DaimlerChrysler SPRINTER2006 User manual

SERVICE MANUAL
2006
SPRINTER
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Copyright © 2004 DaimlerChrysler Corporation
81-370-06070CD

CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN
ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies
in non-automotive applications should be repaired in accordance with instruc-
tions supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The
service procedures recommended and described in this publication were developed for pro-
fessional service personnel and are effective methods for performing vehicle repair. Following
these procedures will help assure efficient economical vehicle performance and service reli-
ability. Some of these service procedures require the use of special tools designed for specific
procedures. These special tools should be used when recommended throughout this publi-
cation.
Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless
removal may cause personal injury. Always wear safety goggles whenever work-
ing on vehicles or vehicle components.
It is important to note that this publication contains various Cautions and Warnings. These
should be carefully read in order to minimize the risk of personal injury, or the possibility that
improper service methods may damage the vehicle or render it unsafe. It is important to note
that these Cautions and Warnings cover only the situations and procedures Daimler-
Chrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation
could not possibly know, evaluate, and advise the
service trade of all conceivable ways that
service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler
Corporation has not undertaken any such broad service review. Accordingly, anyone who uses
a service procedure, or tool, that is not recommended in this publication must assure oneself
thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service
methods they select.
For other Service and Owner Manuals for Chrysler,
Plymouth, Dodge, Dodge Truck, and Jeep
T vehicles, Call
[phone] or FAX [phone] to place an order. Or,
visit our website at techauthority.daimlerchrysler.com.
Tech Authority Online at our website offers you service
information on a subscription basis.

UNITED STATES and CANADA
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone [phone] FAX [phone]
INTERNATIONAL
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone [phone] FAX [phone]

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................1
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................2
FASTENER IDENTIFICATION
DESCRIPTION ..........................3
FASTENER USAGE
DESCRIPTION - FASTENER USAGE .........6
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR ....6
METRIC SYSTEM
DESCRIPTION ..........................6
TORQUE REFERENCES
DESCRIPTION ..........................9
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
located on the lower windshield fence next to the left
a-pillar. The VIN contains 17 characters that provide
data concerning the vehicle. Refer to the VIN
DECODING INFORMATION table to determine the
identification of a vehicle.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1,2&3 World Manufacturer Code
WDX = Incomplete vehicle / Dodge
WD1 = Incomplete vehicle / Dodge
WD0 = Truck / Dodge
WD2 = Truck / Dodge
WD5 = Multi-purpose passenger vehicle / Dodge
WD8 = Multi-purpose passenger vehicle / Dodge
WDW = Bus / Dodge
WDP = Incomplete vehicle / Freightliner
WDY = Truck / Freightliner
WDR = Multi-purpose passenger vehicle / Freightliner
WD3 = Truck / Mercedes-Benz
WD4 = Multi-purpose vehicle / Mercedes-Benz
WD9 = Incomplete vehicle / Mercedes-Benz
4 Model
B = All 4x2 vehicle types / Canada
P = All 4x2 vehicle types / USA
X = 4x2 Chassis-cab
Y = 4x2 Truck
W = 4x2 Multi-purpose passenger vehicle
VA INTRODUCTION 1

POSITION INTERPRETATION CODE = DESCRIPTION
5 & 6 Model, Cab, Weight
D1 = Sprinter, 3000 mm (118 in.) wheelbase, 8,001 up to 9,000
lbs. class G
D2 = Sprinter, 3550 mm (140 in.) wheelbase, 8,001 up to 9,000
lbs. class G
D3 = Sprinter, 4025 mm (158 in.) wheelbase, 8,001 up to 9,000
lbs. class G
D4 = Sprinter, 3550 mm (140 in.) wheelbase, Van 10,001 up to
14,000 lbs. Class H
D5 = Sprinter, 4025 mm (158 in.) wheelbase, Van 10,001 up to
14,000 lbs. Class H
D6 = Sprinter, 3567 mm (140 in.) in connection with 16” wheels,
Van 8,001 to 9,000 lbs. class G
D7 = Sprinter, 4042 mm (159 in.) in connection with 16” wheels,
Van 8,001 to 9,000 lbs. class G
7 & 8 Engine 41 = 2.7L 5 cyl. Diesel 612 (ME9)
42 = 2.7L 5 cyl. Diesel 612 (MF1)
43 = 2.7L 5 cyl. Diesel 647 (MC0)
44 = 2.7L 5 cyl. Diesel 647 (MF2)
9 Check Digit
10 Model Year 6 = 2006
11 Assembly Plant 5 = Düsseldorf Plant, Germany
12 Thru 17 Vehicle Build Sequence
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 1) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
2 INTRODUCTION VA

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
VA INTRODUCTION 3

Fig. 2 FASTENER IDENTIFICATION
4 INTRODUCTION VA
Bolt Markings and Torque- Metric
Commercial Steel Class
9.8 10.9 12.9
Bolt Head Markings
0
~
e
~
G
~
Body
Size
Torque
Torque
Torque
Diam.
Cast Iron
Aluminum
Cast Iron
Aluminum Cast Iron
Aluminum
mm
N•m ft-lb
N•m
ft-lb
N•m
ft-lb N•m
ft-lb
N•m
ft-lb N•m ft-lb
6 9 5 7 4
14
9 11 7
14 9
11 7
7
14
9 11 7
18
14 14 11 23
18 18
14
8 25
18 18 14
32 23
25 18
36
27 28 21
10
40
30 30
25
60
45 45
35 70
50 55 40
12
70
55 55 40
105 75
80 60
125 95
100
75
14 115
85 90 65
160
120 125 95 195
145 150 110
16 180 130 140
100
240
175 190 135 290
210 220 165
18
230 170
180 135
320 240 250
185 400
290
310
230
Bolt Markings and Torque Values- U.S. Customary
SAE Grade Number
5 8
Bolt Head Markings
~
@~
These are all SAE Grade 5 (3) line
@@@
Bolt Torque - Grade 5 Bolt Bolt Torque- Grade 8 Bolt
Body Size
Cast Iron
Aluminum
Cast Iron
Aluminum
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
1/4-20
9 7 8 6 15 11
12
9
-28
12 9 9 7 18 13
14
10
5/16- 18
20
15 16 12 30 22
24 18
-24
23 17 19 14 33 24
25
19
3/8 - 16
40
30 25 20 55 40 40
30
-24
40
30 35 25
60 45
45
35
7/16- 14
60 45 45
35
90 65 65
50
-20
65
50 55 40
95
70
75 55
1/2- 13
95 70 75
55
130
95
100
75
-20
100 75 80
60
150 110
120
90
9/16- 12
135 100
110 80
190
140
150
110
- 18
150 110 115
85
210 155
170
125
5/8 -11
180 135 150 110 255 190 205
150
- 18
210
155 160 120
290 215 230
170
3/4 -10
325 240 255 190 460 340
365
270
- 16
365 270 285 210 515 380 410
300
7/8-9
490 360 380 280 745 550
600
440
-14
530 390 420 310 825 610 660 490
-8
720
530 570 420 1100 820
890 660
-14
800 590 650 480 1200 890
960
710
80bdbd8c

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS ...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID ..........................2
BRAKE FLUID .........................2
HOAT COOLANT .......................2
ENGINE OIL - DIESEL ENGINES ...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID ...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID ...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES .......5
FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS ..........................5
HOISTING
STANDARD PROCEDURE - HOISTING ........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING .........7
MAINTENANCE SCHEDULES
DESCRIPTION ..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown. This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various “special” additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of trans-
mission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VA LUBRICATION & MAINTENANCE 0 - 1

AXLE FLUID
Use oils approved to MB 235.0 or 235.6, such as
Shell Spirax MB90, Caltex Hypoid LD, or MOPARt
part number 4874469, or equivalent. An API GL-5/
MIL-2105-E SAE 90 Hypoid Gear Oil may be substi-
tuted. Reduced axle durability may result if an
unapproved product is used.
BRAKE FLUID
Use brake fluid approved to MB 331.0, such as
Intac B026D, MOPARtBrake & Clutch Fluid, part
number 04549625AC, or equivalent. If the approved
product is not available, use a DOT 4 brake fluid:
minimum dry boiling point (ERBP) 500°F, minimum
wet boiling point (WERBP) 356°F, maximum viscos-
ity 1500 mm
2
/s, conforming to FMVSS 116 and ISO
4925.
HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Use coolant approved to MB 325.0, such
as EURO Peak Coolant/Anti-freeze (OLD WORLD
INDUSTRIES), Zerex G05 or G48 (The Valvoline
Company), Glysantin G05 (BASF AG), MOPARtpart
number 05066386AA, or an equivalent Extended Life
Coolant with the HOAT inhibitor system. This cool-
ant offers the best engine cooling without corrosion
when mixed with 50% anti-freeze and 50% distilled
water to obtain a freeze point of -37°C (-34°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: This coolant may not be mixed with any
other type of antifreeze. Mixing of coolants other
than specified (non-HOAT), may result in engine
damage that may not be covered under the new
vehicle warranty, and decreased corrosion protec-
tion.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise. The increased tempera-
ture can result in engine detonation. In addition, 100
percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37°C (-34°F). The antifreeze concentration
must always be a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
0 - 2 LUBRICATION & MAINTENANCE VA

ENGINE OIL - DIESEL ENGINES
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality.
Only use engine oils that are labeled on the con-
tainer as meeting API (American Petroleum Insti-
tute) and/or DaimlerChrysler specifications MB
228.3, 228.5, 229.3, and 229.5, such as MOPARtSAE
15W-40 HD Diesel Engine Oil (e.g. MOPARtPart
No. 03798231AD), or equivalent.
Do not add any materials (other than leak detec-
tion dyes) to the engine oil. Engine oil is an engi-
neered product and it’s performance may be impaired
by supplemental additives.
When topping off engine oil, only use oil of the
same quality grade and SAE classification.
Always refer to the following viscosity chart for the
proper viscosity grade based on ambient tempera-
ture. Select oil viscosity according to the lowest air
temperature expected before the next oil change.
The temperature limits given for the different SAE
classes should be regarded as guidelines which may
be exceeded temporarily to avoid excessively frequent
engine oil changes.
The following engine oils have been determined to
meet DaimlerChrysler requirements:
DaimlerChrysler
Approved En-
gine Oil
SAE Rating MB Sheet
Number
76 Pure Syn-
thetic Motor Oil 5W-40 229.3
76 Royal Triton
QLT 15W-40 228.3
Agip All Guard
Motor Oil 15W-40 228.3
DaimlerChrysler
Approved En-
gine Oil
SAE Rating MB Sheet
Number
Agip Eurosport 5W-40 229.3
Agip Synthetic
PC 5W-40 229.3
Akron Ultra
Clear C1-4 (1) 15W-40 228.3
BP Vanellus C6
Global Plus 10W-40 228.3
Brad Penn Eu-
ro-Diesel LD 15W-40 228.3
Castrol Elixion
(1) 5W-40 228.5
Castrol Tection
S (1) 15W-40 228.3
Chevron Delo
400 Multigrade 15W-40 228.3
Diesel Special
Benz M&A 15W-40 228.3
Dislub Premium 15W-40 228.3
Exxon XD-3
Extra (1) 15W-40 228.3
FormulaShell
Ultra 5W-40 229.3
FormulaShell
Ultra AB 5W-30 229.5
Gonher Super
Fleet MB-III 15W-40 228.3
Hydroclear
Power-D En-
gine Oil
15W-40 228.3
IDO Premium
15W-40 15W-40 228.3
Kendall GT-1
Full Synthetic
Motor Oil
5W-40 229.3
Long Life EF
Diesel Engine
Oil Multigrade
15W-40 228.3
Lubral Super
Diesel MB-III 15W-40 228.3
Max Raloy Die-
sel 5W-30 228.5
MB Motorenöl
000 989 60 01
13
10W-40 228.5
Mexlub CF-4
MB-3P 15W-40 228.3
Mobil 1 0W-40 0W-40 229.5
OIL VISCOSITY CHART
VA LUBRICATION & MAINTENANCE 0 - 3

DaimlerChrysler
Approved En-
gine Oil
SAE Rating MB Sheet
Number
Mobil Delvac 1 5W-40 228.5
Mobil Delvac
1300 Super (1) 15W-40 228.3
Mobil SHC For-
mula MB 5W-30 229.5
MOPARTPart
No.
04798231AD
15W-40 228.3
Motul 8100 E-
Tech 0W-40 0W-40 229.3
Motul 8100 X-
cess 5W-40 5W-40 229.3
Panolin Indy SV 5W-40 229.3
Pennzoil Euro-
pean Formula
Ultra
5W-30 229.5
Pennzoil Syn-
thetic European
Formula
5W-40 229.3
Premium Syn-
thetik Motorenöl 5W-30 229.5
QS Superfleet 15W-40 228.3
Quaker State
European For-
mula Ultra
5W-30 229.5
Quaker State
Full Synthetic
European For-
mula
5W-40 229.3
Quaker State
Super Series III
(1)
15W-40 228.3
Raloy Diesel
Turbo MX 15W-40 228.3
Raloy Motor
Diesel 15W-40 228.3
Repsol Turbo
UHPD 10W-40 228.5
Roshfrans Vol-
tro Diesel (1) 15W-40 228.3
Shell Helix Ultra 5W-30 229.3
Shell Helix Ultra 5W-40 229.3
Shell Rimula X
CH-4 15W-40 228.3
Shell Rimula X
CH-4 20W-50 228.3
DaimlerChrysler
Approved En-
gine Oil
SAE Rating MB Sheet
Number
Shell Rotella T
Multigrade (1) 15W-40 228.3
Super Diesel
Oil MB-3 15W-40 228.3
Supreme Duty
Diesel Engine
Oil Multi- grade
15W-40 228.3
Unoil GX-7 5W-40 229.3
Ursa Premium
TDX 10W-30 228.3
Ursa Premium
TDX 15W-40 228.3
Valvoline Syn-
Power MXL 0W-30 229.3
(1) Engine oil also meets API classification CI-4.
Other oils may meet requirements - see oil label to
determine
Use of the approved fluid is required if the
ASSYST Oil Service Reminder is followed. Use of a
lower quality oil on this service schedule may cause
severe engine damage.
FUEL REQUIREMENTS - DIESEL ENGINE
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use only commercially available vehicular diesel
fuels No. 2 or No. 1 (ASTM D 975 No. 2-D or No.
1-D).
NOTE: Because of its better quality, the manufac-
turer recommends the use of commercially avail-
able vehicular diesel fuel No. 2.
DIESEL FUELS FOR USE AT VERY LOW TEMPERA-
TURE
At very low temperatures, the fluidity of No. 2 die-
sel fuel may become insufficient due to paraffin sep-
eration. For this reason, the vehicle comes equipped
with a fuel preheater. It permits trouble free engine
operation to a temperature of approximately 14°F
(-10°C) when using No. 2 diesel fuel.
To avoid malfunctions, No. 2 diesel fuel of a low-
ered cloud point is marketed during the cold season.
At temperatures below 14 °F (-10 °C) use winter-
ized or No. 1 diesel fuel only.
0 - 4 LUBRICATION & MAINTENANCE VA

Do not blend other specific fuel additives with die-
sel fuel. They only result in unnecessary cost, and
may be harmful to the engine operation.
POWER STEERING FLUID
No fluid service required. Filled with Power Steer-
ing Fluid approved to MB 236.3, such as Mobil
ATF-D (Exxon Mobil Corporation) or equivalent.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L without Filter Re-
placement 9.5 Quarts with Filter Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of inter-
nal cooler, length and inside diameter of cooler lines,
or use of an auxiliary cooler, these figures may vary.
(Refer to appropriate 21 - TRANSMISSION/AUTO-
MATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE ±.03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to manufac-
turing tolerance and refill procedure
DESCRIPTION SPECIFICATION
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cool-
er options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed proce-
dures.
FLUID FILL / CHECK LOCA-
TIONS
INSPECTION - FLUID FILL / CHECK LOCA-
TIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle. Support the vehicle in the raised
position with jack stands at the front and rear ends
of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
•An axle tube.
•A body side sill.
•A steering linkage component.
•A drive shaft.
•The engine or transmission oil pan.
•The fuel tank.
•A front suspension arm.
VA LUBRICATION & MAINTENANCE 0 - 5

HOIST
A vehicle can be lifted with:
•A single-post, frame-contact hoist.
•A twin-post, chassis hoist.
•A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
The forward lifting pads should be positioned
against the forward flange of the transmission
crossmember brackets at the bottom of the frame
rail. The real lifting pads should be wedged
between the forward flange of the leaf spring
bracket and the frame rail. Safety stands should be
placed under the frame rails at the front and rear
ends.
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
•DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
•IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
•DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
•DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
•DO NOT USE OPEN FLAME NEAR BATTERY.
•REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
•WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
•Battery cable clamp condition, clean if necessary.
•Frozen battery.
•Yellow or bright color test indicator, if equipped.
•Low battery fluid level.
•Generator drive belt condition and tension.
•Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
Fig. 2 HOIST LOCATIONS
1 - TRANSMISSION CROSSMEMBER SUPPORT
2 - REAR LEAF SPRING MOUNT - FRONT
3 - TRANSMISSION CROSSMEMBER
0 - 6 LUBRICATION & MAINTENANCE VA

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

HUB / BEARING
DIAGNOSIS AND TESTING -
(1) Raise and support the vehicle.
(2) Remove the grease cap.
(3) Position a dial indicator against the face of the
wheel hub (Fig. 3).
(4) Tighten the locking screw on the clamping nut
(Fig. 3).
(5) Pull the wheel hub firmly back and forth and
read off the wheel bearing play on the dial gauge.
(Wheel bearing play should be 0.02 - 0.04 mm
(0.000787 - 0.00158 in.).
(6) If necessary, loosen the locking screw and
adjust the wheel bearing play by loosing or tighten-
ing the clamping nut.
(7) Retighten the locking screw and recheck the
wheel bearing play.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(3) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the wheel flange ring (if equipped with
dual rear wheels) (Fig. 5).
(5) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(6) Remove the grease cap (Fig. 4).
(7) Loosen the bolt on the clamping nut and
remove the clamping nut (Fig. 4).
(8) Remove the thrust washer (Fig. 4).
(9) Remove the wheel hub and tapered roller bear-
ing from the stub axle assembly (Fig. 4).
Fig. 2 LCA BUSHING INSTALL
1 - SPECIAL TOOL C-4212F (PRESS)
2 - SPECIAL TOOL 9302-1 (DRIVER)
3 - BUSHING
4 - SPECIAL TOOL 9302-2 (SIZER CUP)
5 - LOWER CONTROL ARM
6 - SPECIAL TOOL 9302-4 (RECEIVER CUP)
Fig. 3 MEASURING & ADJUSTING WHEEL BEARING
1 - WHEEL HUB
2 - LOCKING SCREW
3 - DIAL INDICATOR
2 - 4 FRONT VA