2005 MERCEDES-BENZ SPRINTER fuel pump

Component Page
Map/Reading Lamp Switch.............. 8W-44
Marker Lamp Connector................ 8W-51
Marker Lamps........................ 8W-50
Mass Air Flow Sensor.................. 8W-30
Master Door Lock Switch............... 8W-61
Metering Pump....................... 8W-42
Microphone Connector.................. 8W-55
Multi-Function Switch......... 8W-50, 52, 53, 54
Optional Equipment Relay.............. 8W-11
Panic Alarm Switch.................... 8W-39
Parking Brake Switch.................. 8W-35
Power Distribution Center.............. 8W-10
Power Mirror Motors................... 8W-62
Power Mirror Switch................... 8W-62
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Radio Antenna........................ 8W-47
Radio............................... 8W-47
Radio/Cellular Antenna................. 8W-55
Reading Lamp Connector............... 8W-44
Recirculated Air Solenoid Valve........... 8W-42
Refrigerant Pressure Sensor............. 8W-42
Relay Block.......................... 8W-11
Roof Fan Motor....................... 8W-42
Splices.............................. 8W-70
Seat Belt Switch...................... 8W-43
Seatbelt Tensioners.................... 8W-43
Security System Module................ 8W-39
Sensor.............................. 8W-30
Sentry Key Remote Entry Module......... 8W-39
Shifter Assembly...................... 8W-31
Siren............................ 8W-39, 41
SKREEM Antenna.................... 8W-39
SKREEM Transponder................. 8W-39
Speakers............................ 8W-47Component Page
Speed Control Switch.................. 8W-33
Starter Motor Relay................... 8W-21
Starter Motor........................ 8W-21
Tail Lamp Assemblies.................. 8W-51
TCS Switch.......................... 8W-35
Temperature Switch................... 8W-42
Time Delay Relay..................... 8W-44
Towing/Intrusion Sensor On/Off Switch..... 8W-39
Trailer Tow Connector.................. 8W-54
Trailer Tow Control Module.............. 8W-54
Transmission Control Module............ 8W-31
Transmission Relay.................... 8W-31
Transmission Solenoid Assembly.......... 8W-31
Turn Signals......................... 8W-52
Turn Signal Relay..................... 8W-52
Turn Signal Switch.................... 8W-50
Turn Signal/Anti-Theft Alarm Relays . . . 8W-39, 52
Warm Air Auxiliary Control Module....... 8W-42
Warm Air Auxiliary Heater Assembly...... 8W-42
Warm Air Heater Control Module......... 8W-42
Washer On/Off Switch.................. 8W-53
Washer Pump Motor-Front.............. 8W-53
Water Cycle Valve..................... 8W-42
Water In Fuel Sensor.................. 8W-30
Wheel Speed Sensors................... 8W-35
Window Defoggers..................... 8W-48
Window Defogger Module-Rear........... 8W-48
Window Defogger Relays................ 8W-48
Window Defogger Switch-Rear........... 8W-48
Wiper Motor-Front.................... 8W-53
Wiper On/Off Relay.................... 8W-53
Wiper Switch......................... 8W-53
Wiper/Turn Signal/Engine Start Control
Module........................... 8W-50
8W - 02 - 2 8W-02 COMPONENT INDEXVA

Component Page
Differential Lock Solenoid Valve........ 8W-80-29
Dome Lamp....................... 8W-80-29
Door Lock Motor/Ajar Switch
Assembly-Driver C1............... 8W-80-30
Door Lock Motor/Ajar Switch
Assembly-Driver C2............... 8W-80-30
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C1........... 8W-80-30
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C2........... 8W-80-30
Door Lock Motor/Ajar Switch
Assembly-Passenger C1............ 8W-80-30
Door Lock Motor/Ajar Switch
Assembly-Passenger C2............ 8W-80-31
Door Lock Motor/Ajar Switch
Assembly-Rear C1................ 8W-80-31
Door Lock Motor/Ajar Switch
Assembly-Rear C2................ 8W-80-31
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C1.......... 8W-80-31
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C2.......... 8W-80-31
Dosing Pump...................... 8W-80-32
EGR Valve........................ 8W-80-32
Engine Control Module C1............ 8W-80-32
Engine Control Module C2............ 8W-80-32
Engine Control Module C3............ 8W-80-33
Engine Control Module C4............ 8W-80-33
Engine Control Module C5............ 8W-80-34
Engine Coolant Level Switch.......... 8W-80-34
Engine Coolant Temperature Sensor.... 8W-80-34
Engine Oil Sensor................... 8W-80-34
Evaporator Temperature Sensor........ 8W-80-35
Fog Lamp Switch................... 8W-80-35
Fuel Injector No. 1.................. 8W-80-35
Fuel Injector No. 2.................. 8W-80-35
Fuel Injector No. 3.................. 8W-80-35
Fuel Injector No. 4.................. 8W-80-36
Fuel Injector No. 5.................. 8W-80-36
Fuel Level Sensor................... 8W-80-36
Fuel Pressure Sensor................ 8W-80-36
Fuel Pressure Solenoid............... 8W-80-36
Fuel Shutdown Solenoid.............. 8W-80-37
Fuel Temperature Sensor............. 8W-80-37
Fuse Block No. 1 C1................. 8W-80-37
Fuse Block No. 1 C2................. 8W-80-37
Fuse Block No. 1 C3................. 8W-80-38
Fuse Block No. 1 C4................. 8W-80-38
Fuse Block No. 1 C5................. 8W-80-38
Glow Plug Control Module C1......... 8W-80-38
Glow Plug Control Module C2......... 8W-80-39
Headlamp Adjust Switch............. 8W-80-39
Headlamp Assembly-Left............. 8W-80-39
Headlamp Assembly-Right............ 8W-80-40
Heat Exchanger Connector............ 8W-80-40Component Page
Heat Exchanger Switch.............. 8W-80-40
Heated Seat Module-Driver........... 8W-80-40
Heated Seat Module-Passenger........ 8W-80-41
Heated Seat Switch-Driver............ 8W-80-41
Heated Seat Switch-Passenger......... 8W-80-41
Heater Timer-Auxiliary.............. 8W-80-41
Hood Ajar Switch................... 8W-80-42
Horn............................. 8W-80-42
Horn (VTSS)....................... 8W-80-42
Horn-Switch....................... 8W-80-42
Ignition Lock Switch................. 8W-80-43
Instrument Cluster C1............... 8W-80-43
Instrument Cluster C2............... 8W-80-43
Instrument Panel Socket............. 8W-80-44
Intake Air Temperature Sensor........ 8W-80-44
Interior Lamp No. 1................. 8W-80-44
Interior Lamp No. 2................. 8W-80-44
Interior Lamp No. 3................. 8W-80-44
Interior Lamp No. 4................. 8W-80-45
Interior Lamp No. 5................. 8W-80-45
Interior Lamp-Left.................. 8W-80-45
Interior Lamp-Middle Front........... 8W-80-45
Interior Lamp-Middle Rear........... 8W-80-46
Interior Lamp-Rear No. 1............. 8W-80-46
Interior Lamp-Rear No. 2............. 8W-80-46
Interior Lamp-Right................. 8W-80-47
Interior Light Switch................ 8W-80-47
Interior Light Switch-Driver........... 8W-80-47
Interior Light Switch-Passenger........ 8W-80-47
Interior Light Switch-Rear............ 8W-80-48
Interior Lighting Connector........... 8W-80-48
Intrusion Sensor No. 1............... 8W-80-48
Intrusion Sensor No. 2............... 8W-80-48
Intrusion Sensor No. 3............... 8W-80-48
Kick Down Switch.................. 8W-80-49
License Plate Lamp No. 1............. 8W-80-49
License Plate Lamp No. 2............. 8W-80-49
Locker Switch No. 1................. 8W-80-49
Locker Switch No. 2................. 8W-80-49
Low Fuel Pressure Sensor............ 8W-80-50
Map/Reading Lamp Switch............ 8W-80-50
Marker Lamp Connector............. 8W-80-50
Marker Lamp No. 1-Left Front......... 8W-80-50
Marker Lamp No. 1-Right Front....... 8W-80-50
Marker Lamp No. 2-Left Front......... 8W-80-51
Marker Lamp No. 2-Right Front....... 8W-80-51
Marker Lamp-Left Center............ 8W-80-51
Marker Lamp-Left Rear.............. 8W-80-51
Marker Lamp-Right Center........... 8W-80-51
Marker Lamp-Right Rear............. 8W-80-52
Mass Air Flow Sensor................ 8W-80-52
Master Door Lock Switch............. 8W-80-52
Metering Pump..................... 8W-80-52
Microphone Connector............... 8W-80-52
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSVA

Component Page
Panic Alarm Switch................. 8W-80-53
Parking Brake Switch............... 8W-80-53
Power Mirror Motor-Driver........... 8W-80-53
Power Mirror Motor-Passenger......... 8W-80-53
Power Mirror Switch................ 8W-80-53
Power Window Motor-Driver.......... 8W-80-54
Power Window Motor-Passenger........ 8W-80-54
Power Window Switch-Driver.......... 8W-80-54
Power Window Switch-Master......... 8W-80-54
Power Window Switch-Passenger....... 8W-80-54
Radio Antenna..................... 8W-80-55
Radio C1.......................... 8W-80-55
Radio C2.......................... 8W-80-55
Radio/Cellular Antenna.............. 8W-80-55
Reading Lamp Connector............. 8W-80-56
RECIRCULATED AIR SOLENOID
Valve.......................... 8W-80-56
Refrigerant Pressure Sensor........... 8W-80-56
Remote Keyless Entry Antenna........ 8W-80-56
Roof Fan Motor..................... 8W-80-56
Seat Belt Switch.................... 8W-80-57
Seat Belt Tensioner-Driver............ 8W-80-57
Seat Belt Tensioner-Passenger......... 8W-80-57
Security System Module C1........... 8W-80-57
Security System Module C2........... 8W-80-58
Sentry Key Remote Entry Module
(Skreem)........................ 8W-80-58
Shifter Assembly................... 8W-80-58
Siren............................. 8W-80-59
Speaker-Left Front Door Assembly C1 . . . 8W-80-59
Speaker-Left Front Door Assembly C2 . . . 8W-80-59
Speaker-Left Rear.................. 8W-80-59
Speaker-Right Front Door............ 8W-80-59
Speaker-Right Rear................. 8W-80-60Component Page
Speed Control Switch................ 8W-80-60
Tail Lamp Assembly-Left............. 8W-80-60
Tail Lamp Assembly-Right............ 8W-80-60
TCS Switch (ASR).................. 8W-80-60
Temperature Switch................. 8W-80-61
Time Delay Relay................... 8W-80-61
Towing/Intrusion Sensor On/Off Switch . . 8W-80-61
Trailer Tow Connector............... 8W-80-61
Trailer Tow Control Module C1........ 8W-80-62
Trailer Tow Control Module C2........ 8W-80-62
Transmission Control Module C1....... 8W-80-62
Transmission Control Module C2....... 8W-80-62
Transmission Solenoid Assembly....... 8W-80-63
Turn Signal No. 1-Left Front.......... 8W-80-63
Turn Signal No. 1-Right Front......... 8W-80-63
Turn Signal No. 2-Left Front.......... 8W-80-63
Turn Signal No. 2-Right Front......... 8W-80-64
Warm Air Auxiliary Heater Assembly C1 . 8W-80-64
Warm Air Auxiliary Heater Assembly C2 . 8W-80-64
Washer Pump Motor-Front............ 8W-80-64
Water Cycle Valve................... 8W-80-64
Water In Fuel Sensor................ 8W-80-65
Wheel Speed Sensor-Left Front........ 8W-80-65
Wheel Speed Sensor-Left Rear......... 8W-80-65
Wheel Speed Sensor-Right Front....... 8W-80-65
Wheel Speed Sensor-Right Rear........ 8W-80-65
Window Defogger Module-Rear......... 8W-80-66
Window Defogger Switch-Rear......... 8W-80-66
Window Defogger-Left Rear........... 8W-80-66
Window Defogger-Right Rear.......... 8W-80-66
Wiper Motor-Front.................. 8W-80-66
Wiper/Turn Signal/Engine Start Control
Module (Fuse Block No. 1).......... 8W-80-67
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Lamp Relay-Right Under Driver Seat N/S
License Plate Lamp No. 1 On Rear Of Vehicle N/S
License Plate Lamp No. 2 On Rear Of Vehicle N/S
Locker Switch No. 1 Under Body-Front N/S
Locker Switch No. 2 Under Body-Rear 24
Low Fuel Pressure Sensor Engine Compartment 6,8
Map/Reading Lamp Switch Instrument Panel N/S
Marker Lamp No.1-Left Front Front Of Vehicle-Left Side N/S
Marker Lamp No.2-Left Front Front Of Vehicle-Left Side N/S
Marker Lamp-Left Center Front Of Vehicle-Center Left Side N/S
Marker Lamp-Left Rear Rear Of Vehicle-Left Side N/S
Marker Lamp-Right Center Front Of Vehicle-Center Right Side N/S
Marker Lamp-Right Rear Rear Of Vehicle -Right Side N/S
Mass Air Flow Sensor Engine Compartment 5
Master Door Lock Switch Center Of Instrument Panel N/S
Metering Pump Instrument Panel N/S
Microphone Connector Instrument Panel N/S
Multi-Function Switch Steering Wheel 11
Optional Equipment Relay
(Relay Block)Under Driver Seat N/S
Panic Alarm Switch Instrument Panel N/S
Parking Brake Switch Under Instrument Panel 23
Power Mirror Motor-Driver In Driver Door N/S
Power Mirror Motor-
PassengerIn Passenger Door N/S
Power Mirror Switch On Driver Door N/S
Power Mirror-Driver On Driver Door N/S
Power Mirror-Master On Driver Door N/S
Power Mirror-Passenger On Passenger Door N/S
Power Window Motor-Driver In Driver Door N/S
Power Window Motor-
PassengerIn Passenger Door N/S
Power Window Switch-Driver On Driver Door N/S
Power Window Switch-Master On Driver Door N/S
Power Window Switch-
PassengerOn Passenger Door N/S
Radio Antenna Behind Radio N/S
Radio C1 Behind Radio N/S
Radio C2 Behind Radio N/S
Radio/Cellular Antenna Behind Radio N/S
Reading Lamp Connector Instrument Panel N/S
Recirculated Air Solenoid
ValveUnderhood Right (To The
Instrument Panel)4
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Transmission Control Module
C2Engine Compartment N/S
Transmission Control Relay
(Fuse Block No. 1)In Fuse Block No.1 N/S
Transmission Solenoid
AssemblyTransmission 9
Turn Signal Lamp No.1-Left
FrontFront Of Vehicle On Left Side N/S
Turn Signal Lamp No.1-Right
FrontFront Of Vehicle On Right Side N/S
Turn Signal Lamp No.2-Left
FrontFront Of Vehicle On The Left Side N/S
Turn Signal Lamp No.2-Right
FrontFront Of Vehicle On The Right
SideN/S
Turn Signal Relay (Fuse
Block No. 1)In Fuse Block No.1 N/S
Turn Signal/Anti-Theft Alarm
Relay-Left (Relay Block)Under Driver Seat N/S
Turn Signal/Anti-Theft Alarm
Relay-Right (Relay Block)Under Driver Seat N/S
Warm Air Auxiliary Heater
Assembly C1Instrument Panel 15
Warm Air Auxiliary Heater
Assembly C2Instrument Panel 15
Washer Pump Motor-Front Engine Compartment N/S
Wastegate Solenoid Engine Compartment N/S
Water Cycle Valve Underhood (To The Instrument
Panel)4
Water In Fuel Sensor Engine Compartment 8
Wheel Speed Sensor-Left
FrontLeft Front Wheel 2
Wheel Speed Sensor-Left
RearLeft Rear Wheel 2
Wheel Speed Sensor-Right
FrontRight Front Wheel N/S
Wheel Speed Sensor-Right
RearRight Rear Wheel N/S
Window Defogger Module -
RearRear Of Vehicle N/S
Window Defogger Relay-Left
Rear (Relay Block)Under Driver Seat N/S
Window Defogger Relay-
Right Rear (Relay Block)Under Driver Seat N/S
Window Defogger Switch -
RearInstrument Panel N/S
Window Defogger-Left Rear On Left Rear Window N/S
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(2) Remove the hood.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Evacuate and recover air conditioning system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(5) Disconnect the engine wiring harness at the
vehicle side and carefully guide though the cowl into
the engine area.
(6) Remove the engine cover (Fig. 3).
(7) Remove the air cleaner housing.
(8) Disconnect the charge air hose at the mixing
chamber (Fig. 3).
(9) Remove the radiator assembly.
(10) Disconnect the high pressure and return
hoses at the power steering pump (Fig. 3).
(11) Disconnect the fuel lines at the fuel filter (Fig.
3).
(12) Disconnect the refrigerant line at the A/C
compressor (Fig. 3).
(13) Disconnect the vacuum line for the brake
booster at the vacuum pump.
(14) Disconnect the coolant hose of heating return
flow at the water pump.
Fig. 3 2.7L ENGINE
1 - HEATING SUPPLY COOLANT HOSE 7 - REFRIGERANT LINE
2 - ENGINE COVER 8 - O-RING
3 - HEATING RETURN COOLANT HOSE 9 - POWER STEERING HIGH PRESSURE PIPE
4 - FUEL PIPE 10 - AIR INTAKE HOSE
5 - FUEL PIPE 11 - CHARGE AIR HOSE
6 - RETURN FLOW PIPE 12 - TURBOCHARGER VACUUM HOSE
Fig. 2 ENGINE COVER
1 - SCREW
2 - COVER
VAENGINE 9 - 5
ENGINE (Continued)

(11) Install the transmission cooler lines to trans-
mission.(Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(12) Install transmission electrical connector and
shifter hardware.Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(13) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(14) Install the crank sensor.
(15) Install the starter.
(16) Connect the ground strap (left side).
(17) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(18) Lower the vehicle.
(19) Install the air inlet hose at the turbocharger
(Fig. 3).
(20) Connect the vacuum hose at the turbocharger
(Fig. 3).
(21) Connect the coolant supply and return hoses
(Fig. 3).(22) Connect the brake booster vacuum hose at the
vacuum pump (Fig. 3).
(23) Connect the refrigerant lines (Fig. 3).
(24) Connect the fuel lines at the filter assembly
(Fig. 3).
(25) Connect the power steering hoses (Fig. 3).
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser.
(28) Install air cleaner housing, sensors, and hoses
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).
(29) Route the engine wiring harness inside the
vehicle and connect.
(30) Install the front grill assembly.
(31) Install and align the hood.
(32) Connect the negative battery cable.
(33) Check and fill engine oil.
(34) Fill cooling system to proper level with the
appropriate coolant.
(35) Evacuate and recharge air conditioning.
(36) Check and refill all ancillary system fluid lev-
els.
(37) Start engine and inspect for leaks.
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge
Distribution Pipe to Air
Charge Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to
Cylinder Head14 - 124
12m-Bolt-Cylinder Head to
Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44 -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque
angle)55, 90É 40 -
Bolt-End Cover to
Crankcase9-80
9 - 8 ENGINEVA
ENGINE (Continued)

REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.
(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER ONLY. WEAR PROTECTIVE GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crank-
case(Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(6) Lower vehicle.(7) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(9) Remove tappets (Fig. 13).
(10) Remove the camshaft housing at the cylinder
head (Fig. 13).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING
WHEN HANDLING FUEL.
(11) Remove the high pressure fuel pump interme-
diate gear (Fig. 13).
(12) Disconnect the engine side of the engine har-
ness and set aside.
(13) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
Fig. 13 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 22 ENGINEVA
CYLINDER HEAD (Continued)