the heater core by using O-ring seals and bolts.
The heater core is serviced by removing and disas-
sembling the HVAC housing.
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core whenever the heater water
valve is cycled open by the ATC A/C-heater control.
As the coolant flows through the heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
heater water valve controls the heater output air
temperature by controlling the amount of heated
engine coolant flowing through the heater core. The
blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.
Fig. 13 Electric Coolant Pump
1 - HEATER HOSE
2 - HOSE CLAMP (2)
3 - HEATER HOSE
4 - ELECTRIC COOLANT PUMP
5 - WIRE HARNESS CONNECTOR
6 - NUT (2)
Fig. 14 Front Heater Core
1 - HEATER CORE
2 - BOLT (3)
3 - HEATER CORE TUBES
4 - O-RING SEALS
24 - 76 PLUMBINGVA

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS..................1EXHAUST GAS RECIRCULATION.............4
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
CRANKCASE VENTILATION HEATER
REMOVAL.............................1
INSTALLATION..........................1
CRANKCASE VENTILATION BREATHER
DESCRIPTION..........................2REMOVAL.............................2
INSTALLATION..........................3
CRANKCASE VENTILATION
HEATER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the turbocharger heat shield.
(3) Disconnect the CCV heater wiring harness con-
nector.
(4) Using a slight twisting motion, separate the
CCV breather tube from the heater.
(5) Separate the CCV heater from the turbo-
charger air inlet duct.
INSTALLATION
(1) Clean all mating surfaces.
(2) Insert the CCV heater into the turbocharger
inlet hose aligning the arrow on the heater with the
tab on the hose (Fig. 1).
(3) Connect and properly seat the CCV breather
hose on the CCV heater (Fig. 1).
Fig. 1 CCV HEATER
1 - BREATHER HOSE
2 - HARNESS CONNECTOR
3 - TURBOCHANGER INLET HOSE
4 - HEATER ALIGNMENT AREA
5 - CCV HEATER
VAEMISSIONS CONTROL 25 - 1