2005 MERCEDES-BENZ SPRINTER Service Repair Manual

²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 4). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly, check the following items.
²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully
seated into the connector/component and locked into
position
²Dirt or corrosion on the terminals. Any amount
of corrosion or dirt could cause an intermittent prob-
lem
²Damaged connector/component casing exposing
the item to dirt or moisture
²Wire insulation that has rubbed through causing
a short to ground
²Some or all of the wiring strands broken inside
of the insulation
²Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, wherethe problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem area.
(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 5) is used to indicate this. When han-
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part form it's protective
packing until it is time to install the part.
(5) Before removing the part from it's pakage,
ground the pakage to a known good ground on the
vehicle.
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 6).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
Fig. 4 Probing Tool
1 - SPECIAL TOOL 6801
2 - PROBING END
Fig. 5 ELECTROSTATIC DISCHARGE SYMBOL
VA8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WIRING DIAGRAM INFORMATION (Continued)

STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the circuit being checked
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 7).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting or energizing the items in the
fuse circuit one at a time. When the fuse blows the
circuit with the short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 8).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 9).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 9).
(5) Release the Secondary Terminal Lock, if
required.
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector.
Fig. 6 Testing for Voltage Potential
Fig. 7 Testing for Continuity
1 - FUSE REMOVED FROM CIRCUIT
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATIONVA
WIRING DIAGRAM INFORMATION (Continued)

INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.(6) Connect battery and test all affected systems.
DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 10).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow.
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
Fig. 8 Testing for Voltage Drop
Fig. 9 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
Fig. 10 Diode Identification
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
VA8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
CONNECTOR (Continued)

INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 11).(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 12).
(5) Solder the connection together using rosin core
type solder only (Fig. 13).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 14).
Fig. 11 1 SPLICE BAND
1 - SPLICE BAND
Fig. 12 2 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 13 3 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 14 4 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATIONVA
TERMINAL (Continued)

8W-02 COMPONENT INDEX
Component Page
A/C Auxiliary Fan Relay................ 8W-42
A/C Auxiliary Fan..................... 8W-42
A/C Compressor Clutch................. 8W-42
A/C Control Module-Roof................ 8W-42
A/C Fan Switch....................... 8W-42
A/C Switch-Roof...................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Air Outlet Temperature Sensor........... 8W-42
Airbag Control Module................. 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-42
Ash Receiver Lamp.................... 8W-44
Automatic Temperature Control Module.... 8W-42
Auxiliary Heater Relay................. 8W-42
Auxiliary Heater Switch................ 8W-42
Battery Relay-Auxiliary................ 8W-20
Batteries............................ 8W-20
Beam Select Switch.................... 8W-50
Blower Motors........................ 8W-42
Body Plug Connector................... 8W-11
Boost Pressure Sensor.................. 8W-30
Boost Pressure Solenoid................ 8W-30
Brake Fluid Level Switch............... 8W-35
Brake Lamp Switch.................... 8W-35
Brake Wear Sensors................... 8W-35
Cabin Heater Assembly................. 8W-42
Cabin Heater Control Module............ 8W-42
Camshaft Position Sensor............... 8W-30
Center High Mounted Stop Lamp......... 8W-51
Central Timer Module.................. 8W-45
Cigar Lighter Lamp................... 8W-44
Cigar Lighter......................... 8W-41
Circulation Pump Diode................ 8W-42
Circulation Pump Relay................ 8W-42
Circulation Pump..................... 8W-42
Clockspring....................... 8W-41, 43
Contact Switch Door-Tailgate............ 8W-44
Controller Antilock Brake............... 8W-35
Courtesy Lamps...................... 8W-44
Crankcase Heater..................... 8W-30
Crankshaft Position Sensor.............. 8W-30
Ctel Antenna Connector................ 8W-55
Ctel Connector..................... 8W-47, 55
Cylinder Lock Switch-Driver............. 8W-61
D+ Relay No. 1....................... 8W-10
D+ Relay No. 2....................... 8W-11
Data Link Connector................... 8W-18
Daytime Running Lamp Relays........... 8W-50
Differential Lock Solenoid Valve.......... 8W-31
Dome Lamp.......................... 8W-44
Door Jamb Switches................... 8W-44
Door Lock Motor/Ajar Switch Assemblies . . . 8W-61Component Page
Dosing Pump......................... 8W-42
EGR Valve........................... 8W-30
Engine Control Module................. 8W-30
Engine Control Relay.................. 8W-31
Engine Coolant Level Switch............. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Sensor..................... 8W-30
Evaporator Temperature Sensor.......... 8W-42
Fan Stage 1 Relay..................... 8W-42
Fog Lamp Relay...................... 8W-50
Fog Lamp Switch..................... 8W-50
Fuel Injectors........................ 8W-30
Fuel Level Sensor..................... 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Shutdown Solenoid................ 8W-30
Fuel Temperature Sensor............... 8W-30
Fuses............................ 8W-10, 11
Fuse Blocks.......................... 8W-10
Fuse/Relay Block...................... 8W-11
Fused Ignition Switch Run-Start Relay..... 8W-11
Grounds............................ 8W-70
Generator........................... 8W-20
Glow Plug Control Module.............. 8W-30
Glow Plugs.......................... 8W-30
Hazard Warning Switch................ 8W-52
Headlamp Adjust Switch................ 8W-50
Headlamp Assemblies............... 8W-50, 52
Headlamp Switch..................... 8W-50
Heat Exchanger Connector.............. 8W-42
Heat Exchanger Switch................. 8W-42
Heated Seat Modules.................. 8W-63
Heated Seat Switches.................. 8W-63
Heater Timer-Auxiliary................. 8W-42
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Horn............................... 8W-41
Ignition Lock Switch................... 8W-40
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Instrument Panel Socket................ 8W-40
Intake Air Temperature Sensor........... 8W-30
Interior Lamps....................... 8W-44
Interior Light Switches................. 8W-44
Interior Lighting Connector.............. 8W-44
Intrusion Sensors..................... 8W-39
Kickdown Switch...................... 8W-30
Lamp Relays......................... 8W-50
License Plate Lamps................... 8W-51
Locker Switches...................... 8W-31
Low Fuel Pressure Sensor............... 8W-30
VA8W-02 COMPONENT INDEX 8W - 02 - 1

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

8W-10 POWER DISTRIBUTION
Component Page
Airbag Control Module................ 8W-10-19
Automatic Temperature Control Module . . . 8W-10-30
Auxiliary Heater Switch............... 8W-10-23
Battery.......................... 8W-10-6, 11
Battery Relay- Auxiliary................ 8W-10-6
Beam Select Switch............. 8W-10-12, 18, 28
Blower Motor Resistor Block......... 8W-10-12, 30
Brake Lamp Switch.................. 8W-10-20
Central Timer Module................. 8W-10-16
Cigar Lighter....................... 8W-10-23
Circulation Pump Diode............... 8W-10-30
Circulation Pump Relay............. 8W-10-22, 30
Controller Antilock Brake.............. 8W-10-20
Courtesy Lamp- Driver Door............ 8W-10-24
Courtesy Lamp- Left Sliding Door........ 8W-10-24
Courtesy Lamp- Passenger Door......... 8W-10-24
Courtesy Lamp- Right Sliding Door....... 8W-10-24
Crankcase Heater.................... 8W-10-29
D+ Relay No. 1.................... 8W-10-9, 10
Data Link Connector.................. 8W-10-20
Daytime Running Lamp Relay-
Left Side...................... 8W-10-10, 27
Daytime Running Lamp Relay-
Right Side..................... 8W-10-10, 27
Daytime Running Lamps Relay.......... 8W-10-25
Dome Lamp........................ 8W-10-24
EGR Valve......................... 8W-10-29
Engine Control Module........ 8W-10-15, 19, 29, 34
Engine Control Relay............ 8W-10-12, 29, 34
Fog Lamp Relay..................... 8W-10-28
Fuse 1................. 8W-10-6, 8, 9, 17, 18, 25
Fuse 2...................... 8W-10-6, 8, 11, 18
Fuse 3....................... 8W-10-6, 8, 9, 18
Fuse 4.............. 8W-10-8, 9, 11, 13, 14, 19, 26
Fuse 5................... 8W-10-8, 9, 11, 14, 20
Fuse 6.............. 8W-10-7, 8, 11, 12, 14, 21, 33
Fuse 7................... 8W-10-7, 8, 14, 17, 22
Fuse 8...................... 8W-10-7, 9, 12, 23
Fuse 9................... 8W-10-8, 9, 10, 12, 21
Fuse 10.................... 8W-10-9, 10, 11, 25
Fuse 11....................... 8W-10-9, 10, 26
Fuse 12......................... 8W-10-7, 27
Fuse 13......................... 8W-10-7, 27
Fuse 14......................... 8W-10-7, 28
Fuse 15....................... 8W-10-7, 13, 16
Fuse 16........................... 8W-10-29
Fuse 17......................... 8W-10-12, 29
Fuse 18....................... 8W-10-9, 14, 19
Fuse 19......................... 8W-10-12, 30
Fuse 20....................... 8W-10-7, 12, 30
Fuse 21...................... 8W-10-12, 13, 30
Component Page
Fuse Block No. 1 . . 8W-10-3, 11, 12, 13, 14, 15, 18, 19,
20, 21, 22, 23, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34
Fuse Block No. 2............ 8W-10-10, 17, 25, 26
Fused Ignition Switch Run-Start Relay.... 8W-10-19
G200............................. 8W-10-32
G202........................... 8W-10-10, 19
Generator........................... 8W-10-6
Glow Plug Control Module.............. 8W-10-11
Hazard Warning Switch....... 8W-10-14, 21, 31, 32
Headlamp Assembly- Left...... 8W-10-18, 26, 27, 28
Headlamp Assembly- Right..... 8W-10-17, 18, 27, 28
Headlamp Switch......... 8W-10-12, 18, 25, 26, 27
Horn............................. 8W-10-22
Horn Relay......................... 8W-10-22
Ignition Switch................ 8W-10-12, 13, 14
Instrument Cluster............. 8W-10-10, 18, 19
Interior Lamp- Left Side............... 8W-10-24
Interior Lamp- Middle Rear............ 8W-10-24
Interior Lamp- Rear No. 1.............. 8W-10-24
Interior Lamp- Rear No. 2.............. 8W-10-24
Interior Lamp- Right Side.............. 8W-10-24
Lamp Relay- Left.................... 8W-10-26
Lamp Relay- Right................... 8W-10-17
Multi- Function Switch . . 8W-10-12, 13, 14, 18, 21, 25,
26, 27, 28, 31, 32, 33, 34
Optional Equipment Relay.......... 8W-10-6, 7, 22
Power Distribution Center.......... 8W-10-2, 6, 11
Radio.......................... 8W-10-16, 23
Radio/Cellular Antenna................ 8W-10-16
Sentry Key Remote Entry Module........ 8W-10-22
Shifter Assembly............... 8W-10-14, 19, 20
Starter Motor.................... 8W-10-11, 15
Starter Motor Relay.................. 8W-10-15
Tail Lamp Assembly- Left.............. 8W-10-26
Tail Lamp Assembly- Right............. 8W-10-17
Trailer Tow Connector................. 8W-10-17
Transmission Relay................... 8W-10-22
Turn Signal Relay.................... 8W-10-31
Turn Signal Switch............. 8W-10-13, 26, 31
Turn Signal/Anti-Theft Alarm Relay- Left . . 8W-10-23
Turn Signal/Anti-Theft Alarm Relay- Right . 8W-10-23
Washer On/Off Switch.............. 8W-10-21, 34
Washer Pump Motor- Front............. 8W-10-34
Window Defogger Switch- Rear.......... 8W-10-22
Wiper Motor- Front................... 8W-10-33
Wiper On/Off Relay................ 8W-10-21, 33
Wiper Switch.................. 8W-10-21, 32, 33
Wiper/Turn Signal/Engine Start Control
Module............ 8W-10-14, 21, 31, 32, 33, 34
VA8W-10 POWER DISTRIBUTION 8W - 10 - 1