2006 MERCEDES-BENZ SPRINTER engine

INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 59).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, coat the inside with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Slide the oil pan into position.
(2) Slide the gasket into position.
(3) Add sealant to the joints on the engine block
where indicated (Fig. 58).
Fig. 57 OIL PAN
1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
Fig. 58 OIL PAN GASKET
9 - 60 ENGINEVA

(4) Install the oil pan. Tighten M6 bolts to 9N´m
(80 lbs. in.) and M8 bolts to 20N´m (15 lbs. ft.) (Fig.
59).
(5) Tighten the bolt of the transmission bell hous-
ing to oil pan to 40N´m (30 lbs. ft.).
(6) Install the wiring harness duct (Fig. 57).
(7) Connect the oil level sensor (Fig. 57).
(8) Lower the vehicle.
(9) Lower the engine until the engine mount and
engine supports make contact.
(10) Start and hand tighten the engine mount
bolts.
(11) Lower the engine the rest of the way and
remove the engine support fixture.
(12) Tighten the engine mount bolts to 83 N´m (61
lbs. ft.).
(13) Install the sway bar and tighten bolts to 30
N´m (22 lbs. ft.).
(14) Refill crankcase with the proper engine oil to
the proper level (Refer to LUBRICATION & MAIN-
TENANCE/FLUID TYPES - SPECIFICATIONS).
(15) Reconnect 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.
(16) Start the engine and inspect for leaks.OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 57).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 57).
REMOVAL - OIL PUMP CHAIN
(1) Disconnect negative battery cable.
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
NOTE: Make sure the pin of the thrust spindle is
backed out into the thrust spindle before seating
the thrust spindle to the oil pump chain.
(4) Using special tool #9312±1 riveting tool, thrust
spindle #9312±4 and thrust pin pin #9312±3, position
and fit chain seperating tool and thrust spindle onto
a link of the oil pump chain (Fig. 60).
(5) Screw the thrust pin in and seperate the oil
pump chain link.
Fig. 59 OIL PAN BOLTS
1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55
Fig. 60 OIL PUMP CHAIN LINK REMOVAL
1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
3 - SPECIAL TOOL #9312-1
VAENGINE 9 - 61

(6) Remove pressed - out oil pump chain pin from
chain seperation tool.
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the oil pump chain is followed exactly.
Failure to do so will result in severe engine dam-
age.
INSTALLATION
INSTALLATION
NOTE: If the oil pump is dry, fill it with clean engine
oil before installation. Clean the oil pick±up tube
and strainer.
(1) Clean all sealing surfaces.
(2) Position the oil pump onto the drive chain and
reset tensioner.
(3) Install oil pump retaining bolts and tighten to
18 N´m (160 lbs. in.).
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Refill the crankcase to the appropriate level
with the proper engine oil (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
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.
(6) Start the vehicle and inspect for leaks.
INSTALLATION - OIL PUMP CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
61).(2) Slowly rotate crankshaft in a clockwise direc-
tion until it is possible to connect the ends of the new
and old oil pump chains.
(3) Remove assembly locking element, outer plate
and assembly link (Fig. 62).
Fig. 61 INSTALLING OIL PUMP CHAIN TEMPORARY
LINK
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OLD OIL PUMP CHAIN
3 - NEW OIL PUMP CHAIN
4 - TEMPORARY LINK
9 - 62 ENGINEVA

CAUTION: Insert new riveted link from the rear.
(4) Connect ends of new oil pump chain with new
riveted link (Fig. 63).NOTE: When assembling riveting tool, one piece is
secured by a screw and the other can move loosely
on the thrust spindle.
NOTE: The outer plate will be held in place by a
magnet.
(5) Place new outer plate into tool insert.
NOTE: Ensure that the riveted link and riveting tool
are aligned.
(6) Position riveting tool over new link and press
in new rivet as far as the tool stop.
(7) Remove riveting tool to change inserts.
(8) Install insert on riveting tool and secure with
screw.
(9) Install insert on riveting tool (Fig. 64).
NOTE: The outer plate is held in place magnetically
by riveting tool.
(10) Insert new outer plate into the moving assem-
bly insert.
(11) Position riveting tool so that spacer webs of
the guide are side by side.
(12) Ensure that riveted link and outer plate are
aligned.
NOTE: When turning spindle of riveting tool, be
sure that pins of riveted link are inserted into holes
of outer plate.
(13) Screw in spindle of riveting tool until firm
resistance is felt.
Fig. 62 REMOVING OIL PUMP CHAIN TEMPORARY
LINK
1 - NEW OIL PUMP CHAIN
2 - OLD OIL PUMP CHAIN
3 - TEMPORARY LINK
Fig. 63 INSTALLING NEW RIVETED LINK
1 - NEW RIVETED LINK
2 - OIL PUMP CHAIN
Fig. 64 INSTALLING RIVETING INSERTS INTO
RIVETING TOOL
1 - SPECIAL TOOL #9312-1
2 - SPECIAL TOOL #9312-5 and #9312-9
VAENGINE 9 - 63

(14) Remove riveting tool.
(15) Turn over tool moving assembly insert to the
riveting profile.
NOTE: Rivet pins of the riveted link individually.
(16) Position riveting tool exactly over middle of
pin (Fig. 65).
(17) Tighten riveting tool spindle until it stops.
(18) Remove riveting tool, inspect riveting, re-rivet
if necessary (Fig. 66).
(19) Repeat procedure for both rivets.(20) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(21) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(22) Refill engine with proper oil to the correct
level (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - SPECIFICATIONS).
(23) Connect negative battery cable.
(24) Start engine and inspect for leaks.
OIL SENSOR
DESCRIPTION
Oil level, oil temperature and oil quality are
detected by means of an oil sensor located in the oil
pan. The sensor which operates on the capacitance
principle features an integrated electronic circuit
which analyzes the three signals. the signals are con-
stantly relayed to the ECM and over the CAN bus to
the instrument cluster by means of PWM signal.
OPERATION
Oil quality is detected for indicating the need-
based oil change interval. The oil quality is detected
on the basis of the capacitance of the engine oil
(dielectrics, does not conduct electricity), this being
as much as six times greater in case of poor quality.
Oil level and oil quality are separate of each other.
The information is first of all compensated in the
ECM before being transmitted over the CAN bus.
Faults at the oil sensor are detected by the ECM
and entered into fault memory. The voltage for the
oil sensor (approx.5V) is supplied by the ECM.
Fig. 65 NEW LINK RIVETING
1 - SPECIAL TOOL #9312-5 INSERT
2 - SPECIAL TOOL #9312-1 RIVETING TOOL
3 - SPECIAL TOOL #9312-4 THRUST SPINDLE
4 - SPECIAL TOOL #9312-3 THRUST PIN
5 - SPECIAL TOOL #9312-12 INSERT
6 - OIL PUMP CHAIN
Fig. 66 RIVET INSPECTION
9 - 64 ENGINEVA

REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain engine oil into a suitable, and appropri-
ately marked container.
(4) Remove engine mount to chassis nuts.
(5) Lower vehicle and install engine support.
(6) Remove the turbo charger heat shield to radia-
tor support bolts.
(7) Raise engine until the weight of the engine no
longer rests on the engine mounts.
(8) Raise and support the vehicle.
(9) Detach the front stabilizer bar at the front axle
and rotate it downward.
(10) Unplug the oil level sensor (Fig. 67).
(11) Remove the oil level sensor retaining screw,
oil level sensor and discard the O-ring (Fig. 67).
INSTALLATION
(1) Seat new O-ring on oil level sensor and lubri-
cate O-ring with clean engine oil (Fig. 67).
(2) Install the oil level sensor into the oil pan and
tighten screw to 124 lbs. in.(14N´m) (Fig. 67).
(3) Connect oil level sensor wiring harness connec-
tor (Fig. 67).
(4) Rotate front stabilizer bar upward and secure
to axle beam. Tighten to 22 lbs.ft. (30 N´m)
(5) Lower the vehicle.
(6) Lower the engine into the mounts.
(7) Remove engine support fixture.(8) Raise and support the vehicle.
(9) Tighten both engine mount to chassis nuts.
(10) Install and tighten oil drain plug.
(11) Lower vehicle and install the appropriate
engine oil.
INTAKE MANIFOLD
REMOVAL
WARNING: NO FIRE, SPARKS OR SMOKING.
STORE FUELS ONLY INTO SUITABLE AND APPRO-
PRIATELY MARKED CONTAINERS, AND WEAR
PROTECTIVE CLOTHING. (Refer to 14 - FUEL SYS-
TEM - WARNING).
WARNING: DO NOT OPEN THE COOLING SYSTEM
UNLESS THE COOLANT TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN RADIATOR CAP SLOWLY TO
RELEASE PRESSURE. STORE COOLANT ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS, WEAR PROTECTIVE CLOTHING AND
EYE PROTECTION.
(1) Disconnect the negative battery cable.
(2) Partially drain coolant from the radiator.
(3) Remove the engine cover (Refer to 9 - ENGINE
- REMOVAL).
(4) Remove the high pressure fuel lines (Fig. 68).
Fig. 67 OIL LEVEL SENSOR
1 - OIL PAN
2 - O-RING
3 - WIRING HARNESS
4 - BOLT
5 - OIL LEVEL SENSOR
VAENGINE 9 - 65

(5) Remove the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(6) Remove the fuel rail support block between cyl-
inders #1 and #2 (Fig. 68).
(7) Disconnect the charge air hose at the intake
manifold (Fig. 69).
Fig. 68 FUEL INJECTORS AND HIGH PRESSURE
FUEL LINES
1 - FUEL RAIL
2 - HIGH PRESSURE FUEL INJECTOR LINES
3 - INTAKE MANIFOLD
4 - FUEL INJECTOR
5 - CRANKCASE VENTILATION BREATHER
6 - CAMSHAFT POSITION SENSOR
9 - 66 ENGINEVA

(8) Disconnect the EGR wiring harness connector
(Fig. 69).
(9) Remove the bolt retaining the engine wiring
harness to the intake manifold.
(10) Disconnect the coolant hose at the EGR valve.
NOTE: Collect and store any fluid spillage when
disconnecting components.
(11) Disconnect both fuel lines at the fuel filter
(Fig. 69).
(12) Remove the lower intake manifold support
bracket (Fig. 70).
(13) Raise and support the vehicle.
(14) Remove the rear intake manifold mounting
bolts while accessible from below.
(15) Lower the vehicle.
Fig. 69 INTAKE MANIFOLD
1 - CLIP 6 - ENGINE OIL COOLER
2 - INTAKE MANIFOLD 7 - HIGH PRESSURE FUEL RAIL
3 - EGR VALVE 8 - COOLANT TEMPERATURE SENSOR
4 - EGR VALVE COOLANT HOSE 9 - FUEL RAIL PRESSURE SENSOR
5 - FUEL FILTER 10 - CHARGE AIR HOSE
VAENGINE 9 - 67