Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 172

SCOPE OF WORK FOR MAINTENANCE SERVICE

Oil Service

• Engine: Oil change and filter replacement

Check fluid levels of the following system, refill as neces-
sary.

• If fluid is lost, trace and eliminate cause - as a

separate order.

• Power-assisted steering

Lubrication work:

• Trailer tow hitch (original equipment)

Maintenance

• ASSYST maintenance computer reset

Function check

• Signalling system, warning and indicator lamps

• Headlamps, exterior lighting

• Windshield wipers, windshield washer system

Check for leaks and damage

• Check for abrasion points and ensure that lines

are correctly routed!

• All lines and hoses, sensor cables

• Rubber boots on front axle drive shafts, rubber

boots on front axle suspension ball joints, shock
absorbers

• Check fluid levels for the following systems, cor-

rect as necessary

NOTE: Should there be a loss of fluid which cannot
be explained by regular use, trace and eliminate the
cause.

• Engine cooling system. Check corrosion inhibi-

tor/antifreeze, refill as necessary.

• Hydraulic brake system

• Battery

• Windshield washer system
Engine
• Fuel filter renewal - Every oil service

• Air cleaner with maintenance indicator:

• Check degree of contamination.

• Air cleaner filter element renewed as necessary.
Chassis and body
• Trailer coupling: Check operation, play and

retaining fixtures

• Secondary rubber springs: Visual check

• Tire pressures: Correct as necessary, including

spare tire

• Check thickness of brake pads

• Brake test

• Check condition of steering mechanism

• Heating/ventilation dust filter renewal

ADDITIONAL MAINTENANCE WORK

Automatic transmission once only at 80,000 miles / 128000
km

• Oil and filter change

During every second maintenance service

• Air cleaner without maintenance indicator:

• Air cleaner filter element renewal

• Check poly-V-belt for wear and signs of damage

During every fourth maintenance service

• Change rear axle fluid

ADDITIONAL MAINTENANCE WORK AFTER YEARS

Every 2 years

• Change brake fluid.

Every 3 years

• Air cleaner filter element renewal (note installa-

tion date)

Every 15 years or 100,000 miles

• Coolant renewal

• Note coolant composition

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international

symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 3).

Fig. 3 INTERNATIONAL SYMBOLS

VA

LUBRICATION & MAINTENANCE

0 - 9

SUSPENSION

TABLE OF CONTENTS

page

page

FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

REAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WHEEL ALIGNMENT

. . . . . . . . . . . . . . . . . . . . . . 17

FRONT

TABLE OF CONTENTS

page

page

FRONT

SPECIFICATIONS - TORQUE CHART

. . . . . . . . . 1

SPECIAL TOOLS

FRONT SUSPENSION

. . . . . . . . . . . . . . . . . . . 2

BUSHINGS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 3

HUB / BEARING

DIAGNOSIS AND TESTING -

. . . . . . . . . . . . . . . 4

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 5

KNUCKLE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 6

LOWER BALL JOINT

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 6

LOWER CONTROL ARM

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 7

SPRING

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPRING CLAMP PLATES

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPRING STOP PLATES

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

STABILIZER BAR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

STABILIZER LINK

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 10

STRUT

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 10

FRONT

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Lower Ball Joint To Steer-

ing Knuckle

280

206

—

Strut To Steering Knuckle

185

136

—

Strut To Body

100

74

—

Bottom Spring Clamp

Plate To Front Axle

M12 X 1.5 Bolt

130

96

—

VA

SUSPENSION

2 - 1

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Bottom Spring Clamp

Plate To Front Axle

M10 Bolt

65

48

—

Sway Bar Clamp To The

Front Axle

30

22

—

Hexagon Socket Bolt For

Clamping Nut To Adjust

Wheel Bearing Play

12

9

106

Lower Control Arm To

Front Axle Beam

150

110

—

Stop Plate For Lower

Control Arm

60

44

—

Outer Tie Rod End Nut

130

96

—

Outer Tie Rod End Nut

Jam Nut

50

37

—

SPECIAL TOOLS

FRONT SUSPENSION

SPECIAL TOOL CROSS REFERENCE CHART

MB

TOOL #

MILLER
TOOL #

DESCRIPTION

N/A

9288

LEAF SPRING WEDGE
BLOCK

N/A

9294

LOWER BALL JOINT RE-
MOVE/INSTALLER

N/A

9302

BUSHING REMOVER /IN-
STALLER

N/A

C-3894-A

PULLER TIE ROD

730 589

02 33 00

9282

BALL JOINT SEPARA-
TOR

N/A

C-4212F

BALL JOINT PRESS

Puller Tie Rod C-3894-A

BALL JOINT PRESS - C-4212F

LOWER BALL JOINT REMOVE / INSTALL - 9294

2 - 2

FRONT

VA

BUSHINGS

REMOVAL

(1) Remove the lower control arm (Refer to 2 -

SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).

(2) Install the lower control arm in a vise.

(3) Install special tool C-4212F (Press) with special

tool 9302-1 (Driver) and 9302–3 (Receiver) (Fig. 1).

(4) Press out the old control arm bushing.

INSTALLATION

(1) Install the new control arm bushing into the

control arm.

(2) Press the new bushing into the control arm

using special tool C-4212F and 9302-1 (Driver) with
9302-2 (Sizer cup) and 9302-4 (Receiver) (Fig. 2).

(3) Press the bushing in all the way until the lip is

seated properly into the control arm.

(4) Install the lower control arm to the vehicle

(Refer to 2 - SUSPENSION/FRONT/LOWER CON-
TROL ARM - INSTALLATION).

BALL JOINT SEPARATOR - 9282

LEAF SPRING WEDGE BLOCK - 9288

BUSHING REMOVER / INSTALLER-9302

Fig. 1 LCA BUSHING REMOVAL

1 - SPECIAL TOOL C-4212F (PRESS)
2 - SPECIAL TOOL 9302-1 (DRIVER)
3 - LOWER CONTROL ARM
4 - SPECIAL TOOL 9302-3 (RECEIVER CUP)
5 - BUSHING

VA

FRONT

2 - 3