The 2000-2006 Mercedes-Benz, Dodge Sprinter CDI Diesel Repair Manual by Brooklands covers commercial vehicles with 2.2L and 2.7L diesel engines, equipped with "Common Rail" direct-injection systems. The manual is well laid out and is geared towards a range of users, from vehicle owners to professional mechanics. The manual includes a variety of topics such as Dodge Sprinter engine removal, general lubrication systems, cooling systems, steering, Mercedes brake systems and more. There's even a helpful wiring diagram and a brief troubleshooting section covering the most basic problems. The Brooklands guide is enhanced with detailed illustrations, photos and diagrams showing component placement and how to disassemble sections to reach specific parts in the engine. Vehicle models covered in this manual include:

• 208CDI, 308CDI: 2.2L 4-cylinder turbo diesel
• 211CDI, 311CDI, 411CDI: 2.2L 4-cyl. Type 611 VNT turbo diesel
• 213CDI, 313CDI, 413CDI: 2.2L 4-cyl. Type 611 VNT turbo diesel
• 216CDI, 316CDI, 416CDI: 2.7L 5-cyl. Type 612 VNT turbo diesel

Book Excerpt: 2000-2006 Mercedes-Benz, Dodge Sprinter CDI Workshop Manual 2.2L, 2.7L Diesel Models ENGINE

ENGINE REMOVAL AND INSTALLATION The removal of the engine and transmission requires a suitable lifting hoist or hand crane to lift the power unit out of the vehicle. The engine and transmission is removed from the front end of the vehicle as a complete unit after the parts shown in Fig.1.1 are removed from the front end of the vehicle. The engine and transmission is a heavy unit and the hoist or crane must be strong enough to take the weight of the assembly, remembering that the weight is more than 200 lbs. The following description is a general guideline, as we cannot refer to every possible variation and/or equipment that may be fitted to your vehicle. If an air conditioning system is fitted, it is not possible to remove the engine under DIY conditions, unless you have the system discharged and after completion of the installation, re-charged at a Mercedes dealer or a workshop deling with A/C systems.

CYLINDER HEAD OVERHAUL The cylinder head must be thoroughly cleaned and remains of old gasket material removed. The checks and inspections are to be carried out as required.
VALVE SPRINGS If the engine has high mileage, always replace the valve springs as a set. To check a valve spring, place the old spring and a new spring end to end over a long bolt (with a washer under the bolt head) and fit a nut (again, with a washer). Tighten the nut until the springs are under tension and measure the length of the two springs. If the old spring is shorter by more than 10%, replace the complete spring set. The springs must not be distorted. A spring placed with its flat coil on a surface must not deviate at the top by more than 2mm or 0.08 in.

Subject: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Mercedes-Benz, Dodge Sprinter CDI Diesel service, maintenance, repair. ISBN-10: 185520729X | ISBN-13: 9781855207295