2005 MERCEDES-BENZ SPRINTER Cool

8W-30 FUEL/IGNITION SYSTEM
Component Page
Accelerator Pedal Position Sensor....... 8W-30-8
Airbag Control Module................ 8W-30-7
Automatic Temperature Control
Module........................ 8W-30-2, 3
Boost Pressure Sensor................ 8W-30-7
Boost Pressure Solenoid............... 8W-30-6
Camshaft Position Sensor............. 8W-30-16
Central Timer Module................ 8W-30-7
Controller Antilock Brake............ 8W-30-2, 3
Crankcase Heater................... 8W-30-12
Crankshaft Position Sensor........... 8W-30-14
Data Link Connector................ 8W-30-17
EGR Valve........................ 8W-30-12
Engine Control Module . 8W-30-2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17
Engine Control Relay.............. 8W-30-12, 9
Engine Coolant Level Switch.......... 8W-30-17
Engine Coolant Temperature Sensor.... 8W-30-16
Engine Oil Sensor................... 8W-30-12
Fuel Injector No. 1.................. 8W-30-10
Fuel Injector No. 2.................. 8W-30-11
Fuel Injector No. 3.................. 8W-30-10
Fuel Injector No. 4.................. 8W-30-10
Fuel Injector No. 5.................. 8W-30-11
Fuel Level Sensor................... 8W-30-17
Fuel Pressure Sensor................ 8W-30-15
Fuel Pressure Solenoid............... 8W-30-14
Fuel Shutdown Solenoid.............. 8W-30-14
Fuel Temperature Sensor............. 8W-30-15Component Page
Fuse 5............................ 8W-30-5
Fuse 16............................ 8W-30-9
Fuse 17........................... 8W-30-12
Fuse 18............................ 8W-30-7
Fuse Block No. 1................ 8W-30-7, 9, 12
G100........................... 8W-30-5, 17
G200.............................. 8W-30-9
Glow Plug Control Module............. 8W-30-5
Glow Plug No. 1..................... 8W-30-5
Glow Plug No. 2..................... 8W-30-5
Glow Plug No. 3..................... 8W-30-5
Glow Plug No. 4..................... 8W-30-5
Glow Plug No. 5..................... 8W-30-5
Instrument Cluster.............. 8W-30-2, 3, 17
Intake Air Temperature Sensor......... 8W-30-8
Kickdown Switch.................... 8W-30-4
Low Fuel Pressure Sensor............ 8W-30-13
Mass Air Flow Sensor................. 8W-30-6
Power Distribution Center............. 8W-30-5
Sensor........................... 8W-30-13
Sentry Key Remote Entry Module..... 8W-30-2, 3
Shifter Assembly.................. 8W-30-2, 3
Speed Control Switch................. 8W-30-4
Starter Motor Relay................. 8W-30-17
Transmission Control Module......... 8W-30-2, 3
Water In Fuel Sensor................ 8W-30-13
Wiper/Turn Signal/Engine Start Control
Module.......................... 8W-30-9
VA8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 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

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

ENGINE CONTROL MODULE C3 - BLACK
CAV CIRCUIT FUNCTION
1 18BR/DG SENSOR GROUND
5 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
6 18WT/DG BOOST PRESSURE SENSOR SIGNAL
7 20BR/YL SENSOR GROUND
8 18BR/GY SENSOR GROUND
9 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
10 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
12 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
17 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
18 20YL/DG MASS AIR FLOW SENSOR SIGNAL
19 20BR/BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY
20 18VT IGNITION SWITCH OUTPUT (START)
22 18BR/WT SENSOR GROUND
23 18BR/BL SENSOR GROUND
25 18BK/RD GLOW PLUG MODULE CONTROL
28 20BL/YL K-ECM
30 18RD/BL STARTER MOTOR RELAY 12 VOLT SUPPLY
33 20YL/RD MASS AIR FLOW SENSOR 12 VOLT SUPPLY
35 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY
40 20DG/YL ENGINE RPM
43 18VT/DG STARTER MOTOR RELAY CONTROL
46 18YL/BL FUSE BLOCK NO. 1 C5 CAV 15 COMMON CIRCUIT
48 20WT BOOST PRESSURE SOLENOID CONTROL
ENGINE CONTROL MODULE C4 - BLACK
CAV CIRCUIT FUNCTION
2 20BR/DG SENSOR GROUND
3 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
4 20BR/GY SENSOR GROUND
7 18GY/YL SENSOR GROUND
8 18GY/DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY
10 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
11 18BK/YL WATER IN FUEL SENSOR SIGNAL
12 18RD/BL CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
13 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
14 20DG/VT FUEL PRESSURE SENSOR SIGNAL
15 20GY/BL ENGINE OIL SENSOR SIGNAL
17 20BR/BK SENSOR GROUND
18 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
21 20BK/WT GROUND
22 18RD/BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY
26 20DG SENSOR GROUND
27 20BR/WT SENSOR GROUND
30 18DG/BK SENSOR GROUND
31 20RD/WT FUEL PRESSURE SOLENOID CONTROL
32 20BR/YL FUEL SHUTDOWN SOLENOID CONTROL
34 18BR SENSOR GROUND
36 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
37 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL
38 18GY/RD LOW FUEL PRESSURE SENSOR SIGNAL
39 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
40 20RD/YL EGR VALVE CONTROL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33

ENGINE CONTROL MODULE C5 - GRAY
CAV CIRCUIT FUNCTION
2 14BK COMMON INJECTOR DRIVER NO. 1
3 14BK/YL FUEL INJECTOR NO. 4 CONTROL
4 14BL COMMON INJECTOR DRIVER NO. 2
5 14BK/VT FUEL INJECTOR NO. 2 CONTROL
7 14BK/DG FUEL INJECTOR NO. 5 CONTROL
8 14BK/RD FUEL INJECTOR NO. 3 CONTROL
9 14BK/BL FUEL INJECTOR NO. 1 CONTROL
ENGINE COOLANT LEVEL SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
2 16BR GROUND
ENGINE COOLANT TEMPERATURE SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20BR/WT SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20DG/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTSVA

IGNITION LOCK SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
INSTRUMENT CLUSTER C1
CAV CIRCUIT FUNCTION
1 20BR FUEL LEVEL SENSOR SIGNAL
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL (-)
4 20WT/GY K-IC/ATC/HBM/CHM
5 20BR/BK PARKING BRAKE SIGNAL
7 20BK/DG RIGHT TURN SIGNAL
10 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
11 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
14 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
15 20BR/WT FRONT COURTESY LAMPS CONTROL
16 20YL/RD SEAT BELT SWITCH SIGNAL
17 20DG CAN C BUS (-)
18 20DG/WT CAN C BUS (+)
INSTRUMENT CLUSTER C2 - WHITE
CAV CIRCUIT FUNCTION
3 20RD/YL FUSED B(+)
4 20BR/WT BRAKE WEAR SENSOR SIGNAL
6 18BR GROUND
7 20GY/DG/RD LAMP DRIVER
8 20BL/WT FUSED HIGH BEAM SWITCH OUTPUT
9 20BL/RD/WT VEHICLE SPEED SENSOR OUTPUT
10 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
13 20BK/WT LEFT TURN SIGNAL
15 20BL TERMINAL 61
16 20YL AIRBAG WARNING INDICATOR DRIVER
18 20BL/VT D(+) RELAY NO. 1 CONTROL
18 20BL/VT IC 18-C2 TO ATCM 8-C1
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Dome Lamp Dome Area 20
Door Jamb Switch-Driver Driver Door 21
Door Jamb Switch-Left
SlidingLeft Sliding Door N/S
Door Jamb Switch-Passenger Passenger Door 21
Door Jamb Switch-Right
SlidingRight Sliding Door N/S
Door Jamb Switch-Tailgate Tailgate N/S
Door Lock Motor/Ajar Switch
Assembly - Driver C1Driver Door 21
Door Lock Motor/Ajar Switch
Assembly - Driver C2Driver Door 21
Door Lock Motor/Ajar Switch
Assembly - Left Sliding C1Left Sliding Door 22
Door Lock Motor/Ajar Switch
Assembly - Left Sliding C2Left Sliding Door 22
Door Lock Motor/Ajar Switch
Assembly - Passenger C1Passenger Door 22
Door Lock Motor/Ajar Switch
Assembly - Passenger C2Passenger Door 22
Door Lock Motor/Ajar Switch
Assembly - Right Sliding C1Right Sliding Door N/S
Door Lock Motor/Ajar Switch
Assembly - Right Sliding C2Right Sliding Door N/S
Door Lock Motor/Ajar Switch
Assembly-Rear C1Cargo Door 25
Door Lock Motor/Ajar Switch
Assembly-Rear C2Cargo Door 25
Dosing Pump Engine Compartment N/S
EGR Valve Engine Compartment 8
Engine Control Module C1 Instrument Panel 12
Engine Control Module C2 Instrument Panel 12
Engine Control Module C3 Instrument Panel 12
Engine Control Module C4 Instrument Panel 12
Engine Control Module C5 Instrument Panel 12
Engine Coolant Level Switch Engine Compartment 2, 3
Engine Coolant Temperature
SensorEngine Compartment 7
Engine Oil Pressure Sensor Engine Compartment 8
Evaporator Temperature
SensorInstrument Panel-Right 15
Fan Stage 1 Relay (Relay
Block)Under Driver Seat N/S
Fog Lamp Relay (Relay
Block)Under Driver Seat N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the fuseblock only when the ignition switch is
in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the heating element is
inserted in the receptacle shell, the heating element
resistor coil is grounded through its housing to the
receptacle shell. If the cigar lighter knob is pushed
inward, the heat shield slides up toward the knob
exposing the heating element.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up and glow.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For cigar lighter outlet diagnosis and testing pro-
cedures (Refer to 8 - ELECTRICAL/POWER DISTRI-
BUTION/POWER OUTLET - DIAGNOSIS AND
TESTING)
REMOVAL
For cigar lighter outlet removal procedure (Refer to
8 - ELECTRICAL/POWER DISTRIBUTION/POWER
OUTLET - REMOVAL).
CIRCUIT BREAKER
DESCRIPTION
Automatic resetting circuit breakers are used to
protect the power window voltage supply circuits.
These circuit breakers can protect the systems from a
short circuit, or from an overload condition caused by
an obstructed or stuck power window regulator or
switch.The circuit breaker cannot be repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The circuit breaker contains a bi-metal strip sand-
wiched between two contacts forming the connection
in the circuit. An overload condition causes the
bi-metal strip to heat and bend to the open position,
disconnecting current flow to the circuit. Then as the
system overload or short circuit is removed, the
bi-metal strip cools, re-establishing contact to allow
current flow to the circuit.
DIAGNOSIS AND TESTING - CIRCUIT BREAKER
For complete circuit descriptions and diagrams,
refer toWiring.
(1) Locate the correct circuit breaker in the fuse-
block. Pull out the circuit breaker slightly, but be cer-
tain that the circuit breaker terminals still contact
the terminals in the fuseblock cavities.
(2) Connect the negative lead of a 12-volt DC volt-
meter to a good ground.
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit
from the Power Distribution Center as required.
FUSE BLOCK #1
DESCRIPTION
An electrical fuse block is concealed under the
driver side steering column. The fuse block serves to
distribute electrical current to many of the electrical
systems in the vehicle. The fuse block contains blade-
type mini fuses, relays and micro processors that
enable automatic control of some of the power distri-
bution circuits throughout the vehicle.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the steering column. A finger recess is molded into
the cover for easy removal. A fuse layout map is
molded onto the back side of the cover to ensure
proper fuse identification.
The fuse block cannot be repaired, if the fuse block
is faulty or damaged or if any internal circuit is
faulty or damaged, the entire fuse block must be
replaced.
OPERATION
All of the circuits entering and leaving the fuse
block do so through the instrument panel wire har-
ness. Internal connection of all of the fuse block cir-
cuits is accomplished by an intricate combination of
8W - 97 - 2 8W-97 POWER DISTRIBUTIONVA
CIGAR LIGHTER OUTLET (Continued)