2006 MERCEDES-BENZ SPRINTER Service Manual

towing oil filter fuses check transmission fluid oil reset trunk

Page 1617 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor

Page 1618 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller

(3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller MUST mesh fully
into the slots of the belt pulley.
NOTE: Inspect the running surface of the belt pulley
for wear.
(4) Remove the belt pully/vibration damper.
CAUTION: Care must be taken to prevent severe
damage to the crankshaft and mounting whole for
the front crankshaft seal.
(5) Using a suitable prying tool, remove the front
crankshaft seal from the timing cover (Fig. 34).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the front crankshaft seal
evenly onto the timing cover.(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(3) Remove the retaining lock for the crankshaft/
ring gear.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Fill the crankcase with the correct engine oil to
the proper level.
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.
(7) Start the engine and inspect for leaks.
FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: M6x90 bolts must be used with retaining
lock to prevent damage to rear end cover.
(2) Install retaining lock for crankshaft/starter
ring gear.
NOTE: Flywheel does not need balancing or should
it be interchanged.
(3) Remove flywheel with inner washer (Fig. 35).
Fig. 34 FRONT SEAL REMOVAL/INSTALLATION
1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
3 - WASHER
4 - RETAINING BOLT
VAENGINE 9 - 43

Page 1619 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
INSTALLATION
NOTE: A flex rod torque wrench must not be used
in order to avoid angle errors when tightening to
degrees.
(1) Align flywheel and inner and outer washers
with straight pin. T

Page 1620 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual PISTON & CONNECTING ROD
DESCRIPTION
NOTE: No over sized pistons are available.
The pistons are of a free floating design and made
of optimized aluminum alloy with a graphite coated
bearing surface. Th

Page 1621 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS
NOTE: Connecting rods with blue discoloration,
cross scores or notches must be replaced. Com-
pensate for different weigh

Page 1622 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Allowable out-of-round-
ness and taper of basic
bore.020 mm
Allowable twist of con-
necting rod beari

Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Allowable out-of-round-
ness and taper of basic
bore.020 mm
Allowable twist of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.100 mm
Allowable variation of
axial parallelism of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.045 mm
Allowable difference in
weight of complete con-
necting rod of an engine2g
Connecting rod inner
bushing30.018 to 30.024 mm
Connecting rod outer
bushing32.575 mm to 32.600
mm
Connecting rod basic
bore32.500 mm to 32.525
mm
Piston pin play in con-
necting rod.018 mm to.024 mm
Peak-to-Valley height
(Rz) of connecting rod
bushing on inside5
Connecting rod bolt
threadM8x1
STANDARD PROCEDURE - MEASURING PIS-
TON PROTRUSION
After replacing the pistons/connecting rods or
machining the engine block contact surface, it is then
necessary to measure the piston protrusion.
Measure protrusion between piston crown and cyl-
inder head contact surface without the head gasket
installed. The measurment must be carried out in
the direction of the piston pin in order to eliminate
piston rock.
(1) Measure piston protrusion at the two measur-
ing points (arrows) (Fig. 39).
Piston protrusion with new crankcase should be
0.38 - 0.62 mm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Push back on the chain tensioner and remove
the oil pump chain from the oil pump.
(6) Remove the oil pump.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side.
(7) Remove the connecting rod bearing cap.
NOTE: Do Not mix up the top and bottom connect-
ing rod bearing shells.
(8) Mark the connecting rod bearing shell and the
connecting rod bearing cap to each other.
Fig. 39 MEASURING PISTON PROTRUSION
1 - PISTON PROTRUSION MEASUREMENT
VAENGINE 9 - 47

Page 1623 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual NOTE: If the pistons are used, the direction of
travel arrows and the marking of the pistons may
no longer be visible because of carbon deposits.
The carbon deposits on the pistons must be
removed.
NO

Page 1624 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (10) Mark the connecting rod bearing shell and
connecting rod to each other.
CAUTION: Care must be taken not to damage the
piston.
(11) Remove the piston pin circle clip. (Fig. 40).
(12) Press the pis

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