Mercedes Benz & Dodge Sprinter CDI 2000-2006 Owners Workshop Manual (eBook)

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 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 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 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.

You will know the location of the type identification plate, giving you the max. permissible weight, max. permissible weight on front and rear axles and other important data. Depending on the model version, the type identification plate is located in the engine compartment, at the position shown in Fig. 0.1 or at the bottom of the seat on the driver’s side, as shown in Fig. 0.2.

The engine number can be found on the L.H. side of the cylinder block. Transmission, rear axle and steering also have a serial number, stamped into the housing.

Always quote the complete chassis number and/or engine number and the model year of the Sprinter in question when ordering parts. Important also is the actual model number, which will indicate the construction of the vehicle, for example two or four wheels on the rear axle, etc.

0.2. Filling Capacities

0.3. General Servicing Notes

The servicing and overhaul instructions in this Workshop Manual are laid out in an easy-to-follow step-by-step fashion and no difficulty should be encountered, if the text and diagrams are followed carefully and methodically. The “Technical Data” sections form an important part of the repair procedures and should always be referred to during work on the vehicle.

In order that we can include as much data as possible, you will find that we do not generally repeat in the text the values already given under the technical data headings. Again, to make the best use of the space available, we do not repeat at each operation the more obvious steps necessary - we feel it to be far more helpful to concentrate on the difficult or awkward procedures in greater detail. However, we summarise below a few of the more important procedures and draw your attention to various points of general interest that apply to all operations.

Always use the torque settings given in the various main sections of the manual. These are grouped together in separate sub-sections for convenient reference.

Bolts and nuts should be assembled in a clean and very lightly oiled condition and faces and threads should always be inspected to make sure that they are free from damage burrs or scoring. DO NOT degrease bolts or nuts.

All joint washers, gaskets, tabs and lock washers, split pins and “O” rings must be replaced on assembly. Seals will, in the majority of cases, also need to be replaced, if the shaft and seal have been separated. Always lubricate the lip of the seal before assembly and take care that the seal lip is facing the correct direction.

References to the left-hand and right-hand sides are always to be taken is if the observer is at the rear of the vehicle, facing forwards, unless otherwise stated.

Always make sure that the vehicle is adequately supported, and on firm ground, before commencing any work on the underside of the car. A small jack or a make shift prop can be highly dangerous; proper axle stands are an essential requirement for your own safety.

Dirt, grease and mineral oil will rapidly destroy the seals of the hydraulic system and even the smallest amounts must be prevented from entering the system or coming into contact with the components. Use clean brake fluid or one of the proprietary cleaners to wash the hydraulic system parts. An acceptable alternative cleaner is methylated spirit, but if this is used, it should not be allowed to remain in contact with the rubber parts for longer than necessary. It is also important that all traces of the fluid should be removed from the system before final assembly.

Always use genuine manufacturer’s spares and replacements for the best results.

Since the manufacturer uses metric units when building the cars it is recommended that these are used for all precise units. Inch conversions are given in most cases but these are not necessarily precise conversions, being rounded off for the unimportant values.

Removal and installation instructions in this Workshop Manual cover the steps to take away or put back the unit or part in question. Other instructions, usually headed “Servicing", will cover the dismantling and repair of the unit once it has been stripped from the vehicle. It should be noted that the major instructions cover a complete overhaul of all parts but, obviously, this will not always be necessary and should not be carried...