2006 MERCEDES-BENZ SPRINTER engine

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

(7) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
NOTE: The lower portion of the cylinder head front
cover is sealed with RTV sealant. Carefully tug front
cover after bolt removal to loosen from cylinder
head.
(8) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(9) Remove top side rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).CAUTION: For all work in which the crankshaft
should not rotate, secure camshaft gear to timing
chain.
(10) Mark camshaft sprocket relative to timing
chain.
(11) Unbolt camshaft sprocket from exhaust cam-
shaft.
NOTE: Note the position of dowel pin for camshaft
sprocket alignment during reassembly.
(12) Remove camshaft sprocket.
CAUTION: Camshaft bearing caps must remain in
proper order and position.
NOTE: Slacken the bolts of the camshaft bearing
caps evenly in steps of one turn until the back
pressure is eliminated. Camshafts must not be
twisted when slackening the camshaft bearing
caps.
(13) Paint mark or scribe each camshaft bearing
cap, identifying which camshaft and which position.
(14) Remove the camshaft bearing caps at exhaust
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(15) Remove the camshaft bearing caps at intake
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(16) Slacken the exhaust camshaft bearing cap
bolts individually at the #2 cap then the #5 cap in
steps of one revolution until the back pressure is
removed.
(17) Slacken the intake camshaft bearing cap bolts
individually at the #2 cap then the #5 cap in steps of
one revolution until the back pressure is removed.
(18) Remove the inlet and exhaust camshafts (Fig.
22).
NOTE: Inspect camshaft and housing for wear or
damage. Inspect the housing oiling ducts for build
up or restrictions, clean as necessary. Also inspect
the camshaft end cover for wear or damage, replace
camshaft as necessary.
Fig. 21 CAMSHAFT ALIGNMENT
1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN MARKING
2 - EXHAUST CAMSHAFT SPROCKET BOLTS
3 - EXHAUST CAMSHAFT SPROCKET
4 - CAMSHAFT ALIGNMENT DOTS
5 - INTAKE CAMSHAFT LOCK POSITION
6 - INTAKE CAMSHAFT SPROCKET
7 - INTAKE CAMSHAFT LOCK (SPECIAL TOOL #8929)
8 - INTAKE CAMSHAFT SPROCKET
VAENGINE 9 - 31

INSTALLATION
CAUTION: The camshafts are sensitive to fractur-
ing. Ensure they are installed free of stress. Oil
bucket tappets and camshaft bearing points.
Inspect ease of operation of bucket tappets.
CAUTION: Pay attention to assignment of cam-
shafts. Camshaft code numbers are visible on the
thrust collar of the axial bearing. Install camshafts
so that the two holes in camshaft sprockets are
positioned opposite and the markings of the cam-
shaft and camshaft bearing cap are aligned.
(1) Install inlet and exhaust camshafts.
NOTE: Tappets are Only serviced when replacing
the camshaft housing. Inspect tappet clearence
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - STANDARD PROCEDURE).
(2) Align inlet and exhaust camshafts at axial
bearing (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).NOTE: Pay attention to markings on camshaft bear-
ing caps.
CAUTION: Do not rotate engine counter clockwise.
(3) Position the piston of cylinder #1 to ignition
TDC.
NOTE: Pay attention to markings on camshaft bear-
ing caps and follow the tightening procedure below.
(4) Install the #2 and #5 Exhaust cam bearing
caps (Fig. 23).
(5) Install the #2 and #5 Intake cam bearing caps
(Fig. 23).
(6) Tighten each of the #2 and #5 Intake and
Exhaust bearing cap bolts evenly to 9N´m (80 lbs.
in.) in steps each of 1 revolution (Fig. 23).
(7) Install the remaining Intake and Exhaust cam
bearing caps and tighten them evenly to 9N´m (80
lbs. in.) in steps each of 1 revolution (Fig. 24).
Fig. 22 CAMSHAFTS AND HOUSING ASSEMBLY
1 - CYLINDER HEAD BOLTS
2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
5 - CYLINDER HEAD
Fig. 23 CAMSHAFT BEARING TIGHTENING
SEQUENCE #1
9 - 32 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