Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 189

(4) Open up bleeder, then have a helper press

down the brake pedal. Once the pedal is down close

the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
wheel.

STANDARD PROCEDURE - PRESSURE BLEED-
ING

Use approved brake fluid (Refer to LUBRICATION

&

MAINTENANCE/FLUID

TYPES

-

DESCRIP-

TION). Use fresh, clean fluid from a sealed container
at all times.

Follow the manufacturers instructions carefully

when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 15-20 psi is sufficient for
bleeding.

Fill the bleeder tank with recommended fluid and

purge air from the tank lines before bleeding.

Do not pressure bleed without a proper master cyl-

inder adapter. The wrong adapter can lead to leak-
age, or drawing air back into the system.

HYDRAULIC / MECHANICAL

SPECIFICATIONS

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Brake Lines

14

—

124

Master Cylinder To Brake

Booster Nut

28

—

248

Brake Caliper Adapter

Rear

M12 X 1.5 Bolt

90

66

—

Brake Caliper Adapter

Rear

M14 X 1.5 Bolt

170

125

—

Brake Caliper Adapter

Front

170

125

—

Disc Brake Rotor Locking

Bolt

Front or Rear

23

—

204

Wear Indicator To Caliper

Bolt

Front or Rear

10

—

89

Pedal Bracket to Firewall

23

—

204

Fig. 1 Bleed Hose Setup

1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID

VA

BRAKES - BASE

5 - 5

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Booster To Pedal Bracket

25

—

221

Brake Caliper Guide Pins

M8 Bolt

25

—

221

Brake Caliper Guide Pins

M10 Bolt

30

—

266

ALB Operating Linkage

Lever To The Rear Axle

34

25

300

Wheel Flange Ring To

Rotor

Rear

200

148

—

Wheel Flange Ring To

Rotor

Front

180

133

—

BASE BRAKE

NOTE: Do not resurface the disc brake rotors if
they are out of specifications. (Sprinter Van Rotors
must be replaced with new disc brake rotors only).

SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Front Disc Brake Caliper
Type

Dual Piston Sliding

Rear Disc Brake Caliper
Type

Single Piston Sliding

Disc Brake Caliper

Bosch

Rear Disc Brake Rotor
New
DRW

22 mm (0.866 in.)

Rear Disc Brake Rotor
Wear Limit
DRW

19 mm (0.748 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
DRW

.1 mm (0.00394 in.)

Rear Disc Brake Rotor
Max. Axial Runout
DRW

.02 mm (0.0007 in.)

Front Disc Brake Rotor
New
DRW

22 mm (0.866 in.)

Front Disc Brake Rotor
Wear Limit
DRW

19 mm (0.748 in.)

Front Disc Brake Rotor
Max. Lateral Runout
DRW

0.05 mm (0.0019 in.)

DESCRIPTION

SPECIFICATION

Front Disc Brake Rotor
Max. Axial Runout
DRW

0.02 mm (0.0007 in.)

Front Disc Brake Rotor
New
SRW

22 mm (0.866 in.)

Front Disc Brake Rotor
Wear Limit
SRW

19 mm (0.748 in.)

Front Disc Brake Rotor
Max. Lateral Runout
SRW

0.05 mm (0.0019 in.)

Front Disc Brake Rotor
Max. Axial Runout
SRW

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models 901,902

12 mm (0.47 in.)

Rear Disc Brake Rotor
Wear Limit
Models 901,902

10 mm (0.40 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
Models 901,902

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models 901,902

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models 690.611/63/64,
903

16 mm (0.629 in.)

Rear Disc Brake Rotor
Wear Limit
Models 690.611/63/64,
903

14 mm (0.55 in.)

5 - 6

BRAKES - BASE

VA

DESCRIPTION

SPECIFICATION

Rear Disc Brake Rotor
Max. Lateral Runout
Models 690.611/63/64,
903

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models 690.611/63/64,
903

0.02 mm (0.0007 in.)

Rear Disc Brake Rotor
New
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

16 mm (0.629 in.)

Rear Disc Brake Rotor
Wear Limit
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

14 mm (0.55 in.)

Rear Disc Brake Rotor
Max. Lateral Runout
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

.1 mm (0.0007 in.)

Rear Disc Brake Rotor
Max. Axial Runout
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341

0.02 mm (0.0007 in.)

Brake Booster
Type

Vacuum Diaphragm

SPECIAL TOOLS

BRAKES

SPECIAL TOOL CROSS REFERENCE CHART

MB

TOOL #

MILLER
TOOL #

DESCRIPTION

N/A

C-4007-A

GAUGE SET

N/A

9297

ADAPTERS, BRAKE
PRESSURE

000 589

18 31 00

9296

BRAKE PEDAL WINCH

GAUGE SET - C-4007-A

ADAPTERS, BRAKE PRESSURE - 9297

BRAKE PEDAL WINCH - 9296

VA

BRAKES - BASE

5 - 7

BRAKE LINES

STANDARD PROCEDURE

STANDARD PROCEDURE - ISO FLARING

A preformed metal brake tube is recommended and

preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.

To make a ISO flare use an ISO flaring tool kit.

(1) Cut off damaged tube with Tubing Cutter.
(2) Remove any burrs from the inside of the tube.
(3) Install tube nut on the tube.
(4) Position the tube in the flaring tool flush with

the top of the tool bar (Fig. 2). Then tighten the tool
bar on the tube.

(5) Install the correct size adaptor on the flaring

tool yoke screw.

(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube

(Fig. 2).

(8) Turn the yoke screw in until the adaptor is

squarely seated on the tool bar.

STANDARD PROCEDURE - DOUBLE INVERTED
FLARING

A preformed metal brake tube is recommended and

preferred for all repairs. However, double-wall steel

tube can be used for emergency repair when factory
replacement parts are not readily available.

(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper

flare.

(3) Install replacement tube nut on the tube.
(4) Insert tube in flaring tool.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until

tube contacts recessed notch in gauge that matches
tube diameter.

(7) Tighten the tool bar on the tube
(8) Insert plug on gauge in the tube. Then swing

compression disc over gauge and center tapered flar-
ing screw in recess of compression disc (Fig. 3).

(9) Tighten

tool

handle

until

plug

gauge

is

squarely seated on jaws of flaring tool. This will start
the inverted flare.

(10) Remove the plug gauge and complete the

inverted flare.

BRAKE PADS / SHOES

REMOVAL

REMOVAL - FRONT (SRW)

(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/

WHEELS/WHEELS - REMOVAL).

(4) Remove the wear indicator cable and the wear

indicator (Fig. 4).

Fig. 2 ISO Flaring

1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY

Fig. 3 Inverted Flare Tools

5 - 8

BRAKES - BASE

VA