2005 MERCEDES-BENZ SPRINTER injector

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-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

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 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

EVAPORATOR TEMPERATURE SENSOR
CAV CIRCUIT FUNCTION
1 18BR/DG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 18BR/BL SENSOR GROUND
FOG LAMP SWITCH
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD FUSED B(+)
7 18RD/BK FOG LAMP RELAY CONTROL
10 16BR GROUND
FUEL INJECTOR NO. 1 - BLACK
CAV CIRCUIT FUNCTION
1 14BK/BL FUEL INJECTOR NO. 1 CONTROL
2 14BK COMMON INJECTOR DRIVER NO. 1
FUEL INJECTOR NO. 2 - BLACK
CAV CIRCUIT FUNCTION
1 14BK/VT FUEL INJECTOR NO. 2 CONTROL
2 14BL COMMON INJECTOR DRIVER NO. 2
FUEL INJECTOR NO. 3 - BLACK
CAV CIRCUIT FUNCTION
1 14BK/RD FUEL INJECTOR NO. 3 CONTROL
2 14BK COMMON INJECTOR DRIVER NO. 1
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

FUEL INJECTOR NO. 4 - BLACK
CAV CIRCUIT FUNCTION
1 14BK/YL FUEL INJECTOR NO. 4 CONTROL
2 14BK COMMON INJECTOR DRIVER NO. 1
FUEL INJECTOR NO. 5 - BLACK
CAV CIRCUIT FUNCTION
1 14BK/DG FUEL INJECTOR NO. 5 CONTROL
2 14BL COMMON INJECTOR DRIVER NO. 2
FUEL LEVEL SENSOR
CAV CIRCUIT FUNCTION
2 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
3 20BR FUEL LEVEL SENSOR SIGNAL
FUEL PRESSURE SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20BR/GY SENSOR GROUND
2 20DG/VT FUEL PRESSURE SENSOR SIGNAL
3 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
FUEL PRESSURE SOLENOID
CAV CIRCUIT FUNCTION
1 20BK/WT GROUND
2 20RD/WT FUEL PRESSURE SOLENOID CONTROL
8W - 80 - 36 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)

CYLINDER LEAK DOWN VALUES
CYLINDER LEAK DOWN
PERMISSIBLE TOTAL
LOSS  25%
CYLINDER LEAK DOWN
PERMISSIBLE LOSS AT
VALVES AND CYLINDER
HEAD  10%
CYLINDER LEAK DOWN
PERMISSIBLE LOSS AT
PISTON AND RINGS  20%
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS
If an increased pressure loss was found with the
cylinder leak test, inspect the engine by listening at
the cylinder head gasket, air intake area, exhaust, oil
fill opening and where injectors and glow plugs enter
the cylinder head. Also check the engine coolant in
the radiator or expansion reservoir for the formation
of bubbles.
Possible causes for the pressure loss are:
POSSIBLE CAUSE FOR PRESSURE LOSS
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
GLOW PLUG,
INJECTOR,
ADJACENT
CYLINDERS,
OR AIR
BUBBLES IN
COOLANT1. Sealing
SurfacesRepair Sealing
Surfaces
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder
Head Gasket3. Replace
Cylinder Head
Gasket
AIR LOSS
THROUGH AIR
INTAKE AREA1. Sealing
Surfaces1. Remove
Cylinder Head
for Further
Inspection
2. Intake Valves
and Seats2. Replace
Valves, Guides
or Seats
CONDITION POSSIBLE
CAUSESCORRECTION
AIR LOSS
THROUGH
EXHAUSTSealing
SurfacesRemove
Cylinder Head
for Further
Inspection
2. Exhaust
Valves and
Seats2. Replace
Valves, Guides
or Seats
AIR LOSS
THROUGH OIL
FILL OPENING1. Sealing
SurfacesRemove Engine
for Further
Inspection
2. Pistons,
Piston Rings2. Replace
Pistons or
Piston Rings
It is possible to pin point the pressure loss of the
relevant cylinder by spraying with clean engine oil.
Engine oil seals off the gap between the piston and
cylinder wall briefly. If a reduced pressure loss now
occurs for a short time, the cause is very likely to be
the pistons, piston rings or cylinder contact surfaces
of the relevant cylinder.
Determining the cause can be falsified by the posi-
tion of the piston ring joints. If suspicion exists that
the loss of pressure is caused by the piston ring
joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
REMOVAL
REMOVAL - ENGINE COVER
(1) Remove the retaining screws and remove cover
(Fig. 2).
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES, AND EYE WEAR.
CAUTION: STORE OR DISCARD ALL FLUIDS IN
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS.
(1) Disconnect the negative battery cable.
9 - 4 ENGINEVA
ENGINE (Continued)