MERCEDES-BENZ WORKSHOP REPAIR MANUAL
SWB.LWB.HI-TOP ALL COVERED
ALL SPRINTER.VITO.CDi MODELS COVERED
THE NEW SPRINTER.VITO ALSO COVERED
UPTO 2006
COVERS
ENGINE.BODYWORK/PANELS.WINDOWS.DOORS
CLUTCH.TRANSMISSION.SUSPENSION
BRAKES/ABS.STEERING.AXLES.INTERIOR.EXTERIOR
ELECTRICAL.SERVICE.REPAIR
IAGNOSTICS.ELECTRICAL.SYSTEMS.ELECTRICAL.DIAGRAMS
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This bulletin provides the procedure for replacing the manual transmission gear shift lever assembly and transmission oil. • TGS REPLACEMENT 1. Place the vehicle so it may be raised on a hoist and release the parking brake. 2. Unbutton the shift lever boot hook (A) and open the shift lever boot. 3. Remove the shift lever knob by turning it counterclockwise. 4. Raise the vehicle off the ground and remove the heat shield by unfastening 6 mounting bolts (B). 5. Unfasten the two nuts (C) at the flange in front of the catalytic converter. NOTE: Torque specification: 28.9 ~ 43.4 lb-ft. 6. Unfasten the two nuts (D) that connect the center pipe to the muffler assembly. NOTE: Torque specification: 28.9 ~ 43.4 lb-ft. 7. Disengage the rubber exhaust hanger on the center pipe and remove the center pipe together with the secondary catalytic converter. 8. Draw a straight line across the front propeller shaft rubber coupling (a) and the transmission companion flange(b). This will be used to align when reinstalling. CAUTION: Use care not to exchange locations and directions of bolts and washers when reinstalling to prevent balance issues. 9. Remove the 3 propeller shaft mounting nuts (E) holding the rubber coupler to the transmission output flange. NOTE: Tightening torque : 90~110Nm (9.0~11.0 kgf.m/65~79.5Ib-ft) 10. Lower propeller shaft to gain access to the shift lever.
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APPLICABLE MODEL(S)/VINS 2006 – 2007 Mazda6 with driver’s manual lumbar support DESCRIPTION On some vehicles equipped with a driver’s manual lumbar support, the lumbar will not adjust position or may be inoperative. A new manual lumbar support assembly is available as a replacement service part. NOTE: It is NOT necessary to replace the entire driver’s seat assembly to restore the manual lumbar support function. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify customer concern. 2. Turn ignition switch to ON position. 3. Record all customer’s pre-set radio stations. 4. Adjust driver’s seat back to most forward position. 5. Turn ignition switch to LOCK position. 6. Rotate lumbar dial clockwise to fully relaxed position (end of travel). 7. Disconnect negative battery cable and wait for a minimum of one (1) minute. 8. Remove driver’s seat from vehicle according to Workshop Manual (section 09-13 FRONT SEAT REMOVAL/ INSTALLATION [EXCEPT L3 WITH TC]).
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1. Working in the engine bay, start removal of the stock air box by removing the bolt on the top part of the air box as pictured to the left. Use a 10 mm socket and a ratchet. Put it aside for re-install later. If you have an aftermarket intake, proceed to step #10 for battery removal. 2. Unclip the two (2) clips holding the top part of the air box as pictured to the left. 3. Unplug the MAF connector as pictured to the left. 4. Unclip the rubber hose over the intake as pictured. 5. Loosen the bolt holding the intake piping to the throttle body using a 10mm socket and a ratchet. 6. You can now remove the air box top half from the throttle body. 7. Pull on the hose on the top of the intake to remove it as pictured. 8. Working at the rear of the air box, you will see the MAF wiring is held on the box itself with a tab. Use needle nose pliers to squeeze the tab and push it out. 9. Pull up on the air box to remove it from the engine bay. Take good note of both rubber grommets where it’s installed in as it will need to be re- installed the same way. Put it aside for re-install later. 10. Pull on both tabs holding the top part of the battery box and remove it. This top part has 2 tabs at the back that are inserted in two slots on the bottom part. To remove it, lift the front part up and then slide it toward the front of the car. Put it aside for re- install later. 11. Using a 10 mm socket and ratchet, unbolt the battery holder. There is a bolt on each side of the battery. Put it aside for re-install later. 12. Unbolt both battery terminals using a 10 mm socket with a ratchet. Remove the battery from the engine bay and put it aside for re-install later. 13. Using a 12 mm socket and a ratchet, remove the three (3) bolts at the bottom holding the battery box in place. Put them aside for re-install later. 14. The two (2) grey tabs behind the battery connector on the front part of the battery box needs to be pushed out. Use needle nose pliers to squeeze them and push them out. 15. You can now remove the front part of the battery box as pictured. Put it aside for re-install later. 16. Using needle nose pliers, squeeze the plastic tab holding the wiring harness to the bottom of the battery box and push it out as pictured. 18. Repeat the same for the tab 19. Tilt the battery box toward the front of the car where the air box was. 20. You now have access to the shifter cable and shifter actuator where the short shifter will be installed. Use a long flat head screwdriver to pop the left cable out of the shifter arm. Do not apply too much force, it will come out easily. This is easier done when the shifter is in lower gears (2nd, 4th , 6th or R).
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All Vehicles 1. CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees. As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing. NOTE: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine. NOTE: Operation steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked. Disconnect the battery ground cable. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Loosen the right-hand front wheel nuts. 4. Remove the right-hand front wheel. 5. Remove the engine underschield (if equipped). 6. Remove the right-hand front splash shield. 7. NOTE: Mark the accessory drive belt direction if the belt is to be reused. Remove the accessory drive belt. 1. Loosen the water pump pulley bolts. 2. Working clockwise, loosen the belt and remove it. Remove the water pump pulley. 4. Remove the belt idler pulley. 8. NOTE: Using the access hole in the bottom of transaxle case to stop rotation of engine. Remove the crankshaft pulley/vibration damper. 9. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt. Remove the lower part of the engine front cover. Vehicles with manual transaxle 10. Loosen the center bolt of the right-hand engine support insulator two turns. Vehicles with automatic transaxle 11. Loosen the center bolt of the right-hand engine support insulator two turns. All Vehicles 12. Loosen the center bolt of the left-hand engine support insulator two turns. 13. Lower the vehicle. 14. Detach the coolant expansion tank and position it to one side.
