2005 MERCEDES-BENZ SPRINTER brake fluid

8W-15 GROUND DISTRIBUTION
Component PageA/C Auxiliary Fan........................8W-15-4
A/C Auxiliary Fan Relay...................8W-15-12
A/C Control Module- Roof..................8W-15-28
A/C Fan Switch........................8W-15-21
A/C Switch- Roof.....................8W-15-24, 28
Airbag Control Module....................8W-15-11
Ash Receiver Lamp......................8W-15-22
Automatic Temperature Control Module.........8W-15-24
Auxiliary Heater Relay....................8W-15-12
Auxiliary Heater Switch...................8W-15-24
Battery..............................8W-15-8
Battery Relay- Auxiliary...................8W-15-11
Battery- Auxiliary.......................8W-15-11
Blower Motor- Front......................8W-15-9
Brake Fluid Level Switch...................8W-15-8
Brake Wear Sensor- Left Front................8W-15-8
Brake Wear Sensor- Left Rear...............8W-15-28
Brake Wear Sensor- Right Front...............8W-15-8
Brake Wear Sensor- Right Rear...............8W-15-28
Cabin Heater Assembly....................8W-15-3
Center High Mounted Stop Lamp..............8W-15-6
Central Timer Module....................8W-15-15
Cigar Lighter..........................8W-15-22
Cigar Lighter Lamp......................8W-15-22
Circulation Pump........................8W-15-9
Circulation Pump Relay...................8W-15-12
Clockspring...........................8W-15-10
Controller Antilock Brake.................8W-15-2, 28
CTEL Connector........................8W-15-21
Cylinder Lock Switch- Driver..............8W-15-7, 10
D+ Relay No. 1.........................8W-15-12
D+ Relay No. 2.........................8W-15-14
Data Link Connector.....................8W-15-10
Daytime Running Lamp Relay- Left Side.........8W-15-13
Daytime Running Lamp Relay- Right Side........8W-15-13
Daytime Running Lamps Relay...............8W-15-13
Differential Lock Solenoid Valve...............8W-15-2
Dome Lamp...........................8W-15-6
Dosing Pump...........................8W-15-2
Engine Control Module.....................8W-15-7
Engine Coolant Level Switch.................8W-15-2
Fan Stage 1 Relay.......................8W-15-11
Fog Lamp Relay........................8W-15-11
Fog Lamp Switch.......................8W-15-22
Fuse Block No. 1........................8W-15-7
Fused Ignition Switch Run-Start Relay..........8W-15-14
G100..............................8W-15-2, 3
G101................................8W-15-4
G102................................8W-15-4
G200.........................8W-15-6, 7, 8, 9, 10
G201...............................8W-15-11
G202.............8W-15-11, 12, 13, 14, 15, 16, 17, 18, 19
G203....................8W-15-20, 21, 22, 23, 24, 25
G300..........................8W-15-26, 27, 28
G301...............................8W-15-28
G302...............................8W-15-28
Glow Plug Control Module..................8W-15-2
Hazard Warning Switch....................8W-15-7
Headlamp Adjust Switch...................8W-15-22
Headlamp Assembly- Left...................8W-15-3
Headlamp Assembly- Right..................8W-15-4
Heat Exchanger Connector.................8W-15-12
Heat Exchanger Switch....................8W-15-24
Heated Seat Switch- Driver.................8W-15-25
Heated Seat Switch- Passenger...............8W-15-25
Heater Timer- Auxiliary...................8W-15-24
Hood Ajar Switch........................8W-15-4
Horn Relay...........................8W-15-11
Horn Switch..........................8W-15-10
Ignition Lock Switch.....................8W-15-10
Instrument Cluster......................8W-15-10
Instrument Panel Socket...................8W-15-20Component PageInterior Lamp No. 1......................8W-15-6
Interior Lamp No. 2......................8W-15-6
Interior Lamp No. 3......................8W-15-6
Interior Lamp No. 4......................8W-15-6
Interior Lamp No. 5......................8W-15-6
Interior Lamp- Middle Front................8W-15-5, 6
Interior Lamp- Middle Rear................8W-15-5, 6
Interior Lamp- Rear No. 2...................8W-15-5
Interior Lamp- Right Side.................8W-15-5, 6
Interior Light Switch.....................8W-15-21
Interior Lighting Connector..................8W-15-6
Intrusion Sensor No. 1.....................8W-15-6
Intrusion Sensor No. 2.....................8W-15-6
Intrusion Sensor No. 3.....................8W-15-6
Lamp Relay- Left.......................8W-15-13
Lamp Relay- Right......................8W-15-13
License Plate Lamp No. 1..................8W-15-27
License Plate Lamp No. 2..................8W-15-27
Locker Switch No. 1......................8W-15-20
Map/Reading Lamp Switch.................8W-15-21
Marker Lamp Connector...................8W-15-17
Marker Lamp No. 1- Left Front...............8W-15-16
Marker Lamp No. 1- Right Front..............8W-15-16
Marker Lamp No. 2- Left Front...............8W-15-16
Marker Lamp No. 2- Right Front..............8W-15-16
Marker Lamp- Left Center..................8W-15-17
Marker Lamp- Left Rear...................8W-15-27
Marker Lamp- Right Center.................8W-15-17
Marker Lamp- Right Rear..................8W-15-27
Master Door Lock Switch..................8W-15-25
Metering Pump.........................8W-15-18
Multi- Function Switch.....................8W-15-7
Optional Equipment Relay..................8W-15-19
Panic Alarm Switch......................8W-15-20
Parking Brake Switch....................8W-15-15
Power Mirror Motor- Driver.................8W-15-23
Power Mirror Motor- Passenger...............8W-15-23
Power Mirror Switch.....................8W-15-23
Power Window Switch- Driver...............8W-15-23
Power Window Switch- Master...............8W-15-23
Radio...............................8W-15-21
Reading Lamp Connector...................8W-15-6
Recirculated Air Solenoid Valve...............8W-15-9
Seat Belt Switch........................8W-15-15
Security System Module...................8W-15-15
Sentry Key Remote Entry Module..............8W-15-7
Shifter Assembly........................8W-15-20
Siren................................8W-15-9
Tail Lamp Assembly- Left..................8W-15-26
Tail Lamp Assembly- Right.................8W-15-26
TCS Switch...........................8W-15-25
Time Delay Relay.......................8W-15-17
Towing/Intrusion Sensor On/Off Switch..........8W-15-22
Trailer Tow Connector....................8W-15-28
Trailer Tow Control Module.................8W-15-19
Transmission Control Module................8W-15-19
Transmission Relay......................8W-15-19
Turn Signal No. 1- Left Front.................8W-15-3
Turn Signal No. 1- Right Front................8W-15-4
Turn Signal No. 2- Left Front.................8W-15-3
Warm Air Auxiliary Heater Assembly...........8W-15-18
Washer Pump Motor- Front..................8W-15-4
Water Cycle Valve........................8W-15-9
Window Defogger Module- Rear..............8W-15-15
Window Defogger Relay- Left Rear.............8W-15-14
Window Defogger Relay- Right Rear............8W-15-14
Window Defogger Switch- Rear...............8W-15-20
Window Defogger- Left Rear.................8W-15-26
Window Defogger- Right Rear................8W-15-26
Wiper Motor- Front.......................8W-15-9
Wiper/Turn Signal/Engine Start Control Module.....8W-15-7
VA8W-15 GROUND DISTRIBUTION 8W - 15 - 1

8W-35 ANTILOCK BRAKES
Component Page
Automatic Temperature Control Module . . 8W-35-2
Brake Fluid Level Switch.............. 8W-35-7
Brake Lamp Switch................ 8W-35-3, 4
Brake Wear Sensor- Left Front......... 8W-35-8
Brake Wear Sensor- Left Rear.......... 8W-35-8
Brake Wear Sensor- Right Front........ 8W-35-8
Brake Wear Sensor- Right Rear......... 8W-35-8
Center High Mounted Stop Lamp....... 8W-35-3
Controller Antilock Brake...... 8W-35-2, 3, 4, 5, 6
Data Link Connector................. 8W-35-5
Daytime Running Lamps Relay......... 8W-35-2
Fuse 2............................ 8W-35-5
Fuse 3............................ 8W-35-5
Fuse 5............................ 8W-35-3
Fuse 6............................ 8W-35-5
Fuse 7............................ 8W-35-5
Fuse 9............................ 8W-35-5
Fuse Block No. 1.................... 8W-35-3
Fuse/Relay Block.................... 8W-35-5
G100.............................. 8W-35-4Component Page
G200............................ 8W-35-7, 8
G202.............................. 8W-35-7
G203.............................. 8W-35-2
G300.............................. 8W-35-8
G302.............................. 8W-35-4
Instrument Cluster................. 8W-35-7, 8
Optional Equipment Relay............. 8W-35-5
Parking Brake Switch................ 8W-35-7
Power Distribution Center............. 8W-35-5
Relay Block........................ 8W-35-5
Shifter Assembly.................... 8W-35-3
Tail Lamp Assembly- Left.............. 8W-35-3
Tail Lamp Assembly- Right............ 8W-35-3
TCS Switch........................ 8W-35-2
Wheel Speed Sensor- Left Front......... 8W-35-6
Wheel Speed Sensor- Left Rear......... 8W-35-6
Wheel Speed Sensor- Right Front........ 8W-35-6
Wheel Speed Sensor- Right Rear........ 8W-35-6
VA8W-35 ANTILOCK BRAKES 8W - 35 - 1

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-3
Ambient Temperature Sensor........... 8W-40-8
Automatic Temperature Control
Module........................ 8W-40-4, 8
Battery............................ 8W-40-2
Brake Fluid Level Switch.............. 8W-40-3
Brake Wear Sensor- Left Front......... 8W-40-5
Brake Wear Sensor- Left Rear.......... 8W-40-5
Brake Wear Sensor- Right Front........ 8W-40-5
Brake Wear Sensor- Right Rear......... 8W-40-5
Courtesy Lamp- Driver Door........... 8W-40-6
Courtesy Lamp- Passenger Door........ 8W-40-6
D+ Relay No. 1...................... 8W-40-8
Data Link Connector................. 8W-40-3
Dome Lamp........................ 8W-40-6
Door Jamb Switch- Driver............. 8W-40-6
Door Jamb Switch- Passenger.......... 8W-40-6
Engine Coolant Level Switch........... 8W-40-7
Fuel Level Sensor.................... 8W-40-3
Fuse 1............................ 8W-40-2
Fuse 3............................ 8W-40-6
Fuse 6............................ 8W-40-3
Fuse 18............................ 8W-40-2Component Page
Fuse Block No. 1.................... 8W-40-2
Fuse Block No. 2.................. 8W-40-3, 6
G100.............................. 8W-40-7
G200.......................... 8W-40-2, 3, 5
G202.......................... 8W-40-3, 7, 8
G203.............................. 8W-40-6
G300.............................. 8W-40-5
Generator.......................... 8W-40-2
Headlamp Assembly- Left.............. 8W-40-7
Headlamp Assembly- Right............ 8W-40-7
Ignition Lock Switch................. 8W-40-2
Instrument Cluster....... 8W-40-2, 3, 4, 5, 6, 7, 8
Instrument Panel Socket.............. 8W-40-6
Parking Brake Switch................ 8W-40-3
Power Distribution Center............. 8W-40-2
Radio............................. 8W-40-8
Seat Belt Switch..................... 8W-40-7
Security System Module............... 8W-40-6
Sentry Key Remote Entry Module....... 8W-40-4
Turn Signal/Anti-Theft Alarm Relay- Left . 8W-40-8
Turn Signal/Anti-Theft Alarm Relay-
Right........................... 8W-40-8
VA8W-40 INSTRUMENT CLUSTER 8W - 40 - 1

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Control Module-Roof.............. 8W-80-4
A/C Fan Switch..................... 8W-80-4
A/C Switch-Roof..................... 8W-80-4
Accelerator Pedal Position Sensor....... 8W-80-5
Air Outlet Temperature Sensor......... 8W-80-5
Airbag Control Module................ 8W-80-5
Airbag Squib-Driver.................. 8W-80-5
Airbag Squib-Passenger............... 8W-80-6
Ambient Temperature Sensor........... 8W-80-6
Ash Receiver Lamp.................. 8W-80-6
Automatic Temperature Control
Module C1....................... 8W-80-6
Automatic Temperature Control
Module C2....................... 8W-80-7
Auxiliary Heater Relay (In Relay Block) . . 8W-80-9
Auxiliary Heater Switch............... 8W-80-9
Battery Relay-Auxiliary............... 8W-80-9
Blower Motor Resistor Block........... 8W-80-9
Blower Motor Resistor Block C1......... 8W-80-9
Blower Motor Resistor Block C2........ 8W-80-10
Blower Motor Resistor Block C3........ 8W-80-10
Blower Motor-Front................. 8W-80-10
Body Plug Connector................ 8W-80-10
Boost Pressure Sensor............... 8W-80-10
Boost Pressure Solenoid.............. 8W-80-11
Brake Fluid Level Switch............. 8W-80-11
Brake Lamp Switch C1............... 8W-80-11
Brake Lamp Switch C2............... 8W-80-11
Brake Wear Sensor-Left Front......... 8W-80-11
Brake Wear Sensor-Left Rear.......... 8W-80-12
Brake Wear Sensor-Right Front........ 8W-80-12
Brake Wear Sensor-Right Rear......... 8W-80-12
C100............................. 8W-80-12
C100............................. 8W-80-12
C101............................. 8W-80-13
C101............................. 8W-80-13
C200............................. 8W-80-13
C200............................. 8W-80-14
C201............................. 8W-80-14
C201............................. 8W-80-15
C202............................. 8W-80-15
C202............................. 8W-80-15
C203............................. 8W-80-16
C203............................. 8W-80-16
C204............................. 8W-80-16
C204............................. 8W-80-16
C205............................. 8W-80-17
C205............................. 8W-80-17
C206............................. 8W-80-17
C206............................. 8W-80-17
C207............................. 8W-80-18
C207............................. 8W-80-18Component Page
C208............................. 8W-80-18
C208............................. 8W-80-18
C209............................. 8W-80-18
C209............................. 8W-80-19
C210............................. 8W-80-19
C210............................. 8W-80-19
C211 ............................. 8W-80-19
C211 ............................. 8W-80-19
C214............................. 8W-80-20
C214............................. 8W-80-20
C215............................. 8W-80-20
C215............................. 8W-80-20
C216............................. 8W-80-20
C216............................. 8W-80-20
C217............................. 8W-80-21
C217............................. 8W-80-21
C218............................. 8W-80-21
C218............................. 8W-80-21
C219............................. 8W-80-22
C219............................. 8W-80-22
C220............................. 8W-80-22
C220............................. 8W-80-22
C221............................. 8W-80-23
C221............................. 8W-80-23
C224............................. 8W-80-23
C224............................. 8W-80-23
C225............................. 8W-80-23
C225............................. 8W-80-24
Cabin Heater Assembly C1............ 8W-80-24
Cabin Heater Assembly C2............ 8W-80-24
Camshaft Position Sensor............. 8W-80-24
Center High Mounted Stop Lamp....... 8W-80-24
Central Timer Module C1............. 8W-80-25
Central Timer Module C2............. 8W-80-25
Cigar Lighter...................... 8W-80-25
Cigar Lighter Lamp................. 8W-80-26
Circulation Pump (Cabin Heater
Module)........................ 8W-80-26
Circulation Pump (Rest System)........ 8W-80-26
Circulation Pump Diode.............. 8W-80-26
Clockspring C1..................... 8W-80-26
Clockspring C2..................... 8W-80-27
Controller Antilock Brake............. 8W-80-27
Courtesy Lamp-Driver Door........... 8W-80-27
Courtesy Lamp-Left Sliding Door....... 8W-80-27
Courtesy Lamp-Passenger Door........ 8W-80-28
Courtesy Lamp-Right Sliding Door...... 8W-80-28
Crankcase Heater................... 8W-80-28
Crankshaft Position Sensor........... 8W-80-28
Ctel Connector..................... 8W-80-28
Cylinder Lock Switch-Driver.......... 8W-80-29
Data Link Connector................ 8W-80-29
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

BOOST PRESSURE SOLENOID - BLACK
CAV CIRCUIT FUNCTION
1 20WT BOOST PRESSURE SOLENOID CONTROL
2 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY
BRAKE FLUID LEVEL SWITCH
CAV CIRCUIT FUNCTION
1 20BR/YL PARKING BRAKE SIGNAL
2 16BR GROUND
BRAKE LAMP SWITCH C1
CAV CIRCUIT FUNCTION
1 20WT BRAKE SWITCH OUTPUT
2 16RD/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 20BK/BL/RD BRAKE LAMP SWITCH
BRAKE LAMP SWITCH C2 - BLACK
CAV CIRCUIT FUNCTION
1 20BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 20BK/RD BRAKE LAMP SWITCH OUTPUT
BRAKE WEAR SENSOR-LEFT FRONT
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Blower Motor Resistor Block
C1Instrument Panel 15
Blower Motor Resistor Block
C2Instrument Panel 15
Blower Motor Resistor Block
C3Instrument Panel 15
Blower Motor-Front Underhood Right (To The
Instrument Panel)4
Body Plug Connector Under Driver Seat N/S
Boost Pressure Sensor Engine Compartment-Left 5
Brake Fluid Level Switch Engine Compartment 3
Brake Lamp Switch C1 Pedals Area (Brake) 14
Brake Lamp Switch C2 Pedals Area (Brake) 14
Brake Wear Sensor-Left
FrontOn Left Front Wheel N/S
Brake Wear Sensor-Left Rear On Left Rear Wheel N/S
Brake Wear Sensor-Right
FrontOn Right Front Wheel N/S
Brake Wear Sensor-Right
RearOn Right Rear Wheel N/S
C100 Under Driver Seat 18
C101 Under Instrument Panel-Left 14
C200 Under Instrument Panel-Left 11
C201 Under Instrument Panel-Left 11
C202 Under Instrument Panel-Left 11
C203 Instrument Panel N/S
C204 Upper Instrument Panel-Left 11
C205 Under Driver Seat N/S
C206 Instrument Panel N/S
C207 Near Interior Light Switch-Driver N/S
C208 Near A/C Fan Switch N/S
C209 Instrument Panel N/S
C210 Instrument Panel N/S
C211 Instrument Panel N/S
C212 Instrument Panel N/S
C213 Instrument Panel N/S
C214 Instrument Panel N/S
C215 Instrument Panel N/S
C216 Instrument Panel N/S
C217 Instrument Panel N/S
C218 Under Driver Seat 18
C219 Under Driver Seat 19
C220 Instrument Panel N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (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)

(5) Remove calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) (Fig. 7)
(6) Cut tie straps holding wheel speed sensor and
brake pad wear sensor wire harness to the cradle.
(7) Cut tie straps holding transmission harness to
the cradle.
(8) Remove lower pinch bolt from steering shaft
and disconnect shaft. (Fig. 8)
(9) Siphon the power steering fluid out of the res-
ervoir.
(10) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 8).
(11) Remove bolt and remove power steering hose
support bracket from the cradle. (Fig. 9)
Fig. 7 FRONT DISC BRAKE CALIPER
1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS
Fig. 8 STEERING GEAR
1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
Fig. 9 POWER STEERING HOSE BRACKET
1 - POWER STEERING LINE
2 - SUPPORT BRACKET BOLT
VAFRAME & BUMPERS 13 - 7
ENGINE CRADLE CROSSMEMBER (Continued)