2006 MERCEDES-BENZ SPRINTER Service Manual

engine sport mode horn dashboard ESP clock reset

Page 897 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (4) Connect voltmeter to measure between nega-
tive battery terminal post and a good clean ground
on engine block (Fig. 5). Rotate and hold ignition
switch in Start position. Observe voltmeter. If rea

Page 898 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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
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 AMPER-
AGE 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 shouldoperate. 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.
STARTER SOLENOID
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with a continuity
VASTARTING SYSTEM 8F - 33

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MERCEDES-BENZ SPRINTER 2006 Service Manual tester (Fig. 7). There should be continuity. If OK, go
to Step 4. If not OK, replace faulty starter motor
assembly.
(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 8). There

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MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
(1) Raise and support vehicle.
(2) Position starter motor to transmission housing.
(3) Install 2 mounting bolts. Refer to Torque Spec-
ifications.
(4) Lower vehicle.
(5) Connect battery c

INSTALLATION
(1) Raise and support vehicle.
(2) Position starter motor to transmission housing.
(3) Install 2 mounting bolts. Refer to Torque Spec-
ifications.
(4) Lower vehicle.
(5) Connect battery cable and solenoid wiring to
solenoid (2 nuts). Refer to Torque Specifications.
(6) Position wiring harness trough and install
retaining bolt.
(7) Install new nylon tie-wraps to wiring trough.
(8) Connect negative battery cable.
STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start position. The starter relay is located in the
Fuse/Relay Block. The Fuse/Relay Block is located
under, and to the left side of the drivers seat. See
Fuse/Relay Block cover for relay identification and
location.
The starter relay is an International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
REMOVAL
The starter relay is located in the Fuse/Relay
Block. The Fuse/Relay Block is located under, and to
the left side of the drivers seat. See Fuse/Relay Block
cover for relay identification and location, or refer to
(Fig. 12).
(1) Remove Fuse/Relay Block cover by pushing
down on two tabs located at top of cover (Fig. 13).
(2) Remove relay from Fuse/Relay Block.
(3) Check condition of relay terminals and Fuse/
Relay Block connector terminals for damage or corro-
sion. Repair if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the Fuse/Relay Block
connector). Repair if necessary before installing
relay.
Fig. 11 WIRING TROUGH - FOR STARTER REMOVAL
(VIEW FROM REAR)
1 - WIRING TROUGH
2 - REAR/LEFT END OF TRANS. BELLHOUSING (VIEW FROM
REAR)
Fig. 12 FUSE / RELAY BLOCK
1 - STARTER RELAY LOCATION
2 - FUSE / RELAY BLOCK
VASTARTING SYSTEM 8F - 35

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MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
The starter relay is located in the Fuse/Relay
Block. The Fuse/Relay Block is located under, and to
the left side of the drivers seat. See Fuse/Relay Block
cover for relay identification

Page 902 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS........................... 1
HEATED MIRRORS......................... 9HEATED SEATS........................... 10
HEATED GLASS
TABLE OF CONTENTS

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS........................... 1
HEATED MIRRORS......................... 9HEATED SEATS........................... 10
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM.....2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH......5
REMOVAL.............................6
INSTALLATION..........................6
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR........7
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear window defogger system, also known as
the electric backlight (EBL), consists of a backglass
with two vertical bus bars linked by a series of grid
lines fired onto the inside surface of the rear window.
The EBL system is turned On or Off by a control
switch (Fig. 1) located in the instrument panel near
the right side of the steering wheel, which sends a
request signal to the rear window defogger module
that operates the left and right rear window defogger
relays located in the fuse/relay block under the driv-
ers seat.
Circuit protection is provided by a 30 amp fuse
also located in the fuse/relay block.
OPERATION
When the rear window defogger switch is pressed
to the On position, current is directed through the
switch to the rear window defogger module. The rear
window defogger module then grounds the control
side of the left and right rear window defogger (EBL)
Fig. 1 Rear Window Defogger Switch
1 - REAR WINDOW DEFOGGER SWITCH
2 - INSTRUMENT PANEL
VAHEATED SYSTEMS 8G - 1

Page 903 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual relays which allows battery current to flow to the
rear window defogger grid lines. The heated grid
lines heat the rear glass to help clear the rear win-
dow surfaces of fog or frost.
The electric bac

relays which allows battery current to flow to the
rear window defogger grid lines. The heated grid
lines heat the rear glass to help clear the rear win-
dow surfaces of fog or frost.
The electric backlight (EBL) system is controlled
by the EBL timing circuity, which is integral to the
rear window defogger module. A yellow indicator in
the switch will illuminate to indicate when the EBL
system is turned on.
NOTE: The EBL system turns off automatically after
approximately 10 minutes of initial operation. Each
following activation cycle of the EBL system will
last approximately five minutes.
The EBL system will be automatically turned off
after a programmed time interval of about ten min-
utes. After the initial time interval has expired, if the
rear window defogger switch is pressed to the On
position again during the same ignition cycle, the
EBL system will automatically turn off after about
five minutes.
The EBL system will automatically shut off if the
ignition switch is turned to the Off position, or it can
be turned off manually by pressing the defogger
switch a second time.
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
EBL system, refer to 8W - WIRING DIAGRAM
INFORMATION.
Operation of the electrical backlight (EBL) system
can be confirmed by the following:
(1) Turn the ignition switch to the On position. Set
the rear window defogger switch in the On position.
The rear window defogger operation can be checked
by feeling the rear window glass. A distinct difference
in temperature between the grid lines and the adja-
cent clear glass should be detected within three to
four minutes of operation.
(2) If a temperature difference is not detected, use
a 12-volt DC voltmeter and contact the rear glass
heating grid terminal B with the negative lead, and
terminal A with the positive lead (Fig. 2). The volt-
meter should read battery voltage. If the voltmeter
does not read battery voltage, check the following:²Confirm that the ignition switch is in the On
position.
²Make sure that the rear glass heating grid feed
wires and ground wires are connected to the window
terminals. Confirm that the ground wires have conti-
nuity to ground.
²Check that fuse 7 (15 amp) in fuse block #1 and
fuse 10 (30 amp) in the fuse/relay block are OK. The
fuses must be tight in there receptacles and all elec-
trical connections must be secure.
(3) When the above steps have been completed and
the rear glass heating grid is still inoperative, one or
more of the following is faulty.
²Rear window defogger switch in the instrument
panel.
²Rear window defogger (EBL) relays in the fuse/
relay block.
²Rear window defogger (EBL) relay control circu-
ity in the rear window defogger module.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or the power feed or ground wire
not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
the defogger switch indicator does not illuminate,
check for voltage at the defogger indicator from the
rear window defogger module when the defogger
switch is activated. If power is present, replace the
rear window defogger switch.
(5) If broken defogger grid lines are suspected, use
a 12-volt DC voltmeter and contact terminal B with
the negative lead and each rear glass heating grid
line at it's mid-point with the positive lead. The volt-
meter should read approximately 6 volts at each grid
line mid-point C. If the voltmeter does not read
approximately 6 volts, repair the open grid line(s)
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER GRID - STANDARD PROCE-
DURE).
8G - 2 HEATED GLASSVA

Page 904 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The left and right rear window defogger (EBL)
relays are International Standards Organization
(ISO)-type relays (Fig. 3). Relays conforming to the
ISO specificat

REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The left and right rear window defogger (EBL)
relays are International Standards Organization
(ISO)-type relays (Fig. 3). Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal functions and patterns.
The EBL relays are electromechanical devices that
switch battery current through fuse 10 (30 amp)
located in the fuse/relay block under the driver seat
to the rear window defogger grids and when
equipped, switches battery current to the outside
mirror heating grids. The EBL relays are energized
when the relay coils are provided battery current by
the rear window defogger module.
The EBL relays are located in the fuse/relay block
under the driver seat. Refer to the fuse and relay
map located on the inner surface of the fuse/relay
block cover for the left and right rear window defog-
ger (EBL) relay locations.The black, molded plastic case is the most visible
component of the two rear window defogger (EBL)
relays. Five male spade-type terminals extend from
the bottom of the base to connect each relay to the
vehicle electrical system, and the ISO designation for
each terminal is molded into the base adjacent to
each terminal.
OPERATION
The left and right rear window defogger (EBL)
relays are electromechanical switches that uses a low
current input from the rear window defogger module
to control the high current output to the rear window
defogger grids. The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. The resistor or diode is con-
nected in parallel with the relay coil in the relay, and
helps to dissipate voltage spikes and electromagnetic
interference that can be generated as the electromag-
netic field of the relay coil collapses.
The EBL relay terminals are connected to the vehi-
cle electrical system through receptacles in the fuse/
relay block. The inputs and outputs of the EBL
relays include:
²The common feed terminal (30) receives a bat-
tery current input from fuse 10 (30 amp) in the fuse/
relay block through a fused B(+) circuit at all times.
Fig. 2 Grid Line Test
1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C)
5 - HEATED WINDOW GRID
6 - GROUND WIRE
7 - GROUND (B)
Fig. 3 Rear Window Defogger (EBL) Relays
1 - REAR WINDOW DEFOGGER (EBL) RELAY (2)
2 - TERMINAL PATTERN
VAHEATED GLASS 8G - 3

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