Mercedes-Benz 2005 Sprinter Service Manual page 1212

Table of Contents

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2
INDEX
Description
BACKLITE - BULKHEAD TRIM PANEL -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-81
BACKLITE - BULKHEAD TRIM PANEL -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-81
BACKUP LAMP BULB - INSTALLATION . . . . . 8L-6
BACKUP LAMP BULB - REMOVAL
BALANCE - STANDARD PROCEDURE,
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . 22-3
BALL JOINT - INSTALLATION, LOWER
BALL JOINT - REMOVAL, LOWER . . . . . . . . . . 2-6
BAR - DESCRIPTION, STABILIZER
BAR - INSTALLATION, STABILIZER . . . . . 2-15,2-9
BAR - OPERATION, STABILIZER
BAR - REMOVAL, STABILIZER
. . . . . . . . 2-15,2-9
BASE BRAKE, SPECIFICATIONS . . . . . . . . . . . . 5-6
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
BASECOAT/CLEARCOAT FINISH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 23-74
BATTERY - DESCRIPTION
. . . . . . . . . . . . . . . 8F-6
BATTERY - DIAGNOSIS AND TESTING
BATTERY - OPERATION
. . . . . . . . . . . . . . . . . 8F-7
BATTERY CABLES - DESCRIPTION
BATTERY CABLES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-14
BATTERY CABLES - INSTALLATION . . . . . . . 8F-16
BATTERY CABLES - OPERATION
BATTERY CABLES - REMOVAL
. . . . . . . . . . 8F-16
BATTERY CHARGING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8
BATTERY ELECTROLYTE LEVEL -
STANDARD PROCEDURE, CHECKING . . . . . 8F-12
BATTERY HOLDDOWN - DESCRIPTION . . . . 8F-14
BATTERY HOLDDOWN - INSTALLATION
BATTERY HOLDDOWN - REMOVAL
BATTERY INSTALLATION, INSTALLATION
- AUXILIARY . . . . . . . . . . . . . . . . . . . . . . . . 8F-13
BATTERY INSTALLATION, INSTALLATION
- UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 8F-13
BATTERY REMOVAL, REMOVAL -
AUXILIARY . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-13
BATTERY REMOVAL, REMOVAL - UNDER
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-12
BATTERY SYSTEM - CLEANING . . . . . . . . . . . 8F-5
BATTERY SYSTEM - DESCRIPTION . . . . . . . . 8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
BATTERY SYSTEM - INSPECTION
BATTERY SYSTEM - OPERATION
BATTERY SYSTEM SPECIAL TOOLS,
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 8F-6
BATTERY TESTER - STANDARD
PROCEDURE, USING MICRO 420 . . . . . . . . 8F-11
BATTERY TRAY - DESCRIPTION
BATTERY TRAY - INSTALLATION . . . . . . . . . 8F-16
BATTERY TRAY - OPERATION
. . . . . . . . . . . 8F-16
BATTERY TRAY - REMOVAL
. . . . . . . . . . . . 8F-16
BEAM HEADLAMP BULB -
INSTALLATION, HIGH . . . . . . . . . . . . . . . . . 8L-17
BEAM HEADLAMP BULB -
INSTALLATION, LOW . . . . . . . . . . . . . . . . . . 8L-19
BEAM HEADLAMP BULB - REMOVAL,
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-17
BEAM HEADLAMP BULB - REMOVAL,
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-18
BEAM INDICATOR - DESCRIPTION, HIGH
BEAM INDICATOR - OPERATION, HIGH . . . . 8J-17
BEARING - INSTALLATION, CENTER
BEARING - INSTALLATION, HUB . . . . . . . . . . . 2-5
BEARING - INSTALLATION, OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-122
BEARING - REMOVAL, CENTER
BEARING - REMOVAL, HUB
. . . . . . . . . . . . . . 2-4
BEARING - REMOVAL, OUTPUT SHAFT . . . 21-122
BEARINGS/SEALS - INSTALLATION, AXLE
BEARINGS/SEALS - INSTALLATION, AXLE
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
BEARINGS/SEALS - REMOVAL, AXLE
BEARINGS/SEALS - REMOVAL, AXLE
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
BELT - DIAGNOSIS AND TESTING,
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . 7-5
BELT & RETRACTOR - INSTALLATION,
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . 8O-21
BELT & RETRACTOR - INSTALLATION,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-29
BELT & RETRACTOR - REMOVAL, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-19
Group-Page
Description
BELT & RETRACTOR - REMOVAL, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-27
BELT BUCKLE - INSTALLATION, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
BELT BUCKLE - REMOVAL, FRONT SEAT
. . . . . . . . 8L-5
BELT SWITCH - DESCRIPTION, SEAT
BELT SWITCH - OPERATION, SEAT . . . . . . . 8O-31
BELT TENSIONER - DESCRIPTION, SEAT
. . . . . . 2-6
BELT TENSIONER - OPERATION, SEAT . . . . 8O-32
BELT TENSIONERS - DESCRIPTION
. . . . . . . . . 2-9
BELT TENSIONERS - OPERATION
BELT TURNING LOOP ADJUSTER -
. . . . . . . . . . . 2-9
INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 8O-34
BELT TURNING LOOP ADJUSTER -
REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 8O-33
BELT WEATHERSTRIP - INSTALLATION,
FRONT DOOR INNER . . . . . . . . . . . . . . . . . . 23-87
BELT WEATHERSTRIP - INSTALLATION,
FRONT DOOR OUTER . . . . . . . . . . . . . . . . . 23-87
BELT WEATHERSTRIP - REMOVAL,
. . . . . 8F-7
FRONT DOOR INNER . . . . . . . . . . . . . . . . . . 23-87
BELT WEATHERSTRIP - REMOVAL,
. . . . . . . 8F-14
FRONT DOOR OUTER . . . . . . . . . . . . . . . . . 23-87
BELTS - INSTALLATION, DRIVE . . . . . . . . . . . . 7-8
BELTS - REMOVAL, DRIVE
BEZEL - INSTALLATION, ACCESSORY
. . . . . . . . . 8F-14
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
BEZEL - INSTALLATION, CLUSTER
BEZEL - INSTALLATION, INSTRUMENT
PANEL CENTER . . . . . . . . . . . . . . . . . . . . . . 23-55
BEZEL - REMOVAL, ACCESSORY SWITCH
BEZEL - REMOVAL, CLUSTER . . . . . . . . . . . 23-53
BEZEL - REMOVAL, INSTRUMENT PANEL
. . . 8F-14
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-55
. . . . . . . 8F-14
BLADE - DESCRIPTION, WIPER
BLADE - INSTALLATION, WIPER . . . . . . . . . 8R-16
BLADE - OPERATION, WIPER
BLADE - REMOVAL, WIPER
BLEED PROCEDURE, STANDARD
PROCEDURE - POWER STEERING
PUMP FILL . . . . . . . . . . . . . . . . . . . . . . . . . 19-14
BLEEDING - STANDARD PROCEDURE,
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
BLEEDING - STANDARD PROCEDURE,
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-17
BLEEDING - STANDARD PROCEDURE,
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
. . . . . . . . . 8F-6
BLOCK - DESCRIPTION, BLOWER
. . . . . . . . . 8F-2
MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . 24-16
BLOCK - DIAGNOSIS AND TESTING,
BLOWER MOTOR RESISTOR . . . . . . . . . . . . 24-16
BLOCK - INSTALLATION, BLOWER
MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . 24-17
. . . . . . . . . 8F-16
BLOCK - OPERATION, BLOWER MOTOR
RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
BLOCK - REMOVAL, BLOWER MOTOR
RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
BLOCK #1 - DESCRIPTION, FUSE . . . . . . 8W-97-2
BLOCK #1 - INSTALLATION, FUSE
BLOCK #1 - OPERATION, FUSE
BLOCK #1 - REMOVAL, FUSE
BLOCK #2 - DESCRIPTION, FUSE . . . . . . 8W-97-3
BLOCK #2 - OPERATION, FUSE
BLOCK HEATER - INSTALLATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
. . 8J-17
BLOCK HEATER - REMOVAL, ENGINE . . . . . . 7-14
BLOCK JOURNALS - STANDARD
. . . . . . . . 3-9
PROCEDURE, MEASURE CRANKSHAFT . . . . 9-35
BLOWER MOTOR - INSTALLATION
BLOWER MOTOR - REMOVAL . . . . . . 24-32,24-39
BLOWER MOTOR RELAY - DESCRIPTION . . 24-23
. . . . . . . . . . . 3-8
BLOWER MOTOR RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-24
BLOWER MOTOR RELAY -
. . 3-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-24
BLOWER MOTOR RELAY - OPERATION
BLOWER MOTOR RELAY - REMOVAL . . . . . 24-24
. . . . . . 3-17
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-16
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-16
BLOWER MOTOR RESISTOR BLOCK -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-17
BLOWER MOTOR RESISTOR BLOCK -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
BLOWER MOTOR RESISTOR BLOCK -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
Group-Page
Description
BLOWER MOTOR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . 24-17,24-22
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . 24-17,24-23
. . 8O-22
BLOWER MOTOR SWITCH -
. . . . . 8O-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH - OPERATION . . 24-17,
. . 8O-31
BLOWER MOTOR SWITCH - REMOVAL
. . . . . . . . 7-5
. . . . . . . . . . 7-5
BODY & CABLE - INSTALLATION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
BODY & CABLE - REMOVAL, ANTENNA
BODY PANEL REPAIR - STANDARD
PROCEDURE, PLASTIC . . . . . . . . . . . . . . . . . 23-3
BOLT INSPECTION - STANDARD
PROCEDURE, CYLINDER HEAD . . . . . . . . . . . 9-21
BOOST PRESSURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-17
BOOST PRESSURE SENSOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 14-18
BOOST PRESSURE SENSOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14-18
BOOST PRESSURE SENSOR -
. . . . . . . . . . . . . . . 7-8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
BOOST PRESSURE SENSOR - REMOVAL
BOOSTER - DESCRIPTION, POWER
. . . . . . . 23-54
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER . . . . . . . . . . . . . 5-16
. 23-54
BOOSTER - INSTALLATION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
BOOSTER - OPERATION, POWER BRAKE . . . . 5-19
BOOSTER - REMOVAL, POWER BRAKE
. . . . . . . . . 8R-15
BORES - STANDARD PROCEDURE,
MEASURING CYLINDER . . . . . . . . . . . . . . . . 9-34
. . . . . . . . . . . 8R-15
BOX - INSTALLATION, GLOVE . . . . . . . . . . . 23-56
. . . . . . . . . . . . 8R-16
BOX - REMOVAL, GLOVE
B-PILLAR TRIM - INSTALLATION
B-PILLAR TRIM - REMOVAL
BRACKET - INSTALLATION, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-47
BRACKET - INSTALLATION, PASSENGER
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-27
BRACKET - INSTALLATION, REAR VIEW
MIRROR SUPPORT . . . . . . . . . . . . . . . . . . . 23-72
BRACKET - REMOVAL, LICENSE PLATE
BRACKET - REMOVAL, PASSENGER
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-27
BRAKE - CLEANING, REAR DRUM IN
HAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-3
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-3
BRAKE - REMOVAL, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-3
BRAKE BOOSTER - DESCRIPTION,
. . . . . 8W-97-3
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
. . . . . . . 8W-97-2
BRAKE BOOSTER - INSTALLATION,
. . . . . . . . . 8W-97-3
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
BRAKE BOOSTER - OPERATION, POWER
. . . . . . . 8W-97-3
BRAKE BOOSTER - REMOVAL, POWER
BRAKE CABLES - ADJUSTMENT,
PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
BRAKE FLUID - DESCRIPTION
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-14
BRAKE FLUID LEVEL - STANDARD
. . 24-33,24-40
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
BRAKE FLUID, SPECIFICATIONS
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J-11
BRAKE INDICATOR - OPERATION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J-12
BRAKE LAMP SWITCH - INSTALLATION . . . . 8L-6
. . . 24-23
BRAKE LAMP SWITCH - REMOVAL
BRAKE, SPECIAL TOOLS - PARK
BRAKE, SPECIFICATIONS - BASE
BRAKE SWITCH - INSTALLATION, PARK . . . 8L-20
BRAKE SWITCH - REMOVAL, PARK
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-2
BRAKE WEAR INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J-12
BRAKE WEAR INDICATOR - OPERATION . . . 8J-12
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J-11
VA
Group-Page
24-22
. . . 24-17,
24-23
. . . . 8A-1
. . 14-18
. . . . 5-19
. . . . . . . . . . . . . . 23-56
. . . . . . . . 23-69
. . . . . . . . . . . . 23-68
. . . 23-47
. . . 5-19
. . . . 5-19
. . . . . . . . . . . . 0-3
. . . . . . . . . . 5-14
. . . . . . . 8L-6
. . . . . . . . . 5-23
. . . . . . . . . . 5-6
. . . . . . 8L-20

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