2006 MERCEDES-BENZ SPRINTER Fuel

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).
INSTALLATION
(1) Position and seat the air cleaner element into
the lower housing (Fig. 10).
(2) Install the housing cover and snap retainers
into place (Fig. 10).
(3) Install air flow sensor into housing cover and
connect. (Fig. 10).
(4) Connect the air cleaner restriction sensor (Fig.
10)..
(5) Install heat shield.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the air flow sensor (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/MANIFOLD AIR
FLOW (MAF) SENSOR - REMOVAL).
(4) Disconnect the air intake pressure sensor,
unclip the top of the air cleaner housing and remove
(Fig. 11).
(5) Take out air cleaner element (Fig. 11).
(6) Detach bottom part of the air cleaner housing
at the body (Fig. 11).
(7) Take air intake hose out of inner fender and
out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 11).
#9543 ADAPTOR
#9544 VIBRATION DAMPER PULLER
Fig. 10 AIR CLEANER ELEMENT
1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSING
VAENGINE 9 - 21

(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 FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING
WHEN HANDLING FUEL.
(15) Remove the high pressure fuel pump interme-
diate gear (Fig. 14).
(16) Disconnect the engine side of the engine har-
ness and set aside.
(17) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
(18) Remove the turbocharger oil supply line at
the cylinder head and turbocharger (Fig. 14).
(19) Disconnect the turbocharger at the exhaust
manifold (Fig. 14).(20) Unbolt the transmission oil level indicator
tube fasteners from the cylinder head and engine
block (Fig. 14).
(21) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 14).
NOTE: Capture any fuel spillage when disconnect-
ing fuel lines.
(22) Disconnect the fuel line at the rear of the fuel
rail (Fig. 14).
Fig. 14 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 24 ENGINEVA

(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 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(25) Remove cylinder head (Fig. 15).
NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(26) Clean all mating surfaces and blow out bolt
thread holes.
REMOVAL - CYLINDER HEAD FRONT COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLE IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING FUEL.
RISK OF INJURY FROM SKIN AND EYE CONTACT
WITH FUEL. POUR FUELS ONLY INTO SUITABLE
AND APPROPRIATELY MARKED CONTAINERS.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL.
(5) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(6) Remove bolts attaching front cover.
NOTE: Lower portion of front cover is sealed with
RTV sealant. Carefully tug at front cover until it
loosens from cylinder head.
(7) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 16).
NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
Fig. 15 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL4 - GASKET
5 - BOLT TO TIMING COVER
VAENGINE 9 - 25

REMOVAL - CYLINDER HEAD GUIDE RAIL
(1) Disconnect negative battery cable.
CAUTION: Rotate engine at crankshaft only. DO
NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine back.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove engine cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 16).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.
INSTALLATION
INSTALLATION - CYLINDER HEAD
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents and blow out bolt holes, to
assure that no grease or oil is present during reas-
sembly. If piston or connecting rods have been
replaced, measure piston protrusion. Inspect all cyl-
inder head bolts for defects and stretching before
installation (Refer to 9 - ENGINE/CYLINDER HEAD -
STANDARD PROCEDURE). Inspect facing cylinder
head contact surface.
(1) Position the cylinder head and gasket properly
on engine using the dowel pins as a guide (Fig. 15).
CAUTION: The M12 cylinder head bolts must be
torqued in 3 stages.
NOTE: Add a small amount of clean engine oil to
the cylinder head bolt threads prior to installation.
Fig. 16 CYLINDER HEAD FRONT COVER
1 - TOP GUIDE RAIL
2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN5 - CYLINDER HEAD FRONT COVER
6 - SEAL
7 - TIMING CHAIN TENSIONER
8 - VACUUM PUMP
9 - 26 ENGINEVA

(2) Hand start clean head bolts and tighten per
the following procedure:
²Install M12 cylinder head bolts finger tight (Fig.
15).
²Tighten bolts in numeric order starting with
number 1 to 15 N´m (133 lbs.in.) (Fig. 17).
²Tighten bolts in numeric order starting with
number 1 to 60 N´m (44 lbs.ft.) (Fig. 17).
²Install M8 timing chain cover to cylinder head
bolts. Tighten to 20N´m (177 lbs.in.).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É (Fig.
17).
²Tighten M12 cylinder head bolts in numeric
order starting with number 1 an additional 90É again
(4 stages). (Fig. 17).
(3) Install fuel return flow line between rail and
high pressure pump (Fig. 14).
(4) Connect the coolant hoses to the thermostat
housing (Fig. 14).
(5) Connect the coolant pipe at the cylinder head
(Fig. 14).
(6) Reconnect transmission oil level indicator tube.
Tighten to 14 N´m (124 lbs. in.) (Fig. 14).
(7) Reconnect the turbocharger to the exhaust
manifold. Tighten to 30N´m (22 lbs.ft.) (Fig. 14).
(8) Install oil return flow line with new seals at
turbocharger. Tighten bolt of supply line to turbo-
charger to 18N´m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N´m (80 lbs. in.) (Fig. 14)
(9) Install charge air distribution pipe (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).
(10) Install and properly route the engine wiring
harness, making appropriate connections.
(11) Install high pressure fuel pump intermediate
gear (Fig. 14).(12) Install high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(13) Install the camshaft housing with tappets to
cylinder head (Fig. 14).
(14) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(15) Install top guide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(16) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N´m (59 lbs.ft.).
(20) Remove retaining lock for crankshaft/starter
ring gear.
(21) Install air intake tube at turbocharger (Refer
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).
(22) Install the fasteners retaining the front
exhaust pipe to the support bracket at the read of
the engine.
(23) Install the upper support bracket fastener.
(24) Install the lower turbo support bracket bolt.
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.
(26) Refill cooling system with proper coolant mix-
ture to proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(27) Connect 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.
(28) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
Fig. 17 CYLINDER HEAD BOLT TORQUE
SEQUENCE
VAENGINE 9 - 27

INSTALLATION - CYLINDER HEAD FRONT
COVER
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
NOTE: Dowel pins are used as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
(1) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 18).
NOTE: Install front cover of cylinder head within 10
minutes after applying sealant. Do not spread seal-
ing bead.
(2) Raise locking pawl of top guide rail and guide
front cover onto guide pins.
(3) Install bolts attaching front cover (Fig. 16)
Tighten bolts to 14N´m (124 lbs. in.).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
REMOVE SOURCES OF IGNITION FROM THE AREA.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELS
ONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS.
(4) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).NOTE: Timing chain tensioner must be installed
with a new gasket.
(5) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Connect 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.
(7) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)
INSTALLATION - CYLINDER HEAD GUIDE RAIL
(1) Carefully position the top guide rail onto the
guide pins.
(2) Counter hold the camshaft with an open end
wrench and install driver of inlet camshaft sprocket.
Tight bolt to 50N´m (37 lbs. ft.).
(3) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail
and install front cover at cylinder head (Fig. 16).
(5) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(6) Install engine cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(7) Reconnect negative battery cable.
WARNING: US 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.
(8) Start engine and inspect for leaks.
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING CAM-
SHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
Fig. 18 CYLINDER HEAD COVER SEALING
SURFACE
1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD
9 - 28 ENGINEVA

(3) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(4) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine at crankshaft only. DO NOT
crank engine at the camshaft and DO NOT rotate
the engine backward.
(6) Position piston of cylinder #1 to ignition TDC.
(7) Insert the locking pin (special tool #8929)
through first camshaft bearing cap into the hole in
the left inlet camshaft sprocket (Fig. 19).
NOTE: The two markings in the inlet camshaft
sprockets must be positioned opposite and mark-
ings of camshaft and camshaft bearing cap must be
aligned. If not, perform basic position of camshafts.
(8) Remove locking pin from camshaft bearing cap
hole.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(10) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
Fig. 19 CHECKING CAMSHAFT POSITION
1 - CAMSHAFT SPROCKET ALIGNMENT DOTS
2 - CAMSHAFT LOCK POSITION
3 - INTAKE CAMSHAFT SPROCKET
4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS
5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929)
6 - INTAKE CAMSHAFT SPROCKET
VAENGINE 9 - 29

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
NO WEAR LOOSE CLOTHING.
(11) Start the engine and inspect for leaks.
STANDARD PROCEDURE - INSPECTING TAP-
PET CLEARANCE
(1) Check engine oil level, adjust as necessary.
(2) Warm engine to operating temperature
(approx. 80ÉC, 176ÉF).
(3) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Rotate the engine by the crankshaft until the
camshaft, at the tappet to be tested, is at it's base
circle (camshaft nose must point upward) (Fig. 20).
NOTE: Do not use a tool that will mar or damage
the tappet surface. If applied pressure is too strong
the tappet will appear to drop, but what happens is,
the valve opens.
(5) Use a pressing tool and apply pressure to the
tappet by hand (Fig. 20).
(6) If the tappet drops faster in comparison to the
other tappets, remove the camshaft and replace the
tappet.
REMOVAL
NOTE: Tappets are serviced Only when replacing
the camshaft housing. Inspect tappet clearance
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - STANDARD PROCEDURE).
(1) Disconnect negative battery cable.
(2) Remove engine cover. (Refer to 9 - ENGINE -
REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
(3) Remove high pressure lines and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine at the crankshaft only. DO
NOT rotate the engine at the camshaft. DO NOT
rotate the engine backward.
(5) Position piston of cylinder #1 to ignition TDC.
(6) Lock inlet camshaft (Fig. 21).
Fig. 20 TAPPET CLEARANCE
1 - CAMSHAFT
2 - PRESSURE APPLICATION POINT
3 - HYDRAULIC TAPPET
4 - CAMSHAFT HOLD DOWN
9 - 30 ENGINEVA