2006 MERCEDES-BENZ SPRINTER power steering fluid

(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(13) Connect the engine valley drain hose to the
transmission (Fig. 5).
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(15) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and
CCV heater at the turbocharger (Fig. 4).
(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the
vacuum pump.(24) Connect the fuel lines at the filter assembly
(Fig. 9).
(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser and fan assemblies Con-
nect the fan harness connector.
(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).
(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-
tor.
(32) Install air cleaner housing and connect the air
inlet duct and air flow sensor.
(33) Connect the charge air cooler hose at intake
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).
(34) Route the engine wiring harness inside the
vehicle and connect.
(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
Fig. 8 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
Fig. 9 FUEL FILTER
1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
9 - 10 ENGINEVA

(6) Cut tie straps holding wheel speed sensor and
brake pad wear sensor wire harness to the cradle.
(7) Cut tie straps holding transmission harness to
the cradle.
(8) Remove lower pinch bolt from steering shaft
and disconnect shaft. (Fig. 10)
(9) Siphon the power steering fluid out of the res-
ervoir.(10) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 10).
(11) Remove bolt and remove power steering hose
support bracket from the cradle. (Fig. 11)
(12) Disconnect brake lines from body side, at the
couplings. (Fig. 12)
(13) Support engine cradle with suitable lifting
device.
(14) Remove four cradle support bolts from each
side of the cradle. (Fig. 13)
Fig. 9 FRONT DISC BRAKE CALIPER
1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS
Fig. 10 STEERING GEAR
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
Fig. 11 POWER STEERING HOSE BRACKET
1 - POWER STEERING LINE
2 - SUPPORT BRACKET BOLT
Fig. 12 BRAKE LINES
1 - BRAKE LINES
2 - LINE COUPLINGS
VAFRAME & BUMPERS 13 - 9

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................1COLUMN................................4
GEAR..................................7
LINKAGE................................9
PUMP..................................11
STEERING
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM
There is some noise in all power steering systems.
One of the most common is a hissing sound evident at
a standstill parking. Or when the steering wheel is at
the end of it's travel. Hiss is a high frequency noise
similar to that of a water tap being closed slowly. The
noise is present in all valves that have a high velocity
fluid passing through an orifice. There is no relation-
ship between this noise and steering performance.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
VASTEERING 19 - 1

STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash
panel seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension compo-
nents.2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with other
components.4. Reposition hose.
5. Loose or damaged intermediate shaft or
column.5. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR KNOCK-
ING1. Wrong tire size. 1. Verify tire size.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball joints/
tie rod ends).3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if nec-
essary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
19 - 2 STEERINGVA

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION..........................7
REMOVAL.............................7INSTALLATION..........................7
SPECIFICATIONS - TORQUE CHART.........8
GEAR
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part
of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa-
rate the tie rods from the steering knuckles (Fig. 2)
using special tool C-3894±A.
(6) Remove the left outer tie rod end from the
steering gear.
(7) Remove both spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).(8) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from
the steering gear (Fig. 2).
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.
INSTALLATION
(1) Install the gear to the vehicle.
NOTE: Steering gear must be torqued in a three
step procedure below.
(2) Install the steering gear bolts (Fig. 2). Tighten
to an initial torque of 25 N´m (18 ft. lbs.) Then
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR REMOVAL / INSTALL
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
VAGEAR 19 - 7

torque to 45 N´m (33 ft. lbs.) and a final additional
90É turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N´m (18 ft. lbs.).
(4) Install both the power steering hoses to the
steering gear (Fig. 2). Tighten the high pressure hose
to 37 N´m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
(6) Install the left outer tie rod end to the steering
gear.(7) Install both the outer tie rod ends to the steer-
ing knuckle (Fig. 2). Tighten to 130 N´m (96 ft. lbs.).
(8) Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
U-Joint To Steering Gear 24 18 212
High Pressure Hose To
Steering Gear37 27 328
Return Line To Steering
Gear37 27 328
Steering Gear To Frame
Initial Torque25 18 221
Steering Gear To Frame
Second Torque
Then additional 90É turn45 33 398
19 - 8 GEARVA

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....11
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............12
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS - TORQUE CHART........13
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE........................13FLUID COOLER TUBE
REMOVAL.............................13
INSTALLATION.........................13
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE...........14
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE.......................14
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE....................14
INSTALLATION
INSTALLATION - PRESSURE HOSE.......14
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE...............14
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE...............14
PUMP
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
VAPUMP 19 - 11

(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4) Remove the return hose from the pump (Fig.
1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
19 - 12 PUMPVA