2006 MERCEDES-BENZ SPRINTER heater

(4) Position the two spacer washers between the
body and the rubber grommets for the two mounting
points on the rail.
(5) Tighten the remaining M6 fasteners to 7 N´m
(62 in. lbs.) and the M8 fasteners to 23 N´m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.
(6) Install the seat hex nut at the heater mounting
flange to the crossmembers. Tighten the nut to 60
N´m (44 ft. lbs.)
(7) Install the flexible section of the cabin heater
exhaust tube to the exhaust tube. Tighten the M6
bolt of the clamp securley. Install the hose to the
exhaust tube.
(8) Tighten the two M8 fasteners at the rail to 23
N´m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.
(9) Install the wiring harness (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION - WIRE
HARNESS).
(10) Tighten the hose and tube assembly to the
toe-board crossmember at two locations.
(11) Install the second hose to the underbody hose
and tube assembly.
(12) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(13) Remove the cabin heater support device from
under the vehicle.
(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).
(16) Verify function of the heater unit.
WIRE HARNESS
(1) Carefully route the cabin heater wire harness
from the left side between the heater unit and the
heater shield.
(2) Install the two wiring harness retainers to the
cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retainers to the underbody.
(4) Connect the two cabin heater wire harness con-
nectors to the cabin heater controller.
(5) Connect the cabin heater wire harness to the
dosing pump.
(6) Connect the cabin heater wire harness connec-
tor to the vehicle wiring harness.
(7) Lower the vehicle.
(8) Verify function of the heater unit.
INLET HOSE
REMOVAL
NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - DRAINING
COOLING STSTEM).
(2) Remove clamps from the cabin heater tubes at
the lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the cabin
heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 4).
(5) Remove the two retaining screws and remove
pipe assembly (Fig. 5).
Fig. 4 Cabin Heater Flexible Air Intake Line
1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
VACABIN HEATER 24 - 111

INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N´m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
clamp securely.
(4) Install the cabin heater tubes to the lower
heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).
(7) Verify function of the heater unit.
Fig. 5 Cabin Heater Air Intake And Heater Pipe
Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24 - 112 CABIN HEATERVA

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS..................1EXHAUST GAS RECIRCULATION.............4
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
CRANKCASE VENTILATION HEATER
REMOVAL.............................1
INSTALLATION..........................1
CRANKCASE VENTILATION BREATHER
DESCRIPTION..........................2REMOVAL.............................2
INSTALLATION..........................3
CRANKCASE VENTILATION
HEATER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the turbocharger heat shield.
(3) Disconnect the CCV heater wiring harness con-
nector.
(4) Using a slight twisting motion, separate the
CCV breather tube from the heater.
(5) Separate the CCV heater from the turbo-
charger air inlet duct.
INSTALLATION
(1) Clean all mating surfaces.
(2) Insert the CCV heater into the turbocharger
inlet hose aligning the arrow on the heater with the
tab on the hose (Fig. 1).
(3) Connect and properly seat the CCV breather
hose on the CCV heater (Fig. 1).
Fig. 1 CCV HEATER
1 - BREATHER HOSE
2 - HARNESS CONNECTOR
3 - TURBOCHANGER INLET HOSE
4 - HEATER ALIGNMENT AREA
5 - CCV HEATER
VAEMISSIONS CONTROL 25 - 1

(4) Connect the wiring harness connector to the
CCV heater (Fig. 1).
(5) Install the turbocharger heat shield.
(6) Connect the negative battery cable.
CRANKCASE VENTILATION
BREATHER
DESCRIPTION
The crankcase ventilation breather is a three
staged, filtered, oil separating breather with a oil
return passage into the cylinder head cover (Fig. 2).
The oil separator removes oil from the blow by gasses
to reduce MAF sensor contamination. For service
procedures refer to (Refer to 25 - EMISSIONS CON-
TROL/EVAPORATIVE EMISSIONS/CCV
RESTRICTER - REMOVAL).
REMOVAL
(1) Remove the engine cover.
(2) Disconnect the breather outlet hose at the
breather (Fig. 3).
(3) Remove the breather fasteners (Fig. 3).
(4) Wiggle the breather free from the cylinder head
cover (Fig. 3).
Fig. 2 CCV BREATHER
25 - 2 EVAPORATIVE EMISSIONSVA

INDEX
ABS INDICATOR.......................8J-9ACCELERATOR PEDAL POSITION SENSOR. . . 14-32
ACCESSORY SWITCH BEZEL............23-56
ADR INDICATOR.....................8J-10
AIR CLEANER ELEMENT................9-21
AIR CLEANER HOUSING................9-21
AIR FILTER ....................24-45, 24-58
AIR OUTLET TEMPERATURE SENSOR....24-16
AIR OUTLETS.......................24-45
AIRBAG CONTROL MODULE.............8O-8
AIRBAG INDICATOR...................8J-11
ALB CONTROLLER....................5-16
ALB LEVER..........................5-16
AMBIENT TEMPERATURE INDICATOR.....8J-11
AMBIENT TEMPERATURE SENSOR.......24-17
ANTENNA BODY & CABLE..............8A-1
ARMREST..........................23-79
ASH RECEIVER......................23-57
ASH RECEIVER / CIGAR LIGHTER LAMP
UNIT..............................8L-30
ASSIST HANDLE.....................23-71
AUDIO..............................8A-1
AUTOMATIC TRANSMISSION NAG1 -
SERVICE INFORMATION................21-3
A - PILLAR TRIM.....................23-70
A / C CLUTCH RELAY.................24-24
A / C COMPRESSOR CLUTCH COIL.......24-12
A / C COMPRESSOR CLUTCH............24-8
A / C COMPRESSOR..................24-66
A / C CONDENSER COVER.............24-52
A / C CONDENSER FAN RELAY..........24-26
A / C CONDENSER HOUSING...........24-52
A / C CONDENSER....................24-69
A / C CONTROL MODULE..............24-28
A / C DISCHARGE LINE................24-71
A / C EVAPORATOR COVER.............24-55
A / C EVAPORATOR HOUSING...........24-55
A / C EVAPORATOR...................24-72
A / C EXPANSION VALVE...............24-73
A / C HEATER CONTROL...............24-12
A / C HIGH PRESSURE SWITCH.........24-30
A / C LOW PRESSURE SWITCH.........24-32
A / C PRESSURE TRANSDUCER.........24-14
BACKLITE - BULKHEAD TRIM PANEL.....23-84
BACKUP LAMP BULB..................8L-5
BASECOAT / CLEARCOAT FINISH........23-77
BATTERY CABLES....................8F-14
BATTERY HOLDDOWN.................8F-13
BATTERY SYSTEM.....................8F-1
BATTERY TRAY......................8F-16
BATTERY............................8F-6
BEARINGS - DIFFERENTIAL CASE.........3-38
BEARING / SEAL - AXLE HUB............3-28
BEARING / SEAL - AXLE................3-24
BELT TENSIONERS.....................7-5
BLOWER MOTOR RELAY...............24-33
BLOWER MOTOR RESISTOR............24-17
BLOWER MOTOR SWITCH........24-19, 24-35
BLOWER MOTOR...............24-47, 24-58
BODY...............................23-1
BOOST PRESSURE SENSOR............14-33
BRAKE INDICATOR...................8J-12
BRAKE LAMP SWITCH.................8L-6
BRAKE LINES.........................5-8
BRAKE PADS / SHOES...................5-8
BRAKE WEAR INDICATOR..............8J-13
BRAKES - ABS........................5-30
BRAKES - BASE........................5-2
BRAKE / PARK LAMP BULB.............8L-7
BULKHEAD TRIM PANEL...............23-72
BUMPERS...........................13-1
BUSHINGS............................2-3
B - PILLAR TRIM.....................23-71
CABIN HEATER.....................24-104
CABLE TENSIONER....................5-24
CABLE..............................8P-2
CABLES.............................5-24
CAMSHAFT POSITION SENSOR..........14-33
CAMSHAFT(S)........................9-28
CARGO LAMP SWITCH................8L-31
CARGO / DOME LAMP BULB............8L-30
CARGO / DOME LAMP UNIT............8L-31
CARPETS AND FLOOR MATS...........23-72
CATALYTIC CONVERTER
................11-3
CENTER BEARING
......................3-9
CENTER HIGH MOUNTED STOP LAMP BULB. . . 8L-8CENTER HIGH MOUNTED STOP LAMP UN.....8L-8
CENTER ROLLER ARM
................23-36CENTER TRACK......................23-37
CENTRAL TIMER MODULE..............8E-1
CHARGE AIR COOLER AND PLUMBING....11-4
CHARGING INDICATOR................8J-14
CHARGING SYSTEM..................8F-17
CHECK VALVE.......................8R-11
CHECK.......................23-13, 23-23
CHIME / BUZZER......................8B-1
CIGAR LIGHTER OUTLET............8W-97-1
CIRCUIT BREAKER.................8W-97-2
CLEARANCE LAMP BULB...............8L-9
CLEARANCE LAMP UNIT................8L-9
CLOCK.............................8J-14
CLOCKSPRING......................8O-12
CLUSTER BEZEL.....................23-55
COLUMN............................19-4
CONNECTOR.......................Intro.-9
CONNECTOR/GROUND/SPLICE
LOCATION........................8W-91-1
CONTROLLER ANTILOCK BRAKE.........8E-3
COOLANT LEVEL SENSOR...............7-13
COOLANT LOW INDICATOR.............8J-15
COOLANT............................7-9
COOLING.............................7-1
COWL TRIM........................23-73
CRANKCASE VENTILATION BREATHER......25-2
CRANKCASE VENTILATION HEATER.......25-1
CRANKSHAFT OIL SEAL - FRONT.........9-42
CRANKSHAFT OIL SEAL - REAR..........9-41
CRANKSHAFT POSITION SENSOR........14-35
CRANKSHAFT........................9-39
CUP HOLDER........................23-57
CYLINDER HEAD COVER(S).............9-33
CYLINDER HEAD......................9-22
DAYTIME RUNNING LAMP RELAY.......8L-10
DEFROSTER DUCTS..................24-47
DIFFERENTIAL........................3-31
DIODE............................Intro.-9
DISC BRAKE CALIPER ADAPTER.........5-14
DISC BRAKE CALIPERS.................5-11
DOME LAMP / INTRUSION SENSOR
BULB..............................8L-33
DOME LAMP / INTRUSION SENSOR......8L-33
DOME / READING LAMP BULB..........8L-32
DOME / READING LAMP UNIT..........8L-32
DOOR GLASS............23-15, 23-30, 23-46
DOOR JAMB SWITCH.................8L-34
DOOR LOCK MOTOR...................8N-1
DOOR OPENING SEALS................23-90
DOOR........................23-14, 23-23
DRIVE BELTS..........................7-5
DRIVER AIRBAG.....................8O-16
DRIVER HEATED SEAT SWITCH.........8G-11
D - PILLAR TRIM.....................23-73
ELECTRIC COOLANT PUMP.............24-75
ELECTRICAL.........................5-30
ELECTROHYDRAULIC UNIT............21-105
ENGINE BLOCK HEATER................7-14
ENGINE BLOCK.......................9-37
ENGINE CONTROL MODULE.............8E-3
ENGINE COOLANT TEMP SENSOR........7-15
ENGINE COOLANT THERMOSTAT.........7-16
ENGINE CRADLE CROSSMEMBER........13-8
ENGINE TEMPERATURE GAUGE.........8J-15
ENGINE..............................9-2
ENTRY / EXIT LAMP BULB.............8L-34
ENTRY / EXIT LAMP UNIT..............8L-35
ESP INDICATOR......................8J-16
EVAPORATOR TEMPERATURE
SENSOR......................24-19, 24-37
EXHAUST GAS RECIRCULATION..........25-4
EXHAUST MANIFOLD..................9-68
EXHAUST PIPE.......................11-3
EXHAUST SYSTEM....................11-1
EXHAUST TUBE.....................24-105
EXTERIOR HANDLE.......23-16, 23-31, 23-35
FAN DRIVE VISCOUS CLUTCH...........7-17
FASTENER IDENTIFICATION...........Intro.-3
FASTENER USAGE...................Intro.-6
FINESSE SANDING / BUFFING & POLISH . . 23-78
FLOOR DISTRIBUTION DUCTS..........24-47
FLUID AND FILTER..................21-131
FLUID CAPACITIES.....................0-5
FLUID COOLER TUBE
.................19-13
FLUID FILL / CHECK LOCATIONS
..........0-5
FLUID RESERVOIR
....................5-15
FLUID TYPES
..........................0-1
FLYWHEEL
...........................9-43FOG LAMP BULB.....................8L-10
FOG LAMP RELAY....................8L-11
FOG LAMP SWITCH...................8L-12
FRAME..............................13-3
FREEWHEELING CLUTCH.............21-135
FRONT BUMPER - STEPS...............13-2
FRONT DOOR INNER BELT
WEATHERSTRIP.....................23-90
FRONT DOOR OUTER BELT
WEATHERSTRIP.....................23-90
FRONT FASCIA.......................13-2
FRONT LAMP UNIT...................8L-13
FRONT POSITION LAMP BULB..........8L-14
FRONT SEAT BELT & RETRACTOR.......8O-20
FRONT SEAT BELT BUCKLE............8O-23
FRONT TURN / PARK / SIDE MARKER
LAMP BULB.........................8L-15
FRONT WHEEL SPEED SENSOR..........5-31
FRONT...............................2-1
FUEL DELIVERY.......................14-6
FUEL DOSING PUMP.................24-106
FUEL DRAIN TUBES..................14-10
FUEL FILL DOOR.....................23-48
FUEL FILTER CLOGGED INDICATOR......8J-17
FUEL FILTER........................14-10
FUEL GAUGE........................8J-17
FUEL INJECTOR.......................14-35
FUEL LEVEL SENDING UNIT / SENSOR....14-28
FUEL LINE.........................24-107
FUEL LINES.........................14-11
FUEL PRESSURE SENSOR.............14-39
FUEL PRESSURE SOLENOID............14-40
FUEL PUMP MODULE.................14-18
FUEL PUMP.........................14-13
FUEL QUANTITY CONTROL VALVE.......14-21
FUEL RAIL PRESSURE SENSOR.........14-12
FUEL RAIL..........................14-22
FUEL SYSTEM........................14-1
FUEL TANK.........................14-23
FUEL TEMPERATURE SENSOR..........14-42
FUSE BLOCK #1...................8W-97-2
FUSE BLOCK #2...................8W-97-3
GAP AND FLUSH.....................23-91
GEAR SELECTOR INDICATOR...........8J-18
GEAR...............................19-7
GEARSHIFT CABLE..................21-138
GEAR - PINION / RING.................3-41
GENERATOR DECOUPLER PULLEY.......8F-19
GENERATOR........................8F-18
GLOVE BOX.........................23-58
GLOW PLUG RELAY....................8I-1
GLOW PLUG..........................8I-1
GRILLE............................23-48
HCU (HYDRAULIC CONTROL UNIT).......5-36
HEADLAMP LEVELING MOTOR..........8L-16
HEADLAMP LEVELING SWITCH.........8L-17
HEADLINER.........................23-73
HEADREST..........................23-79
HEATED GLASS.......................8G-1
HEATED MIRRORS....................8G-9
HEATED SEAT ELEMENT...............8G-12
HEATED SEAT RELAY.................8G-12
HEATED SEAT SENSOR................8G-13
HEATED SEATS ......................8G-10
HEATER CORE.......................24-76
HEATER UNIT......................24-110
HEATING & AIR CONDITIONING..........24-1
HIGH BEAM HEADLAMP BULB..........8L-18
HIGH BEAM INDICATOR...............8J-19
HINGE..................23-17, 23-32, 23-51
HOISTING............................0-5
HOLDING CLUTCH B1................21-143
HOLDING CLUTCH B2................21-148
HOLDING CLUTCHES.................21-141
HOOD.............................23-51
HORN SWITCH.......................8H-1
HORN..............................8H-1
HOSES.............................19-14
HUB / BEARING........................2-4
HVAC HOUSING......................24-48
HYDRAULIC / MECHANICAL..............5-5
IGNITION CONTROL....................8I-1
INLET HOSE........................24-111
INPUT CLUTCH K1
...................21-92
INPUT CLUTCH K2
...................21-97
INPUT CLUTCH K3
..................21-102
INPUT CLUTCHES
....................21-90
INPUT SPEED SENSORS
..............21-153
VAINDEX 1
Description Group-Page Description Group-Page Description Group-Page