Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 398
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove vacuum line at vacuum pump (Fig.
48).
NOTE: Observe position of driver on rear of pump.
(3) Remove vacuum pump and seals (Fig. 48)
(4) Clean all sealing surfaces.
INSTALLATION
(1) Clean all sealing surfaces.
(2) Position driver on rear of pump and install vac-
uum pump with new seals. Tighten bolts to 14N·m
(124 lbs. in.). (Fig. 48)
(3) Install vacuum line to vacuum pump (Fig. 48).
(4) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(5) Start the engine and inspect for leaks.
LEFT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534–16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 49)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 49)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 49)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N·m (33 lbs. ft.) (Fig.
49)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 49)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 49).
Fig. 48 VACUUM PUMP
1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING
4 - O-RING
5 - EXHAUST CAMSHAFT
6 - BOLTS
Fig. 49 LEFT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - BRACKET
7 - GROUND CABLE
8 - WASHER
9 - BOLT
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ENGINE
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(6) Lower the engine on to the engine mount and
tighten bolt to 83 N·m (61 lbs.ft.) (Fig. 49)
(7) Remove the engine support fixture and adap-
tors.
RIGHT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534-16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 50)
(4) Lower the vehicle.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 50)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 50)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N·m (33 lbs. ft.) (Fig.
50)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 50)
(5) Hand tighten the engine support to engine
mount bolt (Fig. 50).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N·m (61 lbs.ft.) (Fig. 50)
(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N·m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194°F (90°C). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT
IN
PROPER
AND
APPROPRIATELY
MARKED CONTAINERS.
(1) Partailly drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 51).
(4) Remove the oil cooler from the timing case
cover (Fig. 51).
Fig. 50 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
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ENGINE
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INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N·m (124
lbs. in.) (Fig. 51).
(3) Reconnect
the
coolant
hoses
and
tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N·m ( 18 lbs. ft.) (Fig. 51).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
OIL FILTER
REMOVAL
(1) Unscrew the oil filter cap (Fig. 52)
(2) Remove clean and inspect cap gasket, replace
as necessary.
(3) Remove oil filter (Fig. 52).
INSTALLATION
(1) Inspect oil filter cap gasket, if all right, lubri-
cate with clean engine oil.
(2) Install oil filter.
(3) Screw oil filter cap to housing and tighten to
25N·m (18 lbs. ft.) (Fig. 52). Adjust oil level as neces-
sary.
OIL JET
DESCRIPTION
There are five oil jets installed in the engine block
(Fig. 53). These oil jets are used to cool and lubricate
the piston assemblies.
Fig. 51 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
Fig. 52 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
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ENGINE
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REMOVAL
The engine must be removed from the vehicle and
completely dissassembled to replace the oil jets.
(1) Remove engine from vehicle.
(2) Completely dissassemble engine.
(3) Using an extraction claw #9746 (3) and a slide
hammer (1), remove the oil jets (2) from engine block
(Fig. 54).
INSTALLATION
(1) Install oil jet into special tool #8924.
(2) Align oil jet in location in engine block.
NOTE: Align oil jet with the groove in special tool
#8924.
(3) Drive oil jets into block using special tool #8924
until oil jet is fully seated into engine block (Fig.
55).
(4) Reassemble engine.
(5) Install engine into vehicle.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534–16, to the engine lifting eye and
raise engine slightly (Fig. 56).
Fig. 53 OIL JET LOCATION
1 - ENGINE BLOCK
2 - OIL JET
Fig. 54 OIL JET EXTRACTION CLAW
1 - SLIDE HAMMER
2 - OIL JETS
3 - EXTRACTION CLAW # 9746
Fig. 55 OIL JET INSTALLATION
1 - OIL JET INSTALLER #8942
2 - ENGINE BLOCK
3 - OIL JET
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ENGINE
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