2005 MERCEDES-BENZ SPRINTER jump cable

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNING: Do not tow the vehicle if the key cannot
be turned in the ignition lock. If the key cannot be
turned, the ignition lock remains locked and the
vehicle cannot be steered. With the engine not run-
ning there is no power assistance for the braking
and steering systems. In this case, it is important to
keep in mind that a considerably higher degree of
effort is necessary to brake and steer the vehicle.
The vehicle must not be towed with the front axle
raised and the key in position 2 in the ignition lock
as the drive wheels could then lock due to the
acceleration skid control (ASR)
0 - 6 LUBRICATION & MAINTENANCEVA

battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD
test, the electronic timer function will be activated
and all of the tests will have to be repeated.
(5) After about three minutes, the high-amperage
IOD reading on the multi-meter should become very
low or nonexistent, depending upon the electrical
equipment in the vehicle. If the amperage reading
remains high, remove and replace each fuse or circuit
breaker in the Fuse Blocks, one at a time until the
amperage reading becomes very low, or nonexistent.
Refer to the appropriate wiring information in this
service manual for complete fuseblock fuse, circuit
breaker, and circuit identification. This will isolate
each circuit and identify the circuit that is the source
of the high-amperage IOD. If the amperage reading
remains high after removing and replacing each fuse
and circuit breaker, disconnect the wire harness from
the generator. If the amperage reading now becomes
very low or nonexistent, refer to Charging System for
the proper charging system diagnosis and testing
procedures. After the high-amperage IOD has been
corrected, switch the multi-meter to progressively
lower amperage scales and, if necessary, repeat the
fuse and circuit breaker remove-and-replace process
to identify and correct all sources of excessive IOD. It
is now safe to select the lowest milliampere scale of
the multi-meter to check the low-amperage IOD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the multi-meter reading. The low-am-
perage IOD should not exceed thirty-five milliam-
peres (0.035 ampere). If the current draw exceeds
thirty-five milliamperes, isolate each circuit using the
fuse and circuit breaker remove-and-replace process
in Step 5. The multi-meter reading will drop to
within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this
circuit as required; whether a wiring short, incorrect
switch adjustment, or a component failure is at fault.
STANDARD PROCEDURE - USING MICRO 420
BATTERY TESTER
Always use the Micro 420 Instruction Manual that
was supplied with the tester as a reference. If the
Instruction Manual is not available the following pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) If testing the battery OUT-OF-VEHICLE, clean
the battery terminals with a wire brush before test-
ing. If the battery is equipped with side post termi-
nals, install and tighten the supplied lead terminal
stud adapters. Do not use steel bolts. Failure to prop-
erly install the stud adapters, or using stud adapters
that are dirty or worn-out may result in false test
readings.
(2) If testing the battery IN-THE-VEHICLE, make
certain all of the vehicle accessory loads are OFF,
including the ignition.The preferred test position
is at the battery terminal. If the battery is not
accessible, you may test using both the positive and
negative jumper posts. Select TESTING AT JUMPER
POST when connecting to that location.
(3) Connect the tester (Fig. 6) to the battery or
jumper posts, the red clamp to positive (+) and the
black clamp to negative (±).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Using the ARROW key selectinoroutof vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
tery rating for your area (see menu). The tester will
then run its self programmed test of the battery and
display the results. Refer to the test result table
noted below.
Fig. 6 Micro 420 Battery Tester
VABATTERY SYSTEM 8F - 11
BATTERY (Continued)

SPECIFICATIONS
TORQUE - STARTER - DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Battery Cable Nut at
Starter Solenoid (larger
nut)14 - 124
Starter Mounting Bolts 40 30 -
Starter Solenoid (smaller
nut)6-52
SPECIFICATIONS - STARTER MOTOR - DIESEL
ITEM SPECIFICATION
ENGINE 2.7L TURBO DIESEL
RATED VOLTAGE 12 VOLTS
NUMBER OF FIELDS 4
NUMBER OF POLES 4
NUMBER OF BRUSHES 4
DRIVE TYPE GEAR REDUCTION
FREE RUNNING TEST VOLTAGE 11.5 VOLTS
FREE RUNNING TEST MAXIMUM
AMPERAGE DRAW160 AMPS
FREE RUNNING TEST MINIMUM SPEED 5500 RPM
SOLENOID CLOSING MAXIMUM VOLTAGE 7.8 VOLTS
MAXIMUM CRANKING AMPERAGE DRAW * 500 AMPS
* A COLD OR NEW ENGINE WILL INCREASE STARTER AMPERAGE DRAW. THE USE OF HEAVY
WEIGHT ENGINE OIL WILL ALSO INCREASE STARTER AMPERAGE DRAW.
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with starter motor
removed from vehicle. Refer to Starter Specifications
for specifications.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on the
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect a suitable volt-ampere tester and a
12-volt battery to starter motor in series, and set
ammeter to 100 ampere scale. See instructions pro-vided by manufacturer of volt-ampere tester being
used.
(4) Install jumper wire from solenoid terminal to
solenoid battery terminal. The starter motor should
operate. If starter motor fails to operate, replace
faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to Specifications for
starter motor free running test voltage specifications.
(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to Specifications for starter motor free running test
maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
VASTARTING SYSTEM 8F - 29
STARTING SYSTEM (Continued)

INDICATOR - OPERATION, COOLANT
LOW...............................8J-14
INDICATOR - OPERATION, FUEL FILTER
CLOGGED...........................8J-15
INDICATOR - OPERATION, GEAR
SELECTOR..........................8J-17
INDICATOR - OPERATION, HIGH BEAM....8J-17
INDICATOR - OPERATION, LOW FUEL.....8J-18
INDICATOR - OPERATION, LOW OIL
LEVEL.............................8J-18
INDICATOR - OPERATION,
MAINTENANCE.......................8J-19
INDICATOR - OPERATION, MULTI-
FUNCTION..........................8J-21
INDICATOR - OPERATION, SEATBELT.....8J-22
INDICATOR - OPERATION, TRACTION
CONTROL...........................8J-24
INDICATOR - OPERATION, TRACTION
CONTROL MALFUNCTION..............8J-25
INDICATOR - OPERATION, TURN SIGNAL . . 8J-25
INDICATOR - OPERATION, WAIT-TO-
START .............................8J-26
INDICATOR - OPERATION, WASHER
FLUID..............................8J-27
INDICATOR - OPERATION, WATER-IN-
FUEL..............................8J-28
INDICATOR LAMP (MIL) - DESCRIPTION,
MALFUNCTION.......................8J-20
INDICATOR LAMP (MIL) - OPERATION,
MALFUNCTION.......................8J-20
INDICATORS - DIAGNOSIS AND
TESTING, TREAD WEAR................22-8
INFLATION PRESSURES - DESCRIPTION,
TIRE................................22-7
INITIAL OPERATION - STANDARD
PROCEDURE, POWER STEERING
PUMP.............................19-12
INJECTOR CLASSIFICATION - STANDARD
PROCEDURE........................14-22
INJECTOR, DESCRIPTION - FUEL........14-20
INJECTORS - STANDARD PROCEDURE,
CLEANING FUEL.....................14-22
INLET AIR TEMPERATURE SENSOR -
DESCRIPTION.......................14-29
INLET AIR TEMPERATURE SENSOR -
INSTALLATION.......................14-30
INLET AIR TEMPERATURE SENSOR -
OPERATION.........................14-29
INLET AIR TEMPERATURE SENSOR -
REMOVAL..........................14-30
INLET HOSE - INSTALLATION...........24-78
INLET HOSE - REMOVAL...............24-78
INNER BELT WEATHERSTRIP -
INSTALLATION, FRONT DOOR...........23-87
INNER BELT WEATHERSTRIP -
REMOVAL, FRONT DOOR..............23-87
INPUT SPEED SENSORS - DESCRIPTION . 21-119
INPUT SPEED SENSORS - OPERATION . . . 21-119
INSIDE HANDLE ACTUATOR -
INSTALLATION..................23-34,23-37
INSIDE HANDLE ACTUATOR -
REMOVAL.....................23-34,23-37
INSTRUMENT CLUSTER - DESCRIPTION . . . 8J-2
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING........................8J-7
INSTRUMENT CLUSTER - INSTALLATION . . . 8J-9
INSTRUMENT CLUSTER - OPERATION.....8J-5
INSTRUMENT CLUSTER - REMOVAL......8J-7
INSTRUMENT PANEL - INSTALLATION....8L-29
INSTRUMENT PANEL - REMOVAL........8L-28
INSTRUMENT PANEL ANTENNA CABLE -
INSTALLATION.......................8A-2
INSTRUMENT PANEL ANTENNA CABLE -
REMOVAL...........................8A-1
INSTRUMENT PANEL ASSEMBLY -
INSTALLATION.......................23-61
INSTRUMENT PANEL ASSEMBLY -
REMOVAL..........................23-57
INSTRUMENT PANEL CENTER BEZEL -
INSTALLATION.......................23-55
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL..........................23-55
INSTRUMENT PANEL DUCTS -
INSTALLATION
.......................24-38
INSTRUMENT PANEL DUCTS - REMOVAL
. 24-37
INTAKE MANIFOLD - INSTALLATION
.......9-58
INTAKE MANIFOLD - REMOVAL
..........9-57
INTERIOR - CAUTION
.................23-67INTERIOR - DESCRIPTION, LAMPS/
LIGHTING..........................8L-25
INTERIOR - OPERATION, LAMPS/
LIGHTING..........................8L-26
INTERIOR LIGHTING - SPECIFICATIONS . . . 8L-26
INTERMEDIATE GEAR - INSTALLATION.....9-66
INTERMEDIATE GEAR - REMOVAL........9-61
INTERMEDIATE SHAFT - INSTALLATION....19-5
INTERMEDIATE SHAFT - REMOVAL.......19-5
INTERNATIONAL SYMBOLS -
DESCRIPTION......................Intro.-2
INTERNATIONAL SYMBOLS -
DESCRIPTION.........................0-9
INTRUSION SENSOR - INSTALLATION.....8Q-2
INTRUSION SENSOR - REMOVAL.........8Q-2
INVERTED FLARING - STANDARD
PROCEDURE, DOUBLE..................5-8
ISO FLARING - STANDARD PROCEDURE....5-8
JAMB SWITCH - INSTALLATION, DOOR . . . 8L-31
JAMB SWITCH - REMOVAL, DOOR.......8L-31
JET - DESCRIPTION, OIL................9-51
JET - INSTALLATION, OIL...............9-51
JET - REMOVAL, OIL...................9-51
JOINT - INSTALLATION, LOWER BALL......2-6
JOINT - REMOVAL, LOWER BALL..........2-6
JOURNALS - STANDARD PROCEDURE,
MEASURE CRANKSHAFT AND BLOCK......9-35
JUMP STARTING - STANDARD
PROCEDURE............................0-6
K1 - ASSEMBLY, DRIVING CLUTCH.......21-75
K1 - DISASSEMBLY, DRIVING CLUTCH....21-74
K2 - ASSEMBLY, DRIVING CLUTCH.......21-78
K2 - DISASSEMBLY, DRIVING CLUTCH....21-76
K3 - ASSEMBLY, DRIVING CLUTCH.......21-80
K3 - DISASSEMBLY, DRIVING CLUTCH....21-80
KEY - DESCRIPTION, TRANSPONDER.....8Q-5
KEY - OPERATION, TRANSPONDER.......8Q-5
KEY REMOTE ENTRY MODULE -
DESCRIPTION, SENTRY................8Q-2
KEY REMOTE ENTRY MODULE -
INSTALLATION, SENTRY................8Q-4
KEY REMOTE ENTRY MODULE -
OPERATION, SENTRY..................8Q-3
KEY REMOTE ENTRY MODULE -
REMOVAL, SENTRY...................8Q-3
KEYLESS ENTRY TRANSMITTER -
DESCRIPTION, REMOTE................8N-2
KEY/LOCK CYLINDER - INSTALLATION.....19-7
KEY/LOCK CYLINDER - REMOVAL........19-6
KNUCKLE - INSTALLATION...............2-5
KNUCKLE - REMOVAL...................2-5
LAMP BULB - INSTALLATION, BACKUP....8L-6
LAMP BULB - INSTALLATION,
BRAKE/PARK.........................8L-7
LAMP BULB - INSTALLATION,
CARGO/DOME.......................8L-27
LAMP BULB - INSTALLATION, CENTER
HIGH MOUNTED STOP.................8L-7
LAMP BULB - INSTALLATION,
CLEARANCE..........................8L-8
LAMP BULB - INSTALLATION,
DOME/READING.....................8L-29
LAMP BULB - INSTALLATION,
ENTRY/EXIT.........................8L-32
LAMP BULB - INSTALLATION, FOG.......8L-10
LAMP BULB - INSTALLATION, FRONT
POSITION..........................8L-14
LAMP BULB - INSTALLATION, FRONT
TURN/PARK/SIDE MARKER.............8L-15
LAMP BULB - INSTALLATION, LICENSE
PLATE .............................8L-18
LAMP BULB - INSTALLATION, REAR
SIDE MARKER.......................8L-21
LAMP BULB - INSTALLATION, REAR
TURN..............................8L-22
LAMP BULB - INSTALLATION, REPEATER . . 8L-22
LAMP BULB - REMOVAL, BACKUP........8L-5
LAMP BULB - REMOVAL, BRAKE/PARK....8L-7
LAMP BULB - REMOVAL, CARGO/DOME . . 8L-27
LAMP BULB - REMOVAL, CENTER HIGH
MOUNTED STOP......................8L-7
LAMP BULB - REMOVAL, CLEARANCE
.....8L-8
LAMP BULB - REMOVAL, DOME/
READING
...........................8L-29
LAMP BULB - REMOVAL, ENTRY/EXIT
....8L-31
LAMP BULB - REMOVAL, FOG
..........8L-10
LAMP BULB - REMOVAL, FRONT
POSITION
..........................8L-14LAMP BULB - REMOVAL, FRONT
TURN/PARK/SIDE MARKER.............8L-14
LAMP BULB - REMOVAL, LICENSE
PLATE .............................8L-17
LAMP BULB - REMOVAL, REAR SIDE
MARKER...........................8L-21
LAMP BULB - REMOVAL, REAR TURN....8L-21
LAMP BULB - REMOVAL, REPEATER.....8L-22
LAMP (MIL) - DESCRIPTION,
MALFUNCTION INDICATOR.............8J-20
LAMP (MIL) - OPERATION,
MALFUNCTION INDICATOR.............8J-20
LAMP RELAY - INSTALLATION, DAYTIME
RUNNING............................8L-9
LAMP RELAY - INSTALLATION, FOG......8L-11
LAMP RELAY - REMOVAL, DAYTIME
RUNNING............................8L-9
LAMP RELAY - REMOVAL, FOG.........8L-10
LAMP SWITCH - INSTALLATION, BRAKE . . . 8L-6
LAMP SWITCH - INSTALLATION, FOG....8L-12
LAMP SWITCH - REMOVAL, BRAKE.......8L-6
LAMP SWITCH - REMOVAL, FOG........8L-11
LAMP UN - INSTALLATION, CENTER
HIGH MOUNTED STOP.................8L-8
LAMP UN - REMOVAL, CENTER HIGH
MOUNTED STOP......................8L-8
LAMP UNIT - ADJUSTMENT, FRONT......8L-12
LAMP UNIT - INSTALLATION, ASH
RECEIVER/CIGAR LIGHTER.............8L-27
LAMP UNIT - INSTALLATION, CARGO/
DOME...............................8L-28
LAMP UNIT - INSTALLATION,
CLEARANCE..........................8L-9
LAMP UNIT - INSTALLATION, DOME/
READING...........................8L-30
LAMP UNIT - INSTALLATION, ENTRY/
EXIT...............................8L-32
LAMP UNIT - INSTALLATION, FRONT.....8L-12
LAMP UNIT - INSTALLATION, LICENSE
PLATE .............................8L-18
LAMP UNIT - INSTALLATION, REPEATER . . 8L-23
LAMP UNIT - INSTALLATION, TAIL.......8L-23
LAMP UNIT - REMOVAL, ASH
RECEIVER/CIGAR LIGHTER.............8L-27
LAMP UNIT - REMOVAL, CARGO/DOME . . . 8L-28
LAMP UNIT - REMOVAL, CLEARANCE.....8L-8
LAMP UNIT - REMOVAL, DOME/
READING...........................8L-30
LAMP UNIT - REMOVAL, ENTRY/EXIT....8L-32
LAMP UNIT - REMOVAL, FRONT.........8L-12
LAMP UNIT - REMOVAL, LICENSE PLATE . . 8L-18
LAMP UNIT - REMOVAL, REPEATER......8L-22
LAMP UNIT - REMOVAL, TAIL...........8L-23
LAMP/INTRUSION SENSOR -
INSTALLATION, DOME.................8L-31
LAMP/INTRUSION SENSOR - REMOVAL,
DOME.............................8L-31
LAMP/INTRUSION SENSOR BULB -
INSTALLATION, DOME.................8L-30
LAMP/INTRUSION SENSOR BULB -
REMOVAL, DOME....................8L-30
LAMPS/LIGHTING - EXTERIOR -
DESCRIPTION........................8L-2
LAMPS/LIGHTING - EXTERIOR -
OPERATION..........................8L-3
LAMPS/LIGHTING - EXTERIOR -
SPECIFICATIONS......................8L-5
LAMPS/LIGHTING - INTERIOR -
DESCRIPTION.......................8L-25
LAMPS/LIGHTING - INTERIOR -
OPERATION.........................8L-26
LATCH - INSTALLATION.....23-18,23-35,23-51
LATCH - INSTALLATION, REAR..........23-40
LATCH - INSTALLATION, SAFETY........23-52
LATCH / LOCK CONTROL -
INSTALLATION.......................23-40
LATCH / LOCK CONTROL - REMOVAL.....23-39
LATCH - REMOVAL.........23-18,23-34,23-51
LATCH - REMOVAL, REAR..............23-40
LATCH - REMOVAL, SAFETY............23-52
LATCH RELEASE CABLE - INSTALLATION . . 23-51
LATCH RELEASE CABLE - REMOVAL.....23-51
LATCH RELEASE HANDLE -
INSTALLATION
.......................23-52
LATCH RELEASE HANDLE - REMOVAL
....23-52
LATCH STRIKER - INSTALLATION
........23-18
LATCH STRIKER - INSTALLATION, REAR
. . 23-41
LATCH STRIKER - REMOVAL
...........23-18
VAINDEX 9
Description Group-Page Description Group-Page Description Group-Page