2006 MERCEDES-BENZ SPRINTER warning

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

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

NOTE: The piston of cylinder #1 must be positioned
at ignition TDC when the inlet camshaft is locked.
(8) Insert locking pin through the first camshaft
bearing cap into the whole in the camshaft sprocket.
NOTE: Do Not use old camshaft sprocket bolts.
(9) Fit camshaft sprocket with timing chain fitted
on, onto exhaust camshaft paying attention to posi-
tion of dowel pin. Tighten bolt to 18N´m (159 lbs.in.).
(10) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(11) Inspect/Set basic position of camshafts (Refer
to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
STANDARD PROCEDURE).
(12) Insert slide rail and bolt the driver into the
inlet camshaft. Tighten bolt driver to 50N´m (37 lbs.
in.).
(13) Install front cover at cylinder head.
(14) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
NOTE: Refer to the appropriate injector servicing
procedures for cleaning of injectors and recesses.
(15) Clean and install injectors (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE), (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(16) Reconnect negative battery cable.WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
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 CLOTHING.
(17) Start engine and inspect for leaks.Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
(18) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect the air inlet and set aside.
(3) Detach hose from oil separator.
(4) Disconnect the camshaft position sensor.
(5) Disconnect fuel injector and glow plug harness
and set aside.
(6) Remove fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(7) Disconnect the out let line.
(8) Remove cylinder head cover retaining bolts and
remove cover (Fig. 25).
Fig. 24 CAMSHAFT BEARING TIGHTENING
SEQUENCE #2
VAENGINE 9 - 33

INSTALLATION
NOTE: Do Not tighten the cylinder head cover first.
The fuel injectors are aligned by way of the cylinder
head cover.
(1) Fit cylinder head cover with new gasket and
install bolts, hand tight (Fig. 25).
(2) Insert all fuel injectors, tensioning claws and
lines. Insert new bolts and tighten. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(3) Tighten cylinder head cover bolts to 9 N´m (80
lbs. in.).
(4) Install and properly route fuel injector and
glow plug wiring harness, making appropriate con-
nections.
(5) Connect the camshaft position sensor.
(6) Connect the return flow line.
(7) Attach oil separator hose.
(8) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(9) Start engine and inspect for leaks. Care must
be take to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide. For servicing of the valve seals
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
SPRINGS - REMOVAL).
Fig. 25 CYLINDER HEAD COVER
1 - ENGINE WIRING HARNESS 7 - GASKET
2 - GLOW PLUG CONNECTOR 8 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR 9 - CRANKCASE VENT LINE
4 - OUTLET LINE 10 - GASKET
5 - INTAKE MANIFOLD 11 - FUEL INJECTOR
6 - GASKET 12 - GROUND
9 - 34 ENGINEVA

VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS
(1) Disconnect negative battery cable.
(2) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
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/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(6) Remove top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(7) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: The timing chain must be held in up position
so as not to jam during procedure.
(8) Position piston of cylinder to be processed to
DTC by rotating the crankshaft clockwise.DO NOT
crank engine. DO NOT rotate engine backward.
CAUTION: Make sure the crankshaft lock is in posi-
tion and properly secured for each cylinder being
serviced. Failure to do so may result in damage to
the vehicle or personal injury.
(9) Install crankshaft lock, special tool #8932.
(10) Seal injector hole with adaptor # 9534 and
retain with original tensioning claw.
(11) Connect regulated air supply to special tool #
9534 and pressurize the cylinder to 5 bar (73 psi.).
WARNING: Valve springs and retainers must be
kept in order of the cylinder they were removed.
NOTE: Using valve service tools #9307, screw
retaining fork into threaded edge of cylinder head
and position thrust piece vertically at top of each
exhaust valve spring retainer. Use the cam bearing
cap threaded holes to position service tool for
removal of intake valve spring retainers.
(12) Compress valve spring (Fig. 26).(13) Remove valve collates (Fig. 26).
(14) Remove top valve spring retainer and valve
spring (Fig. 27).
Fig. 26 VALVE COMPRESSOR
1 - VALVE ASSEMBLY TOOL
2 - VALVE COLLATE
3 - MAGNET
Fig. 27 VALVE ASSEMBLY
1 - VALVE
2 - BOTTOM VALVE SPRING RETAINER
3 - VALVE STEM SEAL
4 - VALVE SPRING
5 - TOP VALVE SPRING RETAINER
6 - VALVE COLLATES
7 - CYLINDER HEAD
VAENGINE 9 - 35

(15) Remove valve stem seals (Fig. 28).
(16) Remove bottom valve spring retainer (Fig. 27).
NOTE: Inspect all cylinder head components for
wear or damage.
(17) Repeat procedure for each cylinder as neces-
sary.
REMOVAL - VALVES
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
WARNING: Suitably mark the valve and the position
in the cylinder head before removal. Failure to do
so will result in improperly seated valves and pos-
sible engine damage after reassembly.
NOTE: Using tool, screw retaining fork into
threaded edge of cylinder head and position thrust
piece vertically at top of valve spring retainer.
(4) Using a suitable valve spring compressor, com-
press valve spring.
(5) Remove valve collets (Fig. 27).
(6) Remove top valve spring retainer and valve
spring (Fig. 27).
(7) Remove valve stem seals (Fig. 28).(8) Repeat steps 5 through 9 for each valve as nec-
essary.
(9) Remove cylinder head from assembly board.
WARNING: Valves, springs and retainers must be
kept in order of the cylinder they were removed.
(10) Remove valves.
INSTALLATION
INSTALLATION - VALVE SPRINGS
NOTE: Inspect all valve springs and retainers for
wear or damage. Replace as necessary. Do Not
reuse gaskets.
(1) Position piston of cylinder to be processed to
TDC by rotating the crankshaft clockwise.DO NOT
crank engine or rotate engine counter clock-
wise.
(2) Install crankshaft lock, special tool #8932.
(3) Seal injector hole with adaptor # 9534 and
retain with original tensioning claw.
(4) Connect regulated air supply to special tool #
9534 and pressurize the cylinder to 5 bar (73 psi.).
(5) Install lower valve spring retainer (Fig. 27).
(6) Install valve stem seal (Fig. 29).
(7) Install valve spring (Fig. 27).
(8) Install valve spring retainer (Fig. 27).
Fig. 28 VALVE STEM SEAL
1 - PLIERS
2 - VALVE STEM SEAL
Fig. 29 VALVE SEAL INSTALLATION
1 - DRIFT
2 - PROTECTIVE COVER
3 - VALVE
9 - 36 ENGINEVA

NOTE: Using valve service tools #9307, screw
retaining fork into threaded edge of cylinder head
and position thrust piece vertically at the top of
each exhaust valve spring retainer. Use the cam
bearing cap threaded holes to position service tool
for installation of intake valve spring retainers.
NOTE: Ensure that the valve keepers are seated
properly.
(9) Compress valve and install valve collates (Fig.
26).
CAUTION: Make sure the crankshaft lock is in posi-
tion and properly secured for each cylinder being
serviced. Failure to do so may result in damage to
the vehicle or personal injury.
(10) Repeat procedure for each cylinder as neces-
sary.
(11) Remove special tooling from cylinder head.
(12) Position piston of #1 cylinder to ignition TDC.
(13) Install camshafts and check basic position
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - INSTALLATION).
(14) Install top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(15) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(16) Install timing chain tensioner with new gas-
ket (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(17) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
(18) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(19) Reconnect negative battery cable.
(20) Start the engine, allow to warm, turn engine
off and inspect for leaks. Care must be taken to
observe the fuel system warning (Refer to 14 - FUEL
SYSTEM - WARNING)
(21) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
INSTALLATION - VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.NOTE: Inspect all valves, springs and retainers for
wear or damage. Replace as necessary.
(1) Install valves in their original position in the
cylinder head.
(2) Install lower valve spring retainer.
(3) Install valve stem seal.
(4) Install valve spring.
(5) Install valve spring retainer.
NOTE: Using tool, screw retaining fork into
threaded edge of cylinder head and position thrust
piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated
properly.
(6) Using a suitable valve spring compressor, com-
press valve spring and install valve keepers.
(7) Repeat steps 3 through 7 for each valve as nec-
essary.
(8) Remove valve assembly from cylinder head.
(9) Install cylinder head on engine block (Refer to
9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(10) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
(11) Connect negative battery cable.
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. 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 CLOTHING.
(12) Start engine and check for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)
(13) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING ENGINE
CORE AND OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 30).
VAENGINE 9 - 37

CAUTION: Oil thread and head contact surfaces of
bolts that retain the crankshaft bearing caps;
tighten bolts from inside to outside, beginning at
the fit bearing. Rotate crankshaft to check clear-
ance.
(1) Install crankshaft.
CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way the crankshaft
bearing caps fit. If correctly installed, the lug, or
raised boss, on the crankshaft bearing cap is point-
ing to the left when viewed in the direction of travel
(intake side).
(2) Install the crankshaft bearing caps. Tighten
bolts in two stages. 55N´m (40.5 lbs. ft.), then 90É.
(3) Install the pistons (Refer to 9 - ENGINE/EN-
GINE BLOCK/PISTON & CONNECTING ROD -
INSTALLATION).
(4) Install the end cover (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
(5) Install the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install the engine (Refer to 9 - ENGINE -
INSTALLATION).
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to the owners manual for
specifications.
(8) Fill the cooling system with the proper coolant,
to the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(9) Connect the 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.
(10) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with the transmission removed
from the vehicle.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain the engine oil.NOTE: Loosen all of the oil pan bolts to assure that
the oil pan gasket is not damaged when removing
the rear main oil seal and end cover assembly.
NOTE: Inspect the oil pan gasket for damage. If the
oil pan gasket is damaged, remove the oil pan and
replace the oil pan gasket.
(4) Loosen the oil pan bolts.
(5) Remove the flywheel.
CAUTION: Care must be taken when removing the
rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.
(6) Remove the rear main seal/adaptor retaining
bolts and carefully pry the adaptor from the crank-
case at the adaptor shoulders (Fig. 33).
VAENGINE 9 - 41