2005 MERCEDES-BENZ SPRINTER CD changer

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

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-42 AIR CONDITIONER/HEATER
Component Page
A/C Auxiliary Fan................... 8W-42-2
A/C Auxiliary Fan Relay............... 8W-42-2
A/C Compressor Clutch............... 8W-42-2
A/C Control Module- Roof.......... 8W-42-14, 15
A/C Fan Switch.................. 8W-42-10, 16
A/C Switch- Roof................. 8W-42-10, 14
Air Outlet Temperature Sensor......... 8W-42-4
Ambient Temperature Sensor........... 8W-42-3
Automatic Temperature Control
Module . . . 8W-42-2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,
19, 21
Auxiliary Heater Relay............ 8W-42-17, 18
Auxiliary Heater Switch........... 8W-42-12, 24
Blower Motor Resistor Block....... 8W-42-5, 6, 7
Blower Motor- Front................ 8W-42-5, 7
Cabin Heater Assembly....... 8W-42-8, 9, 10, 11,
12, 13, 17, 20, 22, 24
Cabin Heater Control Module.......... 8W-42-13
Circulation Pump.................... 8W-42-9
Circulation Pump Diode............ 8W-42-9, 11
Circulation Pump Relay............... 8W-42-9
Controller Antilock Brake............. 8W-42-19
D+ Relay No. 1...................... 8W-42-3
Data Link Connector........... 8W-42-5, 12, 22
Daytime Running Lamps
Relay............ 8W-42-14, 15, 16, 19, 21, 24
Dosing Pump...................... 8W-42-11
Evaporator Temperature Sensor......... 8W-42-4
Fan Stage 1 Relay................... 8W-42-8
Fuse 1.......................... 8W-42-2, 20
Fuse 3............................ 8W-42-17
Fuse 4............................ 8W-42-11
Fuse 7............................ 8W-42-9Component Page
Fuse 8....................... 8W-42-8, 14, 24
Fuse 9............................ 8W-42-3
Fuse 11........................... 8W-42-22
Fuse 20....................... 8W-42-2, 9, 16
Fuse 21.......................... 8W-42-6, 7
Fuse Block No. 1............ 8W-42-2, 6, 7, 9, 24
Fuse Block No. 2.................... 8W-42-3
Fuse Block No. 3...... 8W-42-8, 11, 16, 17, 20, 22
Fuse/Relay Block................. 8W-42-2, 14
G100............................. 8W-42-11
G102.............................. 8W-42-2
G200.......................... 8W-42-3, 5, 9
G202................. 8W-42-2, 8, 9, 17, 18, 22
G203............. 8W-42-6, 7, 14, 16, 19, 21, 24
G301............................. 8W-42-14
Heat Exchanger Connector...... 8W-42-17, 18, 19
Heat Exchanger Switch........... 8W-42-18, 19
Heater Timer- Auxiliary . 8W-42-6, 7, 12, 19, 20, 21
Instrument Cluster................... 8W-42-3
Metering Pump..................... 8W-42-22
Recirculated Air Solenoid Valve......... 8W-42-5
Refrigerant Pressure Sensor............ 8W-42-4
Roof Fan Motor..................... 8W-42-16
Security System Module.............. 8W-42-22
TCS Switch........................ 8W-42-19
Temperature Switch.............. 8W-42-10, 15
Warm Air Auxiliary Control Module . . 8W-42-20, 22
Warm Air Auxiliary Heater
Assembly.................. 8W-42-20, 22, 23
Warm Air Heater Control Module....... 8W-42-23
Water Cycle Valve................... 8W-42-3
VA8W-42 AIR CONDITIONER/HEATER 8W - 42 - 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

HEADLAMP ASSEMBLY-RIGHT - BLACK
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16YL/WT FOG LAMP RELAY OUTPUT
3 16BR GROUND
4 16BR GROUND
5 16VT/WT HEADLAMP ADJUST SWICHT OUTPUT
6 16BK/WT RIGHT TURN SIGNAL
7 18YL/DG (DRL) DAYTIME RUNNING LAMP RELAY-RIGHT SIDE OUT-
PUT
7 18YL (EXCEPT DRL) HEADLAMP SWITCH OUTPUT
8 16BR GROUND
9 16WT FUSED HIGH BEAM SWITCH OUTPUT
10 16GY/RD RIGHT LAMP RELAY OUTPUT
HEAT EXCHANGER CONNECTOR
CAV CIRCUIT FUNCTION
A 12BR GROUND
B 12RD/BL AUXILIARY HEATER RELAY OUTPUT
C 16VT/BL HEAT EXCHANGER CONNECTOR CAV C TO HEAT
EXCHANGER SWITCH CAV 7
D 16VT/YL HEAT EXCHANGER CONNECOTR CAV D TO HEAT
EXCHANGER SWITCH CAV 4
HEAT EXCHANGER SWITCH
CAV CIRCUIT FUNCTION
1 16GY/DG/RD DAYTIME RUNNING LAMPS RELAY OUTPUT
3 16BK/BL/DG S201 COMMON CIRCUIT
4 16VT/YL HEAT EXCHANGER SWITCH CAV 4 TO HEAT
EXCHANGER CONNECTOR CAV D
5 16BR GROUND
7 16VT/BL HEAT EXCHANGER SWITCH CAV 7 TO HEAT
EXCHANGER CONNECOTR CAV C
8 16BK/BL/DG S201 COMMON CIRCUIT
10 16BR GROUND
HEATED SEAT MODULE-DRIVER
CAV CIRCUIT FUNCTION
1 16VT/DG HEATED SEAT SWITCH-DRIVER LOW OUTPUT
2 16VT/RD S366 COMMON CIRCUIT
4 16BR GROUND
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTSVA

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Fog Lamp Switch Instrument Panel N/S
Fuel Injector No. 1 Engine Compartment 7
Fuel Injector No. 2 Engine Compartment 6,7
Fuel Injector No. 3 Engine Compartment 6,7
Fuel Injector No. 4 Engine Compartment 6,7
Fuel Injector No. 5 Engine Compartment 7
Fuel Level Sensor Underbody-Middle 24
Fuel Pressure Sensor Engine Compartment 6
Fuel Pressure Solenoid Engine Compartment-Rear 5
Fuel Temperature Sensor Engine Compartment 7
Fuse Block No.1 C1 Under Fuse Block No.1 N/S
Fuse Block No.1 C2 Under Fuse Block No.1 N/S
Fuse Block No.1 C3 Under Fuse Block No.1 N/S
Fuse Block No.1 C4 Under Fuse Block No.1 N/S
Fuse Block No.1 C5 Under Fuse Block No.1 N/S
Fuse Block No.1 Control
ModuleUnder Driver Seat N/S
Fuses (Fuse Block No. 1) Steering Column 13
Fuses (Fuse Block No. 2) Under Driver Seat 17
Fuses (Fuse Block No. 3) Under Driver Seat N/S
Fuses (Fuse/Relay Block) Under Driver Seat 17,18
Fuses (PDC) Battery Area 3
Generator No.1 Engine Compartment N/S
Generator No.2 Engine Compartment-Right 2,8
Glow Plug Control Module C1 Engine Compartment-Left Front 1
Glow Plug Control Module C2 Engine Compartment-Left Front 1
Glow Plug No. 1 On Engine N/S
Glow Plug No. 2 On Engine N/S
Glow Plug No. 3 On Engine N/S
Glow Plug No. 4 On Engine N/S
Glow Plug No. 5 On Engine N/S
Headlamp Adjust Switch Instrument Panel N/S
Headlamp Assembly-Left On Front Of Vehicle (Left Side) N/S
Headlamp Assembly-Right On Front Of Vehicle (Right Side) N/S
Heat Exchanger Connector Instrument Panel N/S
Heat Exchanger Switch Engine Compartment N/S
Heated Seat Module-Driver Under Driver Seat N/S
Heated Seat Module-
PassengerUnder Passenger Seat N/S
Heated Seat Switch-Driver On Driver Seat N/S
Heated Seat Switch-
PassengerOn Passenger Seat N/S
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut-Connection of Circuit
506-53
Alternator
Bolt-Generator to Timing
Case Cover20 15 -
Bolt-Generator to Cooler
Housing6-53
Bolt-Cooler Housing of
Generator to Crankcase20 - 177
Nut-B+ Circuit to
Generator13-18 - 115-159
Nut-D+ Circuit to
Generator5-44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to
Crankcase18
- 133
Bolt-Oil Pipe to Crankshaft
Bearing Cap8-70
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat
Exchanger to Timing
Cover Case15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube
to Cylinder Head14 - 123
Bolt-Oil Level Sensor to
Oil Pan14 - 123
Coolant Pre-Heater
Coolant Pre-Heater in
Engine Block35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant
Pump8-35 6 - 26 -
Bolt-Coolant Pump to
Timing Case Cover 6m/8m14/20 10 - 15 -
Bolt-Thremostat Housing
to Cylinder Head9-80
Coolant Drain Plug to
Crankcase30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage,
torque, torque angle)20/90É 15 -
VAENGINE 9 - 11
ENGINE (Continued)

(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).
(8) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(9) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(12) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(13) Remove accessory drive belt pulley and vibra-
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).
(14) Remove the power steering pump.
NOTE: NO NOT open the air conditioning system.
(15) Unplug AC compressor electrical connector
and unbolt AC compressor. Relocate in lower engine
compartmentwith outopening the system.
(16) Remove the generator with wiring attached
and relocate somewhere in the engine compartment.
(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 65).
(20) Remove the cylinder head to timing cover
bolts (Fig. 65).
(21) Remove the timing cover bolts and cover (Fig.
65).
(22) Remove remaining ancillary components
attached to the timing case cover (Fig. 65).
NOTE: Inspect condition of hoses and clamps,
replace as necessary.
(23) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 65).
INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace the front crankshaft seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 66).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N´m (177 lbs in) (Fig. 65).
(6) Install the M8 bolts of cylinder head on timing
case cover. Tighten bolts to 20 N´m (177 lbs in) (Fig.
65).
(7) Install timing chain tensioner with new seal-
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
Fig. 65 TIMING CHAIN COVER
1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER
9 - 60 ENGINEVA
TIMING CHAIN COVER (Continued)