2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 1593 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual #8932 CRANKSHAFT LOCK
#8936 FRONT CRANKSHAFT SEAL INSTALLER
#8938A EXTRACTION CLAW
#8940 VIBRATION DAMPER REMOVER
9 - 18 ENGINEVA

Page 1594 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual #8941 SLIDE HAMMER
#8942 OIL JET INSTALLER
#8944 REAR MAIN SEAL INSTALLER
#9307 VALVE SERVICE TOOLS
VAENGINE 9 - 19

Page 1595 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual #8951 ASSEMBLY LINKS
#9285 FUEL LINE WRENCH
# 9286 GLOW PLUG PLIERS
#9295 COMPRESSION HOSE ADAPTOR
#9525 TIMING CHAIN GUIDE
# 9539 FUEL LINE PLIERS
9 - 20 ENGINEVA

Page 1596 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual AIR CLEANER ELEMENT
REMOVAL
(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.
10).
(3) Unclip the air cleaner housing lid (Fig. 10).
(4) Remove air cleaner element (Fig. 10).
I

Page 1597 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
INSTALLATION
NOTE: Ensure that the seal between the inner
fender well and th

(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
INSTALLATION
NOTE: Ensure that the seal between the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 11).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 11).
(3) Install air cleaner element (Fig. 11).
(4) Install and clip air cleaner top to air cleaner
body and connect the air intake pressure sensor (Fig.
11).
(5) Install air flow sensor (Fig. 11).
(6) Install heat shield.
(7) Connect negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of high temperature
resistant aluminum alloy and features optimized spi-ral swirl intake ducts and a separate camshaft hous-
ing made of die cast aluminum. The combustion
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The
intake and exhaust valves have solid valve stems and
conical valve springs. The cylinder head is not ser-
viceable and must be replaced should a repair
become necessary.
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 12).
Cylinder Head
BoltsThread Diame-
ter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE CYLIN-
DER HEAD SURFACE
NOTE: DO NOT machine the cylinder head surface.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 13).
Fig. 11 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER
Fig. 12 Measuring Cylinder Head Bolts
9 - 22 ENGINEVA

Page 1598 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual NOTE: The camshaft housing Must Not be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 13) CYLINDER

Page 1599 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (12) Remove the camshaft housing at the cylinder
head (Fig. 14).
(13) Remove the high pressure pump.
(14) Remove the front head cover plate.
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING

Page 1600 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (23) Remove upper timing case to cylinder head
bolts (Fig. 15).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(24) Remove cylinder head bolts and inspect (Refer
to

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