2006 MERCEDES-BENZ SPRINTER relay

ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 INTERNAL ENGINE CONTROL RELAY CONTROL
86 INTERNAL FUSED B(+)
87 INTERNAL ENGINE CONTROL RELAY OUTPUT
87A --
FUSES (FUSE BLOCK NO. 1)FUSE
NO.AMPS FUSED CIRCUIT FUNCTION
1- - -
2 10A 16WT FUSED HIGH BEAM SWITCH OUTPUT
3 10A 16WT FUSED HIGH BEAM SWITCH OUTPUT
4 10A 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 10A 16BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 20A INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 15A 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20A 16RD/YL FUSED B(+)
9 15A INTERNAL FUSED B(+)
10 10A 16GY/DG/RD HEADLAMP SWITCH OUTPUT
11 10A 16GY/BK FUSED LEFT LAMP RELAY OUTPUT
12 10A 18YL HEADLAMP SWITCH OUTPUT
13 10A 18YL HEADLAMP SWITCH OUTPUT
14 15A 16BK/YL/WT FOG LAMP RELAY SIGNAL
15 10A 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
16 15A 12BK/BL ENGINE CONTROL RELAY OUTPUT
17 15A 16BK/RD ENGINE CONTROL RELAY OUTPUT
18 15A 14BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
19 15A 14RD/BK (OBD) FUSED B(+)
20 15A 16RD/BL FUSED B(+)
21 30A 12RD FUSED B(+)
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CONNECTOR PINOUTS

FUSES (FUSE BLOCK NO. 2)FUSE
NO.AMPS FUSED CIRCUIT FUNCTION
1 10A 16RD/GY FUSED B(+)
2 10A 16RD FUSED B(+)
3 15A 16RD FUSED B(+)
4 7.5A 16RD/YL FUSED B(+)
5 25A 14RD/WT FUSED B(+)
6 7.5A 18RD/YL FUSED B(+)
7 25A 16BK/YL OPTIONAL EQUIPMENT RELAY OUTPUT
8 10A 16BK/RD OPTIONAL EQUIPMENT RELAY OUTPUT
9 15A 16RD/YL/WT FUSED D+ RELAY NO. 1 OUTPUT
10 7.5A 16RD/YL/WT FUSED D+ RELAY NO. 1 OUTPUT
11 7.5A 16RD/YL/WT FUSED D+ RELAY NO. 1 OUTPUT
12 25A 14RD FUSED B(+)
13 15A 14RD FUSED B(+)
14 10A 14RD FUSED B(+)
15 25A 16BK/YL/DG OPTIONAL EQUIPMENT RELAY OUTPUT
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267
CONNECTOR PINOUTS

FUSES (FUSE/RELAY BLOCK)FUSE
NO.AMPS FUSED CIRCUIT FUNCTION
1 30A 14BL/YL FUSED B(+)
2- - -
3- - -
4- - -
5 10A 16RD/YL FUSED B(+)
6 7.5A 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
7 25A 14RD FUSED B(+)
8 40A 12RD FUSED B(+)
9 40A 12RD FUSED B(+)
10 30A 12RD/GY FUSED B(+)
STARTER MOTOR RELAY (FUSE/RELAY BLOCK)CAV CIRCUIT FUNCTION
30 12BK/YL STARTER MOTOR RELAY OUTPUT
85 18VT/DG STARTER MOTOR RELAY CONTROL
86 18RD/BL (EXCEPT OBD) STARTER MOTOR RELAY 12 VOLT SUPPLY
86 18BK/RD (OBD) STARTER MOTOR RELAY 12 VOLT SUPPLY
87 12VT IGNITION SWITCH OUTPUT (START)
87A --
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CONNECTOR PINOUTS

KICK DOWN SWITCH - BLACKCAV CIRCUIT FUNCTION
1 18BR/DG KICKDOWN SWITCH SIGNAL
2 18BR (EXCEPT OBD) SENSOR GROUND
2 18BR (OBD) GROUND
MASS AIR FLOW SENSOR - BLACKCAV CIRCUIT FUNCTION
1 16YL/RD (OBD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 20YL/RD (EXCEPT OBD) MASS AIR FLOW SENSOR 12 VOLT SUPPLY
2 20BR/VT (OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
3 20BR/YL (EXCEPT OBD) MASS AIR FLOW SENSOR GROUND
3 20YL/BL (OBD) MASS AIR FLOW SENSOR GROUND
4 20BR/BK (EXCEPT OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
4 20YL/DG (OBD) MASS AIR FLOW SENSOR SIGNAL
5 20YL/DG (EXCEPT OBD) MASS AIR FLOW SENSOR SIGNAL
OXYGEN SENSOR (OBD)CAV CIRCUIT FUNCTION
1 20DG/BK O2 1/1 PUMP CELL SIGNAL
2 20GY/WT O2 1/1 VIRTUAL GROUND
3 20GY/BL O2 1/1 HEATER CONTROL
4 20RD/DG FUSED ENGINE CONTROL RELAY OUTPUT
5 20DG/YL O2 1/1 PUMP CELL CONTROL
6 20GY O2 1/1 SENSOR CELL SIGNAL
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271
CONNECTOR PINOUTS

FUSED IGNITION SWITCH RUN-START RELAY (RELAY BLOCK)CAV CIRCUIT FUNCTION
30 14RD FUSED B(+)
85 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
86 16BR GROUND
87 14BK/YL FUSED IGNITION SWITCH RUN-START RELAY OUTPUT
87A --
SPEED CONTROL SWITCHCAV CIRCUIT FUNCTION
1 18GY OFF SIGNAL
2 18BK VERIFICATION SIGNAL
3 18BL RESUME SIGNAL
4 18YL DECEL/SET SIGNAL
5 18DG ACCEL/SET SIGNAL
6 18RD S/C SWITCH 12 VOLT SUPPLY
WATER IN FUEL SENSOR - BLACKCAV CIRCUIT FUNCTION
1 18BR WATER IN FUEL SENSOR GROUND
2 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
3 18BK/YL WATER IN FUEL SENSOR SIGNAL
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273
CONNECTOR PINOUTS

(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle
and secure axle to device.
(3) Remove wheels and tires.
(4) Unplug wear indicator cable (Fig. 2) and (Fig.
3).
(5) Detach cable connector for brake pad wear
indicator.
(6) Remove ABS sensor and clamp bushing from
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(7) Remove cable ties from the park brake cables.
Release connection cable of brake pad wear indicator
and ABS sensor cable up to the relay unit of the
parking brake.
(8) Remove brake cables.
(9) Remove hand brake cable at relay unit.(10) Remove bracket for brake cables at rear axle
tube.
(11) Remove stabilizer bar from axle brackets.
(12) Remove shock absorber bolts from rear axle.
(13) Remove ALB lever from rear axle bracket.
(14) Pull vent line of rear axle out of frame.
(15) Remove propeller shaft.
(16) Remove brake calipers.
(17) Remove U-brackets and plates (Fig. 2) and
(Fig. 3).
(18) Remove axle from the vehicle.
Fig. 3 DUAL REAR WHEEL AXLE
1 - SPRING 12 - BRAKE HOSE
2 - SPRING SHACKLE 13 - LUG NUT
3 - PLATE 14 - NUT
4 - COLLAR NUT 15 - WASHER
5 - BRAKE CABLE 16 - BOLT
6 - REAR AXLE 17 - SHOCK ABSORBER
7 - ALB LEVER 18 - PROPELLER SHAFT
8 - NUT 19 - BOLT
9 - BOLT 20 - ABS SENSOR
10 - WEAR INDICATOR CABLE 21 - SENSOR BUSHING
11 - WEAR INDICATOR CONNECTOR
VAREAR AXLE 3 - 15

(1) Raise axle into position.
(2) Install plates and U-brackets (Fig. 4) and (Fig.
5) withnewnuts. Tighten nuts to 170 N´m (125 ft.
lbs.).
(3) Install propeller shaft and tighten bolts to 70
N´m (52 ft. lbs.).
NOTE: On installation of the propeller shaft, joint
arrows must be flush and must point towards the
frame floor. Tighten the propeller shaft in this posi-
tion.
(4) Install ALB lever to axle bracket and tighten
newnut 34 N´m (46 ft. lbs.).
(5) Install shock absorbers to rear axle and tighten
bolts to:
²M12 x 1.5 Bolt - 70 N´m (52 ft. lbs.)
²M14 x 1.5 Bolt - 110 N´m (81 ft. lbs.)
(6) Install stabilizer bar to axle and tighten bolts
to:
²SRW Axle - 25 N´m (18 ft. lbs.)²DRW Axle - 70 N´m (52 ft. lbs.)
(7) Install calipers with adapters and lines.
(8) Install brake hoses and hold-down clips.
(9) Install and adjust park brake cables.
(10) Install connection cable of brake pad wear
indicator and ABS sensor cable up to the relay unit
of the parking brake.
(11) Install cable ties to the park brake cables.
(12) Install ABS sensor and clamp bushing to
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(13) Attach connector cable for brake pad wear
indicator.
(14) Plug in cable of brake pad wear indicator.
(15) Install the wheels and tires.
(16) Fill axle with appropriate lubricant.
(17) Remove lifting device from under the axle.
(18) Remove support and lower vehicle.
Fig. 5 DUAL REAR WHEEL AXLE
1 - SPRING 12 - BRAKE HOSE
2 - SPRING SHACKLE 13 - LUG NUT
3 - PLATE 14 - NUT
4 - COLLAR NUT 15 - WASHER
5 - BRAKE CABLE 16 - BOLT
6 - REAR AXLE 17 - SHOCK ABSORBER
7 - ALB LEVER 18 - PROPELLER SHAFT
8 - NUT 19 - BOLT
9 - BOLT 20 - ABS SENSOR
10 - WEAR INDICATOR CABLE 21 - SENSOR BUSHING
11 - WEAR INDICATOR CONNECTOR
VAREAR AXLE 3 - 17

(1) Disconnect the negative battery cable.
(2) Drain the cooling system.
(3) Record the location and snip the wire ties.
(4) Unscrew the engine block heater from the core
plug hole and remove (Fig. 6).
INSTALLATION
(1) Screw the block heater into the core hole (Fig.
6).
(2) Route the heater wiring harness away from
and interference and secure with wiring tie straps.
(3) Refill the cooling system.
(4) Connect the negative battery cable.
(5) Start the engine and inspect for leaks.
ENGINE COOLANT TEMP SEN-
SOR
DESCRIPTION
The ECM determines the operating temperature of
the engine by using the signal from the coolant tem-
perature sensor. The coolant temperature sensor has
a negative temperature coefficient (NTC) resistor
contained in the plastic housing. NTC means; the
higher the temperature, then the lower the resis-
tance. The ECM also uses the coolant temperature
sensor signal to calculate glow plug relay triggering.
If the coolant temperature sensor fails during opera-
tion, the ECM will switch on the cooling fan to pre-
vent engine overheating (A/C models only).
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. Open
cap slowly to release pressure. Store coolant in
suitable and appropriately marked container. Wear
protective gloves, clothes and eye wear.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partailly drain coolant system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Unplug coolant temperature sensor electrical
connector.
NOTE: Capture any residual coolant that may flow.
(5) Remove coolant temperature sensor (Fig. 7).
INSTALLATION
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 coolant
in suitable and appropriately marked container.
Wear protective gloves, clothes and eye wear.
(1) Position and install coolant temperature sensor
(Fig. 7).
(2) Connect coolant temperature sensor electrical
connector (Fig. 7).
Fig. 6 ENGINE BLOCK HEATER
1 - ENGINE BLOCK HEATER
2 - CORE PLUG
3 - ENGINE MOUNT
4 - WIRING TIE STRAPS
Fig. 7 ENGINE COOLANT TEMPERATURE SENSOR
1 - RETAINING CLAMP
2 - ENGINE COOLANT TEMPERATURE SENSOR
VAENGINE 7 - 15