2006 MERCEDES-BENZ SPRINTER warning

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System 2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194ÉF). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING COOLANT. OPEN CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
VAENGINE 9 - 3

REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES, AND EYE WEAR.
(1) Disconnect the negative battery cable.
NOTE: REPLACE THE AIR CONDITIONING DRIER
WHEN EVER THE AIR CONDITIONING SYSTEM IS
OPENED.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Evacuate and recover air conditioning system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(4) Remove the front grille and fascia assembly.(5) Disconnect the engine wiring harness at the
cabin side and carefully guide though the cowl into
the engine area.
Fig. 2 ENGINE COVER
1 - ENGINE COVER
2 - FASTENERS
VAENGINE 9 - 5

(39) Fill cooling system to proper level with the
appropriate coolant.
(40) Evacuate and recharge air conditioning.
(41) Check and refill all ancillary system fluid lev-
els.(42) Start engine and inspect for leaks (Refer to 14
- FUEL SYSTEM - WARNING).
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge Distri-
bution Pipe to Air Charge
Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to Cylin-
der Head14 - 124
12m-Bolt-Cylinder Head
to Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44, 90É,90É -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque an-
gle)55, 90É 40, 90É -
Bolt-End Cover to Crank-
case9-80
Bolt-Timing Case Cover
to Crankcase20 15 -
Plug-Coolant Drain to
Crankcase30 22 -
Oil Pan
6m-Bolt-Oil Pan to Crank-
case9-80
8m-Bolt-Oil Pan to Crank-
case20 15 -
Bolt-Oil Pan to End Cover 9 - 80
Bolt-Oil Pan to Timing
Case Cover9-80
Bolt-Oil Pan to Transmis-
sion Bell Housing40 30 -
Plug-Oil Pan to Oil Drain 47 35 -
Connecting Rod
VAENGINE 9 - 11

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
HEAD SPECIFICATIONS.
(8) Measure valve setback at points (2) indicated
(Fig. 13) CYLINDER HEAD SPECIFICATIONS.
NOTE: If measurement is less than dimension ª2º
no further correct valve clearance compensation is
possible; replace the cylinder head.
CYLINDER HEAD SPECIFICATIONS
Description Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat RingsExhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crankcase
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE).
(6) Loosen the lower turbo support bracket bolt.
(7) Remove the upper support bracket bolt.
(8) Loosen the fasteners retaining the exhaust pipe
to the support bracket at the rear of the engine.
(9) Lower vehicle.
(10) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(11) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
Fig. 13 Cylinder Head Measurments
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
VAENGINE 9 - 23

(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