2006 MERCEDES-BENZ SPRINTER engine

(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: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
STANDARD PROCEDURE - MEASURING CYLIN-
DER BORES
NOTE: This must be done with engine completely
disassembled.
(1) Thoroughly clean all cylinder bores with appro-
priate cleaning solvent.
(2) Measure each cylinder at the three measuring
points shown (Fig. 31).
(3) Using the three measurment point, measure
cylinder in the longitudinal and in the transverse
direction (Fig. 31).
Fig. 30 CORE HOLE PLUG REMOVAL
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 38 ENGINEVA

(4) Use the measurment and table below to group
cylinder bores:
Standard size 88.0 mm
Group code letter A 88.000-88.006 mm
Group code letter X 88.006-88.012 mm
Group code letter B 88.012-88.018 mm
Wear limit in longitudinal
in transverse direction0.020 mm
Permissible variation of
cylinder shape (when
new)0.000-0.014 mm
CRANKSHAFT
DESCRIPTION
The engine features a forged crankshaft supported
by six bearings. The bearing caps are machined
together with the crankshaft and must not be inter-
changed. The bearing surfaces are induction hard-
ened. The connecting rods and main bearing journals
are filleted. An optional vibration damper with a sec-ond pulley is used to drive an additional A/C com-
pressor.
STANDARD PROCEDURE - MEASURE CRANK-
SHAFT AND BLOCK JOURNALS
NOTE: After any bearing damage occurred, remove
all debris which is present in the main oil gallery,
connecting rod bores, and in the crankshaft and oil
galleries. Include removal of the inserting steel ball
of the main oil gallery before cleaning.
(1) Remove crankshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT - REMOVAL).
(2) Clean all engine parts thoroughly.
CAUTION: After bearing has damage has occurred,
replace connecting rods which have suffered over-
heating because of bearing damage. The connect-
ing rod must not have any cross scores and
notches.
(3) Inspect connecting rod. If damage is present,
inspect crankshaft, replace as necessary.
(4) Inspect crankcase.
Fig. 31 MEASURING CYLINDER BORES
1 - MEASURING POINT OF CYLINDER BORE
2 - MEASURING POINT OF CYLINDER BORE
3 - MEASURING POINT OF CYLINDER BORE
1a - UPPER REVERSAL POINT OF #1 PISTON RING
1b - BOTTOM DEAD CENTER OF PISTON
1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING
1A - LONGITUDINAL DIRECTION
1B - TRANSVERSE PDIRECTION
VAENGINE 9 - 39

(5) Inspect standard size of crankshaft bearing
shells.
(6) Inspect crankshaft bearing cap.
(7) Mount crankshaft radially.
(8) Inspect crankshaft bearing play.
NOTE: Radial mounting of the main bearings of
standard size crankshaft is possible by assigning
the color-coded bearing shells.
ASSIGN CRANKSHAFT BEARING SHELLS
The oil pan rail of the cylinder block is marked
with chisel punches indicating what bearing shell are
used.
(9) Assign crankshaft bearing shells.
(10) Mount crankshaft axially.
(11) Inspect crankshaft bearing play.
REMOVAL
(1) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Remove end cover. (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
(4) Remove pistons (Refer to 9 - ENGINE/ENGINE
BLOCK/PISTON & CONNECTING ROD -
REMOVAL).
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 crankshaft bear-
ing caps fit.
(5) Unbolt crankshaft bearing caps (Fig. 32).
(6) Inspect crankshaft bearing caps and bolts for
wear and stretching.
(7) Remove crankshaft.
INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.
CAUTION: Oil grooves in the thrust washers must
point toward the thrust collars of the crankshaft.
CAUTION: Thrust washers in the bearing cap each
have two retaining lugs as a anti-twist lock.
Fig. 32 CRANKSHAFT ASSEMBLY
1 - BEARING HALVES IN ENGINE BLOCK
2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
7 - MAIN BEARING BOLTS
9 - 40 ENGINEVA

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

INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor
evenly onto the assembly sleeve. The rear main oil
seal lip MUST NOT roll over the edge of the tool.
(1) Position the rear main oil seal/adaptor with
assembly sleeve onto the crankshaft so that the
dowel sleeves fit into the guide holes (Fig. 33). Care
must be taken so that the oil pan gasket is not dam-
aged.
(2) Install the rear main seal/adaptor to crankcase
bolts and tighten to 9´Nm (80 lbs.in) (Fig. 33).
(3) Tighten the M6 oil pan bolts to 9N´m (80 lbs
in) and the M8 bolts to 20 N´m (15 lbs ft).
(4) Install the fly wheel and tighten bolts in two
stages (Fig. 33). 45N´m (33 lbs. ft.) then 90É.(5) Install the oil pan drain plug and tighten to
25N´m (18 lbs ft).
(6) Lower the vehicle.
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to owners manual for spec-
ifications.
(8) Connect the negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(9) Start the engine and inspect for leaks.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the accessory drive belt.
Fig. 33 REAR MAIN SEAL/ADAPTER
1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL 8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER
6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - 42 ENGINEVA

(3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller MUST mesh fully
into the slots of the belt pulley.
NOTE: Inspect the running surface of the belt pulley
for wear.
(4) Remove the belt pully/vibration damper.
CAUTION: Care must be taken to prevent severe
damage to the crankshaft and mounting whole for
the front crankshaft seal.
(5) Using a suitable prying tool, remove the front
crankshaft seal from the timing cover (Fig. 34).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the front crankshaft seal
evenly onto the timing cover.(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(3) Remove the retaining lock for the crankshaft/
ring gear.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Fill the crankcase with the correct engine oil to
the proper level.
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.
FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: M6x90 bolts must be used with retaining
lock to prevent damage to rear end cover.
(2) Install retaining lock for crankshaft/starter
ring gear.
NOTE: Flywheel does not need balancing or should
it be interchanged.
(3) Remove flywheel with inner washer (Fig. 35).
Fig. 34 FRONT SEAL REMOVAL/INSTALLATION
1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
3 - WASHER
4 - RETAINING BOLT
VAENGINE 9 - 43