2006 MERCEDES-BENZ SPRINTER check oil

NO START VERIFICATION - VER-1 APPLICABILITY
1. NOTE: IMPORTANT! If the Engine Control Module or Sentry Key Immobilizer
Module has been replaced, ensure the programming procedure for the module has
been performed in accordance with the Service Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
ROAD TEST VERIFICATION - VER-2 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4. If not, proceed to step 5.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) has not been changed, perform steps 7 and 8, otherwise,
continue with step 9.
7. With the DRB IIIt, erase all diagnostic trouble codes (DTCs), then disconnect the DRB IIIt.
8. Turn the ignition off for at least 10 seconds.
9. If equipped with a Transfer Case Position Switch, perform step 10, otherwise, continue with
step 11.
10. With the ignition switch on, place the Transfer Case Shift Lever in each gear position,
stopping for 15 seconds in each position.
11. Ensure no DTCs remain by performing steps 12 through 15.
12. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
13. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
14. Upon completion of the road test, turn the engine off and check for DTCs with the DRB IIIt.
15. If the repaired DTC has set again, the repair is not complete. Check for any pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the
repair was successful and is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
247
VERIFICATION TESTS
Verification Tests ÐContinued

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID..........................2
BRAKE FLUID.........................2
HOAT COOLANT.......................2
ENGINE OIL - DIESEL ENGINES...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......5FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........7
MAINTENANCE SCHEDULES
DESCRIPTION..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VALUBRICATION & MAINTENANCE 0 - 1

Do not blend other specific fuel additives with die-
sel fuel. They only result in unnecessary cost, and
may be harmful to the engine operation.
POWER STEERING FLUID
No fluid service required. Filled with Power Steer-
ing Fluid approved to MB 236.3, such as Mobil
ATF-D (Exxon Mobil Corporation) or equivalent.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L without Filter Re-
placement9.5 Quarts with Filter
Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of inter-
nal cooler, length and inside diameter of cooler lines,
or use of an auxiliary cooler, these figures may vary.
(Refer to appropriate 21 - TRANSMISSION/AUTO-
MATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE  .03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to manufac-
turing tolerance and refill procedure
DESCRIPTION SPECIFICATION
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cool-
er options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed proce-
dures.
FLUID FILL / CHECK LOCA-
TIONS
INSPECTION - FLUID FILL / CHECK LOCA-
TIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle. Support the vehicle in the raised
position with jack stands at the front and rear ends
of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
VALUBRICATION & MAINTENANCE 0 - 5

effect panels. If necessary, remove the wheels from
the lifted end of the vehicle and lower the vehicle
closer to the ground, to increase the ground clearance
at the opposite end of the vehicle. Install lug nuts on
wheel attaching studs to retain brake drums.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies.
MAINTENANCE SCHEDULES
DESCRIPTION
The use of special lubricant additives is not recom-
mended. The use of such additives may affect the
warranty rights. With regard to legal stipulations
concerning emissions control, please note that
engines have to be serviced and adjusted in accor-
dance with special instructions and using special
measuring equipment. Modifications to or interfer-
ence with the emissions control systems are not per-
missible.
MAINTENANCE - WITHOUT ASSYST MAINTE-
NANCE COMPUTER
Maintenance Intervals
²Oil service ±Normal Operationevery 10,000
miles or 16,000 km or 12 months.
²Maintenance service every 30,000 miles or
48,000 km.
Additional work must be carried out at yearly
intervals.
MAINTENANCE - WITH ASSYST MAINTENANCE
COMPUTER
ASSYST provides information on the best possible
timing for maintenance work.
When the next maintenance service is due, this
will be indicated in the multi-function display with
the wrench icon symbol displayed in km/miles or
days.
²One wrench icon showing indicates Oil Service
is necessary.
²Two wrench icons showing indicates Mainte-
nance Service is necessary ± displayed in km/miles or
days.
If the display shows the number of days, a clock
symbol will also appear in the multi-function display.You should have the maintenance performed
within the stated period/distance.
The service indicator will be reset after an oil ser-
vice and/or maintenance service has been performed.
REGULAR CHECK - UPS
To maintain the safe operation of the vehicle, it is
recommended that the following tasks be performed
on a regular basis (i.e. weekly or whenever the vehi-
cle is refueled). Check:
²Engine oil level
²Brake system - fluid level
²Battery - acid level
²Windshield washer system and headlamp clean-
ing system - fluid level
²Mechanical assemblies (e.g. engine, transmis-
sion, etc.) - check for leaks
²Condition of tires and tires pressures
²All exterior lights
SPECIAL MAINTENANCE REQUIREMENTS
If bodies built by manufacturers other than
DaimlerChrysler Corporation are fitted to the vehi-
cle, the maintenance requirements and lubrication
intervals specified by the body manufacturer must be
adhered to, in addition to all standard maintenance
requirements.
Coolant
Corrosion inhibitor/antifreeze concentration in the
coolant should be checked before the onset of winter
(once year in countries with high prevailing temper-
atures).
Replace the coolant every five years or 100,000
miles.
Dust Filter for Heating / Ventilation Replacement
The dust filter and the tailgate interior filter are to
be renewed during routine maintenance service. If
operating conditions are dusty, these filters should be
renewed more frequently.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
At a minimum, change the engine oil and oil filter
once a year ± even if the vehicle mileage per year is
extremely low. For standard oil service schedules
refer to the chapter oil service and maintenance ser-
vice.
Once a Year
Select the viscosity of the engine oil (SAE classes)
according to the outside air temperature.
Only use engine oil approved by DaimlerChrysler
Corporation if following the ASSYST system guide-
lines.
0 - 8 LUBRICATION & MAINTENANCEVA

SCOPE OF WORK FOR MAINTENANCE SERVICE
Oil Service
²Engine: Oil change and filter replacement
Check fluid levels of the following system, refill as neces-
sary.
²If fluid is lost, trace and eliminate cause - as a
separate order.
²Power-assisted steering
Lubrication work:
²Trailer tow hitch (original equipment)
Maintenance
²ASSYST maintenance computer reset
Function check
²Signalling system, warning and indicator lamps
²Headlamps, exterior lighting
²Windshield wipers, windshield washer system
Check for leaks and damage
²Check for abrasion points and ensure that lines
are correctly routed!
²All lines and hoses, sensor cables
²Rubber boots on front axle drive shafts, rubber
boots on front axle suspension ball joints, shock
absorbers
²Check fluid levels for the following systems, cor-
rect as necessary
NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.
²Engine cooling system. Check corrosion inhibi-
tor/antifreeze, refill as necessary.
²Hydraulic brake system
²Battery
²Windshield washer system
Engine
²Fuel filter renewal - Every oil service
²Air cleaner with maintenance indicator:
²Check degree of contamination.
²Air cleaner filter element renewed as necessary.
Chassis and body
²Trailer coupling: Check operation, play and
retaining fixtures
²Secondary rubber springs: Visual check
²Tire pressures: Correct as necessary, including
spare tire
²Check thickness of brake pads
²Brake test
²Check condition of steering mechanism
²Heating/ventilation dust filter renewal
ADDITIONAL MAINTENANCE WORK
Automatic transmission once only at 80,000 miles / 128000
km
²Oil and filter change
During every second maintenance service
²Air cleaner without maintenance indicator:
²Air cleaner filter element renewal
²Check poly-V-belt for wear and signs of damage
During every fourth maintenance service
²Change rear axle fluid
ADDITIONAL MAINTENANCE WORK AFTER YEARS
Every 2 years
²Change brake fluid.
Every 3 years
²Air cleaner filter element renewal (note installa-
tion date)
Every 15 years or 100,000 miles
²Coolant renewal
²Note coolant composition
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).
Fig. 3 INTERNATIONAL SYMBOLS
VALUBRICATION & MAINTENANCE 0 - 9

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION........................11
DIAGNOSIS AND TESTING - SPRING AND
SHOCK.............................11
SPECIFICATIONS - TORQUE CHART......12
SHOCK
DIAGNOSIS AND TESTING - SHOCK......13
REMOVAL...........................13
INSTALLATION.......................13
SPRING
DESCRIPTION........................14
OPERATION.........................14
REMOVAL
REMOVAL - (SRW)...................14REMOVAL - (DRW)...................14
INSTALLATION
INSTALLATION - (SRW)...............14
INSTALLATION - (DRW)...............15
SPRING SHACKLE
REMOVAL...........................15
INSTALLATION.......................15
STABILIZER BAR
REMOVAL...........................15
INSTALLATION.......................15
STABILIZER LINK
REMOVAL...........................16
INSTALLATION.......................16
REAR
DESCRIPTION
The rear suspension is comprised of:
²Shock Absorbers
²Jounce Bumpers
²Stabilizer Bar
²Leaf Springs
²Drive Axle
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND
SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mountingbushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio-
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
VAREAR 2 - 11

LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
STANDARD PROCEDURE - DRAIN AND FILL
NOTE: Drain oil when warm.
(1) Clean area around oil fill plug and drain plug.
(2) Remove oil drain plug (2) and drain oil (Fig. 1).
(3) Install oil drain plug and tighten to N´m 100
(74 ft. lbs.).
(4) Remove oil fill plug (1) and fill housing up to
bottom edge of oil fill hole (Fig. 1).
(5) Install oil fill plug and tighten to N´m 100 (74
ft. lbs.).
Fig. 1 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
VAREAR AXLE 3 - 13

SEAL - PINION
REMOVAL
(1) Remove wheels.
(2) Push back brake pads and release hand brake.
NOTE: If it is not possible to spin rear axle shafts
manually, detach rear brake cables.
(3) Drain rear axle oil.
NOTE: On dual rear wheel axle remove axle shafts.
(4) Remove propeller shaft.
(5) Spin pinion flange by hand and check axial
play of bearing.
CAUTION: There must not be any thrust bearing
play. If play excess or there are particles (shavings)
in the drained oil, replace gear assembly.
(6) Measure and record torque to rotate the pinion.
(7) Mark pinion position to pinion flange (1) (Fig.
57).
(8) Unlock collared nut.
(9) Hold pinion flange (1) with Flange Wrench
C-3281 and remove nut.(10) Remove pinion flange (1) from pinion shaft
with Flange Puller 8992 (2) (Fig. 58).
(11) Check sealing surfaces of joint flange for score
marks and replace joint flange if necessary.
(12) Remove pinion seal/seals (1) (Fig. 59).
Fig. 57 COLLARED NUT
1 - PINION FLANGE
2 - COLLARED NUT
Fig. 58 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
Fig. 59 PINION SEALS
1 - SEALS
2 - AXLE
VAREAR AXLE 3 - 39