2000-2006 Mercedes-Benz Sprinter Van Service & Repair Manual

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ABOUT THIS BOOK This Owners Edition - Workshop Manual covers the Mercedes- Benz Sprinter Van and Camper Diesel models fitted with 2151cc (four-cylinder 2.2 litre) and 2686cc (five-cylinder 2.7 litre) engines (types 611 DELA & 612 DELA), with the modes covered: 208 CDI, 308 CDI, 211 CDI, 311 CDI, 411 CDI, 213 CDI, 313 CDI, 413 CDI, 216 CDI, 316 CDI, & 416 CD. Identification type 901, 902, 903 and 904 depending on the version. All engines operate with the “Common Rail” injection system, known as CDI models built between 2000 and the end of 2006. It has been specially written for the practical owner who wants to maintain a vehicle in first-class condition and carry out the bulk of his or her own servicing and repairs. Comprehensive step-by-step instructions are provided for service and overhaul operations to guide the reader through what might otherwise be unfamiliar and complicated tasks. Numerous drawings are included to amplify the text. With the aid of this manual, many aspects of service, overhaul and repair are within the scope of an owner with a reasonable degree of mechanical aptitude. Some operations however demand more skill. Other jobs require the use of special tools and in some cases testing facilities and techniques that are not generally available. Only you can judge whether a job is within your capabilities. We do however try to assist the reader to come to an informed decision. Whilst every effort has been made to ensure that the information provided is correct, it is obviously not possible to guarantee complete freedom from errors or omissions. Information to be found in the driver’s handbook is not "****** DEMO - www.ebook-converter.com*******"

necessarily duplicated here and it is not possible within this volume to cover every aspect to be found in the manufacturer’s own workshop manual which is of much greater size and complexity. However, it should be consulted if more detailed information is needed. Always remember that you are responsible for your own safety and that of others when working on a vehicle. Take particular care with safety-related systems like the brakes and steering, and seek professional advice if in any doubt. Never work under a vehicle unless it is properly supported (a single jack is not enough). Take care with power tools, also regard as potentially harmful fuel, lubricants, solvents and sealers which should always be and kept in labelled, sealed containers. With care and common sense, the practical owner can make an excellent job of maintenance and overhaul. The benefits include money saved and the satisfaction of work well done. You will be adding to your knowledge, too: knowing more about the vehicle you own will help you to make logical decisions about what needs to be done, even if it does in some instances have to go into a professional repair shop. The Mercedes-Benz Sprinter is a vehicle that will respond to careful regular servicing and is built to a standard that will ensure a long life if this is remembered. © Copyright Brooklands Books Ltd. 2010 and PR Publications Limited This book has been compiled from text and illustrations supplied by PR Publications Limited and have been used with "****** DEMO - www.ebook-converter.com*******"

their kind permission. Text and illustrations may not be reproduced, transmitted or copied by any means without the prior written permission of Brooklands Books Limited and PR Publications Limited. Whilst every effort is made to ensure the accuracy of the particulars in this manual, neither the Publisher nor the Distributors nor the Dealer, by whom this manual is supplied shall under any circumstances be held liable for any inaccuracy or the consequences thereof. ISBN 9781855209749 MBSWHEK Brooklands Books Ltd. PO Box 146, Cobham, Surrey KT11 1LG, England Tel. 01932 865051 Fax 01932 868803 "****** DEMO - www.ebook-converter.com*******"

CONTENTS Introduction Chapter 1 Engines Lubrication System Cooling System Diesel Fuel Injection System (CDI) Chapter 2 Clutch Chapter 3 Manual Transmission (Gearbox) Chapter 4 Front Axle Chapter 5 Rear Axle Propeller Shaft Chapter 6 Front and Rear Suspension Chapter 7 Steering Chapter 8 Brake System Chapter 9 Electrical System Chapter 10 Turbo Charger and Exhaust System Chapter 11 Servicing and Maintenance Fault Finding Section Wiring Diagram Index "****** DEMO - www.ebook-converter.com*******"

0. INTRODUCTION Our Owners Manual are based on easy-to-follow step-by-step instructions and advice, which enables you to carry out many jobs yourself. Moreover, now you have the means to avoid these frustrating delays and inconveniences that so often result from not knowing the right approach to carry out repairs that are often of a comparatively simple nature. Whilst special tools are required to carry out certain operations, we show you in this manual the essential design and construction of such equipment, whenever possible, to enable you in many cases to improvise or use alternative tools. Experience shows that it is advantageous to use only genuine parts since these give you the assurance of a first class job. You will find that many parts are identical in the range covered in this manual, but our advice is to find out before purchasing new parts. Always buy your spare parts from an officially appointed dealer. 0.0. General Information The manual covers the listed Mercedes-Benz commercial vehicles with 2.2 and 2.7 litre direct injection diesel engine, fitted with “Common Rail” injection system. The following models are covered: • 208 CDI, 308 CDI are fitted with the 2.2 litre four-cylinder diesel engine with a conventional turbocharger, a charge air cooler and a performance of 60 kW (83 BHP) at 3800 rpm (engine type 611) • 211 CDI, 311 CDI and 411 CDI are fitted with the 2.2 litre "****** DEMO - www.ebook-converter.com*******"

four-cylinder diesel engine with a so-called variable nozzle turbocharger, VNT for short, and a performance of 109 kW (80 BHP) at 3800 rpm (engine type 611). • 213 CDI, 313 CDI and 413 CDI are fitted with the 2.2 litre four-cylinder diesel engine with the same turbocharger, but the performance has been increased to 129 kW (95 BHP) at 3800 rpm (engine type 611). • The remaining models 216 CDI, 316 CDI and 416 CDI are fitted with the 2.7 litre five-cylinder engine with a performance of 156 kW (115 BHP) at 3800 rpm (engine type 612). The engine is similar to the four-cylinder engine, with the additional cylinder added on. The engine has a VNT turbocharger as explained above and a charge air cooler (intercooler). In general you can identify the model by the two numbers before the “CDI". All models with “08” have the 2.2 litre engine, models with “11” also have the 2.2 litre engine with increased performance, models ending with “13” have the more powerful 129 BHP engine, models with “16” have the five- cylinder engine. Many different body versions, model numbers and engine versions are used in the range of vehicles marketed. You should familiarise yourself with the model number of your vehicle. Lack of space prevents us from listing every model. We should like to stress that not all vehicles are sold in any particular country. All vehicles covered in the manual are fitted with either a five-speed transmission, an automatic transmission, or a six- speed transmission known as “Sprintshift”. The various model numbers are followed by further numbers, which enables the workshop to identify your model "****** DEMO - www.ebook-converter.com*******"

correctly when it comes to spare parts, accessory parts, etc. The different vehicles are available with a number of different wheel bases. The following lists some of the available options: • Sprinter panel vans are available with “normal” length and “medium” length (wheelbase 3000 and 3550 mm). • Sprinter panel vans with high roof are available with “normal”, “medium” and “long” (wheelbase 3000, 3550 and 4025 mm). • Sprinter Pick-Ups with standard cab and crew cab are available with “normal", “medium” and “long” (wheelbase 3000, 3550 and 4025 mm). The same applies to Sprinter Tippers and Sprinter Chassis. Some of these models are not available in the UK. The front suspension consists of a transversely fitted leaf spring. A suspension arm with ball joint is used at the bottom. A hydraulic, telescopic shock absorber is bolted to the steering knuckle and attached to the body with the upper end. The stabiliser bar is bolted to the chassis and connected to the two lower suspension arms. The rear axle has been taken from the earlier MB transporters, i.e. a rigid axle with leaf springs and hydraulic, telescopic shock absorbers is used, but disc brakes are fitted to the rear wheels. Disc brakes at the front and rear make up the brake system, assisted by a brake servo unit. The vacuum for the servo unit is taken from a special exhauster pump (vacuum pump). Depending on the model, ABS can be fitted as standard or is available as optional extra. Models can also have an automatic brake differential, known as “ABD”, standard fitting on various "****** DEMO - www.ebook-converter.com*******"

models The rack and pinion steering is servo-assisted. Fig. 0.1 - The position of the vehicle type identification plate in the engine compartment. 0.1. Identification When you purchased the vehicle you will have received various data cards which have all important vehicle details, as for example chassis number and component numbers as well as identification of optional equipment, etc. Your Owner’s Manual will give you further instructions on the use of these cards. Fig. 0.2 - The position of the type identification plate in the door opening. "****** DEMO - www.ebook-converter.com*******"

2000-2006 Mercedes-Benz Sprinter Van Service & Repair Manual

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