2006 MERCEDES-BENZ SPRINTER check engine

(4) Remove the fog lamp switch from the face of
the cluster bezel.
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
(1) Position the fog lamp switch to the proper
mounting hole on the face of the cluster bezel (Fig.
16).
(2) Using hand pressure, push the fog lamp switch
firmly and evenly into the switch mounting hole of
the cluster bezel until both of the latches on the
switch body are fully engaged.
(3) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
FRONT LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front grille from the vehicle. (Refer
to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).(3) Remove the two screws that secure the cover at
the inboard side of the front lamp unit (Fig. 18).
(4) Remove the cover from the front lamp unit.
(5) From the engine compartment, disconnect the
vehicle wire harness connector from the connector
receptacle for the front lamp unit.
(6) Remove the four screws that secure the front
lamp unit to the front of the vehicle.
(7) Remove the front lamp unit from the front of
the vehicle.
INSTALLATION
(1) Position the front lamp unit to the front of the
vehicle (Fig. 18).
(2) Install and tighten the four screws that secure
the front lamp unit to the front of the vehicle.
(3) From the engine compartment, reconnect the
vehicle wire harness connector to the connector
receptacle for the front lamp unit.
(4) Position the cover to the front lamp unit.
(5) Install and tighten the two screws that secure
the cover at the inboard side of the front lamp unit.
(6) Reinstall the front grille onto the vehicle.
(Refer to 23 - BODY/EXTERIOR/GRILLE - INSTAL-
LATION).
(7) Reconnect the battery negative cable.
(8) Check and adjust the front lamp alignment as
required. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/FRONT LAMP UNIT - ADJUST-
MENTS).
Fig. 17 Fog Lamp Switch Remove/Install
1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
Fig. 18 Front Lamp Unit Remove/Install
1 - SCREW (2)
2 - COVER
3 - SCREW (4)
4 - LAMP UNIT
5 - WIRE HARNESS CONNECTOR
VALAMPS/LIGHTING - EXTERIOR 8L - 13

WIPERS/WASHERS
DESCRIPTION
An electrically operated intermittent wiper and
washer system is standard factory-installed safety
equipment on this model (Fig. 1). The wiper and
washer system includes the following major compo-
nents, which are described in further detail else-
where in this service information:
²Check Valve- The washer system check valve
is integral to the plumbing fitting located in the
washer plumbing between the cowl plenum washer
hose and the two washer nozzle hoses, and is locatedbeneath the cowl top panel at the base of the wind-
shield in the engine compartment.
²Multi-Function Switch- The multi-function
switch is secured to the top of the steering column,
just below the steering wheel. Only the left (lighting)
control stalk, right (wiper) control stalk and the haz-
ard warning switch button for the multi-function
switch are visible, the remainder of the switch is con-
cealed beneath the steering column shrouds. The
multi-function switch contains all of the switches for
Fig. 1 Wiper & Washer System
1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL SWITCH 4 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH
2 - WIPER MOTOR, LINKAGE & PIVOTS MODULE 5 - RAIN SENSOR (W/AUTOMATIC WIPERS ONLY)
3 - WIPER RELAY 6 - RAIN SENSOR CONTROL MODULE (W/AUTOMATIC WIPERS
ONLY)
8R - 2 WIPERS/WASHERSVA

CHECK VALVE
DESCRIPTION
A single washer system check valve is standard
equipment on this model, and is installed in the
washer system plumbing (Fig. 4). The check valve is
integral to the washer plumbing fitting located on
the underside of the cowl top panel behind the rear
of the hood panel opening in the engine compart-
ment. The check valve consists of a molded plastic
body with three barbed hose nipples, one at the inlet
side of the valve body and two at the outlet side. The
check valve cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The check valve provides more than one function
in this application. It serves as a plumbing connector
fitting between the engine compartment and washer
nozzle sections of the washer supply hose. It prevents
washer fluid from draining out of the washer supply
hoses back to the washer reservoir. This drain-back
would result in a lengthy delay from when the
washer switch is actuated until washer fluid was dis-
pensed through the washer nozzles, because the
washer pump would have to refill the washer plumb-
ing from the reservoir to the nozzles. Such a drain-
back condition could also result in water, dirt, or
other outside contaminants being siphoned into the
washer system through the washer nozzle orifice.
This water could subsequently freeze and plug the
nozzle, while other contaminants could interfere with
proper nozzle operation and cause improper nozzle
spray patterns. In addition, the check valve prevents
washer fluid from siphoning through the washer noz-
zles after the washer system is turned Off.
When the washer pump pressurizes and pumps
washer fluid from the reservoir through the washer
plumbing, the fluid pressure unseats a diaphragm
from over a sump well within the valve by overridingthe spring pressure applied to it by a piston. With
the diaphragm unseated, washer fluid is allowed to
flow toward the two washer nozzles. When the
washer pump stops operating, the spring pressure on
the piston seats the diaphragm over the sump well in
the valve and fluid flow in either direction within the
washer plumbing is prevented. The check valve can-
not be adjusted or repaired and, if faulty or damaged,
it must be replaced.
REMOVAL
(1) Unlatch and open the hood panel.
(2) Disconnect the washer hoses from the three
barbed nipples of the check valve unit (Fig. 5).
(3) Remove the check valve unit from the under-
side of the cowl top panel.
INSTALLATION
(1) Position the check valve unit to the underside
of the cowl top panel (Fig. 5).
(2) Reconnect the three washer hoses to the
barbed nipples of the check valve unit.
(3) Close and latch the hood.
Fig. 4 Check Valve
1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE (2)
Fig. 5 Check Valve Remove/Install
1 - COWL HOOD SEAL
2 - CHECK VALVE
3 - HOSE TO WASHER NOZZLE (2)
4 - HOSE FROM WASHER PUMP
VAWIPERS/WASHERS 8R - 11

WASHER HOSES / TUBES
DESCRIPTION
The washer plumbing consists of a small diameter
rubber hose that is routed from the barbed outlet
nipple of the washer pump/motor on the washer res-
ervoir to the check valve just below the cowl top
panel behind the rear of the hood opening in the
engine compartment (Fig. 14). The other two barbed
nipples of the check valve are connected to two short
lengths of hose that each terminate at a molded plas-
tic elbow that passes through a rubber grommet from
the engine compartment to the outside of the cowl
top panel near each wiper pivot. The two washer noz-
zle hoses are then connected from the elbow fittings
on the outside of the cowl top panel along the under-
side of the wiper arms to the two washer nozzles.
Washer hose is available for service only as roll
stock, which must then be cut to length. The molded
plastic washer hose fittings cannot be repaired. If
these fittings are faulty or damaged, they must be
replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized
and fed by the washer pump/motor through the
washer system plumbing and fittings to the two
washer nozzles. Whenever routing the washer hoseor a wire harness containing a washer hose, it must
be routed away from hot, sharp, or moving parts;
and, sharp bends that might pinch the hose must be
avoided.
WASHER NOZZLE
DESCRIPTION
Fig. 14 Washer Plumbing
1 - WASHER SUPPLY HOSE 4 - ELBOW FITTING (2)
2 - CHECK VALVE 5 - WIPER ARM WASHER HOSE (2)
3 - WASHER NOZZLE HOSE (2) 6 - WASHER RESERVOIR
Fig. 15 Washer Nozzle
1 - WASHER NOZZLE
2 - NIPPLE
3 - ORIFICE (3)
8R - 18 WIPERS/WASHERSVA

TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD.................Left Hand Drive Vehicles
RHD ...............Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX . . . Manual Transmissions-Front Wheel Drive
AT....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC..........Double Over Head Cam Engine
Built-Up-Export....... Vehicles Built For Sale In
Markets Other Than North America
Except Built-Up-Export . Vehicles Built For Sale In
North America
CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies gage of wire, and color.
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
SECTION IDENTIFICATION AND INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections thesplices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru 8W-
09General information and Diagram
Overview
8W-10 thru 8W-
19Main Sources of Power and Ve-
hicle Grounding
8W-20 thru 8W-
29Starting and Charging
8W-30 thru 8W-
39Powertrain/Drivetrain Systems
8W-40 thru 8W-
49Body Electrical items and A/C
8W-50 thru 8W-
59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru 8W-
69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
CONNECTOR, GROUND, AND SPLICE INFOR-
MATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
VA8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5

²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING
WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle's
electrical system can cause damage to the equip-
ment and provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 4). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATIONVA

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................5
INSTALLATION
INSTALLATION - ENGINE COVER..........9
INSTALLATION........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS.....................11
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
AIR CLEANER HOUSING
REMOVAL.............................21
INSTALLATION.........................22
CYLINDER HEAD
DESCRIPTION.........................22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............22
REMOVAL
REMOVAL - CYLINDER HEAD............23
REMOVAL - CYLINDER HEAD FRONT
COVER.............................25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD........26
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE..................30
REMOVAL.............................30
INSTALLATION.........................32CYLINDER HEAD COVER(S)
REMOVAL.............................33
INSTALLATION.........................34
VALVE STEM SEALS
DESCRIPTION.........................34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............35
REMOVAL - VALVES...................36
INSTALLATION
INSTALLATION - VALVE SPRINGS........36
INSTALLATION - VALVES...............37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................38
CRANKSHAFT
DESCRIPTION.........................39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....39
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
FLYWHEEL
REMOVAL.............................43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - CRANKSHAFT LOCK.....44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................47
REMOVAL.............................47
INSTALLATION.........................49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................53
INSTALLATION.........................54
VAENGINE 9 - 1

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System 2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194ÉF). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING COOLANT. OPEN CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
VAENGINE 9 - 3