2006 MERCEDES-BENZ SPRINTER engine

²Tighten the nut to 60 N´m (44 ft. lbs.)
²Loosen the nut 90 degrees.
²Retighten the nut to 80 N´m (59 ft. lbs.).
(3) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL INJECTOR - INSTALLA-
TION).
(4) Connect negative battery cable.
(5) Start engine, allow to warm, turn engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM -
DIAGNOSIS AND TESTING).
FUEL TEMPERATURE SENSOR
DESCRIPTION
The fuel temperature sensor is integrated in the
high pressure fuel pump next to the fuel quantity
valve. The sensor detects the temperature of the fuel
and supplies that information to the ECM. The sen-
sor ranges from - 40ÉF (- 40C) to 284ÉF (140ÉC). If
the engine is cold, the actual value sent will read
ambient temperature. The value rises after the
engine has been started.
OPERATION
An negative temperature coefficient (NTC) resistor
integrated in the fuel temperature sensor alters it's
electrical resistance in line with the fuel temperature
(the resistance drops as the temperature rises). The
ECM uses this reading to calculate optimum engine
performance under all driving conditions. If the fuel
is to warm, the rail pressure in the system is low-
ered. The controller quantity of the pressure regulat-
ing valve is reduced and the fuel temperature is
lowered.
REMOVAL
NOTE: Capture and properly store all fluid seepage
in appropriately marked containers.
(1) Disconnect the negative battery cable.
(2) Remove the fuel temperature sensor from the
high pressure pump (Fig. 19).
INSTALLATION
(1) Clean sealing surfaces.
(2) Install new seal on sensor.
(3) Screw the sensor into the high pressure pump
and tighten to 18 lbs.ft. (25 N´m) (Fig. 19)
(4) Connect negative battery cable.
(5) Start engine, allow to warm, shut engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION - WARNING).
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The intake air temperature sensor is located
between the charge air pipe and the charge air dis-
tribution of the cylinders. The intake air temperature
sensor measures the temperature of the air as it is
supplied to the cylinders and transmits the value to
the ECM. This is required in order to determine the
density of the air being supplied for the combustion
process. The value range is from minus 40ÉF up to
302ÉF (minus 40ÉC to 150ÉC).
Fig. 19 HIGH PRESSURE FUEL PUMP
1 - HIGH PRESSURE PUMP
2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
8 - VACUUM PUMP
14 - 42 FUEL INJECTIONVA

OPERATION
The Negative Temperature Coefficient (NTC)
resister located within the intake air temperature
sensor alters it's resistance in line with the charge
air temperature. If the engine is cold, the value
equals ambient temperature. For a temperature of
68ÉF (20ÉC) the resistance is approximately 6000
ohms. For a temperature of 104ÉF (40ÉC) the resis-
tance is approximately 3300 ohms (Fig. 20).
REMOVAL
(1) Disconnect the negative battery cable.
(2) Unplug the wiring harness connector at the
intake air temperature sensor.
(3) Press together the sensor locking arms and
remove the sensor from the charge air pipe (Fig.
21).
INSTALLATION
(1) Position the intake air temperature sensor
above the charge air pipe access hole.
(2) Press together the sensor locking tabs, seat the
sensor to the pipe and release tabs (Fig. 21).
(3) Connect negative battery cable.
INTAKE AIR PRESSURE SEN-
SOR
DESCRIPTION
An absolute pressure sensor is mounted to the air
cleaner housing. The sensor is used by the ECM to
adjust for changes in altitude and for air intake
obstructions due to a clogging air cleaner.
OPERATION
The ECM uses the intake air pressure sensor to
monitor the intake pressure. Monitoring this pres-
sure allows better control of the variable geometry
turbocharger to suit the driving environment and
preserve turbocharger durability.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor electrical connector.
(3) Remove the air intake pressure sensor.
Fig. 20 INLET AIR TEMPERATURE SENSOR
1 - INTAKE AIR TEMPERATURE SENSOR
2 - PIPE
Fig. 21 BOOST PRESSURE AND INLET AIR
TEMPERATURE SENSORS
1 - CHARGE AIR DUCT
2 - INTAKE AIR TEMPERATURE SENSOR
3 - BOOST PRESSURE SENSOR
VAFUEL INJECTION 14 - 43

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................1COLUMN................................4
GEAR..................................7
LINKAGE................................9
PUMP..................................11
STEERING
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM
There is some noise in all power steering systems.
One of the most common is a hissing sound evident at
a standstill parking. Or when the steering wheel is at
the end of it's travel. Hiss is a high frequency noise
similar to that of a water tap being closed slowly. The
noise is present in all valves that have a high velocity
fluid passing through an orifice. There is no relation-
ship between this noise and steering performance.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
VASTEERING 19 - 1

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION..........................7
REMOVAL.............................7INSTALLATION..........................7
SPECIFICATIONS - TORQUE CHART.........8
GEAR
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part
of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa-
rate the tie rods from the steering knuckles (Fig. 2)
using special tool C-3894±A.
(6) Remove the left outer tie rod end from the
steering gear.
(7) Remove both spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).(8) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from
the steering gear (Fig. 2).
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.
INSTALLATION
(1) Install the gear to the vehicle.
NOTE: Steering gear must be torqued in a three
step procedure below.
(2) Install the steering gear bolts (Fig. 2). Tighten
to an initial torque of 25 N´m (18 ft. lbs.) Then
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR REMOVAL / INSTALL
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
VAGEAR 19 - 7

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....11
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............12
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS - TORQUE CHART........13
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE........................13FLUID COOLER TUBE
REMOVAL.............................13
INSTALLATION.........................13
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE...........14
REMOVAL - RETURN LINE FROM PUMP TO
COOLER TUBE.......................14
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE....................14
INSTALLATION
INSTALLATION - PRESSURE HOSE.......14
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE...............14
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE...............14
PUMP
DESCRIPTION
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump. The
power steering pumps are constant flow rate and dis-
placement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use approved fluid only in the power
steering system (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION). No other
power steering or automatic transmission fluid is to
be used in the system. Damage may result to the
power steering pump and system if any other fluid
is used, and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
VAPUMP 19 - 11

(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4) Remove the return hose from the pump (Fig.
1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
19 - 12 PUMPVA

SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pump To
Timing Case Cover/Sup-
port21 15 185
High Pressure Flexible
Hose To Power Steering
Pump38 28 336
Power Steering Pulley To
Pump30 22 265
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED
PROCEDURE
(1) Remove the cap from the fluid reservoir.
Check cap seal for damage and replace if
needed.
(2) Fill the power steering pump with approved
fluid (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).Do not fill fluid
beyond the MAX mark.
(3) Raise the vehicles front wheels off the ground.
(4) With the engine off turn the steering wheel
from right to left.Perform this step until all the
bubble formations can no longer be seen in the
power steering reservoir.
(5) Start the engine and turn the steering wheel
with the engine at idle speed then shut the engine off
and check for correct oil level and no bubble in the
system.
(6) Reinstall power steering cap tightly.
(7) Test the system for leaks and proper operation.
FLUID COOLER TUBE
REMOVAL
(1) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(2) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(3) Remove the left headlight assembly.
(4) Disconnect the return lines from the cooler
tube.
(5) Remove the radiator clips (2).
(6) Remove the heat shield bolt for the turbo at
the core support.
(7) Remove the right headlight assembly.(8) Remove the core support bolts (4) and discon-
nect the hood latch cable.
(9) Remove the fan bracket bolts (4) to the radiator
(Fig. 2).
(10) Remove the two upper screws for the con-
denser (Fig. 2).
(11) Remove the condenser air dam shield.
(12) Remove the mounting screws for the cooler
tube (Fig. 2).
(13) Remove the cooler tube from the vehicle.INSTALLATION
(1) Install the cooler tube to the vehicle.
(2) Install the cooler tube mounting screws (Fig.
2).
(3) Install the condenser air dam shield.
(4) Install the condenser upper mounting screws
(Fig. 2).
(5) Install the fan bracket bolts to the radiator
(Fig. 2).
Fig. 2 FLUID COOLER TUBE
1 - MOUNTING SCREWS (4)
2 - FLUID COOLER
3 - ELECTRIC COOLING FAN
4 - A/C CONDENSOR
VAPUMP 19 - 13

AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION
DESCRIPTION
The NAG1 automatic transmission (Fig. 1) is an
electronically controlled 5-speed transmission with a
lock-up clutch in the torque converter. The ratios for
the gear stages are obtained by 3 planetary gear sets.
Fifth gear is designed as an overdrive with a high-
speed ratio.
NAG1 identifies a family of transmissions and
means ªNºew ªAºutomatic ªGºearbox, generation 1.
Various marketing names are associated with the
NAG1 family of transmissions, depending on the
transmisson variation being used in a specific vehi-
cle. Some examples of the marketing names are:
W5A300, W5A380, and W5A580. The marketing
name can be interpreted as follows:
²W = A transmission using a hydraulic torque
converter.
²5 = 5 forward gears.
²A = Automatic Transmission.²580 = Maximum input torque capacity in New-
ton meters.
The gears are actuated electronically/hydraulically.
The gears are shifted by means of an appropriate
combination of three multi-disc holding clutches,
three multi-disc driving clutches, and two freewheel-
ing clutches.
Electronic transmission control enables precise
adaptation of pressures to the respective operating
conditions and to the engine output during the shift
phase which results in a significant improvement in
shift quality.
Furthermore, it offers the advantage of a flexible
adaptation to various vehicle and engines.
Basically, the automatic transmission with elec-
tronic control offers the following advantages:
²Reduces fuel consumption.
²Improved shift comfort.
²More favourable step-up through the five gears.
Fig. 1 NAG1 Automatic Transmission
1 - TORQUE CONVERTER 11 - PARKING LOCK GEAR
2 - OIL PUMP 12 - INTERMEDIATE SHAFT
3 - DRIVESHAFT 13 - FREEWHEEL F2
4 - MULTI-DISC HOLDING CLUTCH B1 14 - REAR PLANETARY GEAR SET
5 - DRIVING CLUTCH K1 15 - CENTER PLANETARY GEAR SET
6 - DRIVING CLUTCH K2 16 - ELECTROHYDRAULIC CONTROL UNIT
7 - MULTI-DISC HOLDING CLUTCH B3 17 - FRONT PLANETARY GEAR SET
8 - DRIVING CLUTCH K3 18 - FREEWHEEL F1
9 - MULTI-DISC HOLDING CLUTCH B2 19 - STATOR SHAFT
10 - OUTPUT SHAFT 20 - TORQUE CONVERTER LOCK-UP CLUTCH
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 3