2006 MERCEDES-BENZ SPRINTER automatic transmission

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Page 1087 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 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

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

Page 1094 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch Relay............. 8W-10-11
A/C Roof Auxiliary Fan Relay............. 8W-10-11
Airbag Control Module................. 8W-10-19
Automatic T

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch Relay............. 8W-10-11
A/C Roof Auxiliary Fan Relay............. 8W-10-11
Airbag Control Module................. 8W-10-19
Automatic Temperature Control Module..... 8W-10-30
Auxiliary Heater Control................ 8W-10-23
Battery........................... 8W-10-6, 11
Battery Relay-Auxiliary.................. 8W-10-6
Beam Select Switch.............. 8W-10-12, 18, 28
Blower Motor Resistor Block........... 8W-10-12, 30
Boost Pressure Servomotor............... 8W-10-29
Brake Lamp Switch.................... 8W-10-20
Brake Lamp Switch 4 Pole............... 8W-10-20
Central Timer Module.................. 8W-10-16
Cigar Lighter........................ 8W-10-23
Circulation Pump Diode................. 8W-10-30
Circulation Pump Relay-Cabin Heater
Module........................ 8W-10-22, 30
Courtesy Lamp-Driver Door.............. 8W-10-24
Courtesy Lamp-Left Sliding Door.......... 8W-10-24
Courtesy Lamp-Passenger Door........... 8W-10-24
Courtesy Lamp-Right Sliding Door......... 8W-10-24
Crankcase Heater..................... 8W-10-29
D+ Relay No. 1..................... 8W-10-9, 10
Data Link Connector................... 8W-10-20
Daytime Running Lamp Relay-Left Side . . . 8W-10-10, 27
Daytime Running Lamp Relay-Right Side . . 8W-10-10, 27
Daytime Running Lamps Relay........... 8W-10-25
Dome Lamp......................... 8W-10-24
EGR Valve.......................... 8W-10-29
Engine Control Module....... 8W-10-12, 15, 19, 29, 34
Engine Control Relay............. 8W-10-12, 29, 34
Fog Lamp Relay...................... 8W-10-28
Fuel Pump....................... 8W-10-12, 30
Fuel Pump Relay................... 8W-10-12, 30
Fuse 1.................. 8W-10-6, 8, 9, 17, 18, 25
Fuse 2....................... 8W-10-6, 8, 11, 18
Fuse 3........................ 8W-10-6, 8, 9, 18
Fuse 4.............. 8W-10-8, 11, 13, 14, 17, 19, 26
Fuse 5.................... 8W-10-8, 9, 11, 14, 20
Fuse 6.................. 8W-10-7, 8, 11, 14, 21, 33
Fuse 7....................... 8W-10-7, 8, 14, 22
Fuse 8....................... 8W-10-7, 9, 12, 23
Fuse 9.................... 8W-10-8, 9, 10, 12, 21
Fuse 10..................... 8W-10-9, 10, 11, 25
Fuse 11........................ 8W-10-9, 10, 26
Fuse 12.......................... 8W-10-7, 27
Fuse 13.......................... 8W-10-7, 27
Fuse 14.......................... 8W-10-7, 28
Fuse 15........................ 8W-10-7, 13, 16
Fuse 16......................... 8W-10-12, 29
Fuse 17......................... 8W-10-12, 29
Fuse 18........................ 8W-10-9, 14, 19
Fuse 19......................... 8W-10-12, 30
Fuse 20........................ 8W-10-7, 12, 30
Fuse 21....................... 8W-10-12, 13, 30
Component Page
Fuse Block No. 1 . 8W-10-3, 11, 12, 13, 14, 15, 18, 19, 20,
21, 22, 23, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34
Fuse Block No. 2.............. 8W-10-10, 17, 25, 26
Fused Ignition Switch Run-Start Relay...... 8W-10-19
G200........................... 8W-10-31, 32
G202........................... 8W-10-10, 19
Generator........................... 8W-10-6
Glow Plug Control Module............... 8W-10-11
Hazard Warning Switch...... 8W-10-13, 14, 21, 31, 32
Headlamp Assembly-Left........ 8W-10-18, 26, 27, 28
Headlamp Assembly-Right....... 8W-10-17, 18, 27, 28
Headlamp Switch........... 8W-10-12, 18, 25, 26, 27
Horn.............................. 8W-10-22
Horn Relay......................... 8W-10-22
Ignition Switch.................. 8W-10-12, 13, 14
Instrument Cluster............... 8W-10-10, 18, 19
Interior Lamp-Left.................... 8W-10-24
Interior Lamp-Middle Front.............. 8W-10-24
Interior Lamp-Middle Rear.............. 8W-10-24
Interior Lamp-Rear No. 1................ 8W-10-24
Interior Lamp-Rear No. 2................ 8W-10-24
Interior Lamp-Right................... 8W-10-24
Lamp Relay-Left...................... 8W-10-26
Lamp Relay-Right..................... 8W-10-17
Mass Air Flow Sensor.................. 8W-10-22
Multi-Function Switch . . 8W-10-12, 13, 14, 18, 21, 25, 26,
27, 28, 31, 32, 33, 34
Optional Equipment Relay........... 8W-10-6, 7, 22
Oxygen Sensor....................... 8W-10-29
Power Distribution Center........... 8W-10-2, 6, 11
Radio........................... 8W-10-16, 23
Radio/Cellular Antenna................. 8W-10-16
Rain Sensor Control Module.............. 8W-10-33
Sentry Key Remote Entry Module.......... 8W-10-22
Shifter Assembly................... 8W-10-14, 19
Starter Motor..................... 8W-10-11, 15
Starter Motor Relay................... 8W-10-15
Tail Lamp Assembly-Left................ 8W-10-26
Tail Lamp Assembly-Right............... 8W-10-17
Trailer Tow Connector.................. 8W-10-17
Transmission Relay.................... 8W-10-22
Turn Signal Relay..................... 8W-10-31
Turn Signal Switch............... 8W-10-13, 26, 31
Turn Signal/Anti-Theft Alarm Relay-Left..... 8W-10-23
Turn Signal/Anti-Theft Alarm Relay-Right.... 8W-10-23
Washer On/Off Switch............... 8W-10-21, 34
Washer Pump Motor-Front............... 8W-10-34
Window Defogger Switch-Rear............ 8W-10-22
Wiper Motor-Front.................... 8W-10-33
Wiper On/Off Relay................. 8W-10-21, 33
Wiper Switch................... 8W-10-21, 32, 33
Wiper/Turn Signal/Engine Start Control
Module............. 8W-10-14, 21, 31, 32, 33, 34
VA8W-10 POWER DISTRIBUTION 8W - 10 - 1

Page 1128 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 8W-11 FUSE BLOCK
Component Page
A/C Auxiliary Fan Relay................ 8W-11-19
Additional Heat Exchanger Relay....... 8W-11-24, 34
Additional Heat Exchanger Switch......... 8W-11-27
Ash Receiver Lam

8W-11 FUSE BLOCK
Component Page
A/C Auxiliary Fan Relay................ 8W-11-19
Additional Heat Exchanger Relay....... 8W-11-24, 34
Additional Heat Exchanger Switch......... 8W-11-27
Ash Receiver Lamp.................... 8W-11-27
Automatic Temperature Control Module . . . 8W-11-16, 27
Battery Relay-Auxiliary................. 8W-11-16
Body Plug Connector.............. 8W-11-28, 38, 39
CTEL Connector................... 8W-11-21, 30
Cabin Heater Module................ 8W-11-21, 34
Central Timer Module............... 8W-11-16, 18
Cigar Lighter Lamp.................... 8W-11-27
Circulation Pump Diode................. 8W-11-34
Controller Antilock Brake............. 8W-11-21, 33
D+ Relay No. 1............... 8W-11-14, 15, 25, 38
D+ Relay No. 2.................. 8W-11-16, 28, 38
Data Link Connector................... 8W-11-18
Daytime Running Lamp Relay-Left Side..... 8W-11-15
Daytime Running Lamp Relay-Right Side.... 8W-11-15
Daytime Running Lamps Relay...... 8W-11-16, 25, 26
Fan Stage 1 Relay..................... 8W-11-24
Fog Lamp Switch................... 8W-11-21, 27
Fuse 1................ 8W-11-13, 14, 19, 20, 25, 26
Fuse 2........... 8W-11-13, 17, 29, 30, 31, 33, 36, 37
Fuse 3................ 8W-11-13, 14, 17, 18, 19, 20,
21, 22, 23, 24, 25, 28
Fuse 4..................... 8W-11-13, 14, 17, 21
Fuse 5................... 8W-11-13, 14, 18, 21, 23
Fuse 6................ 8W-11-13, 18, 24, 29, 33, 36
Fuse 7................ 8W-11-13, 21, 29, 30, 33, 34
Fuse 8................ 8W-11-14, 20, 24, 29, 34, 35
Fuse 9............. 8W-11-13, 14, 15, 16, 21, 25, 38
Fuse 10.................. 8W-11-14, 15, 19, 26, 36
Fuse 11....................... 8W-11-14, 15, 20
Fuse 12....................... 8W-11-28, 29, 33
Fuse 13.................... 8W-11-28, 29, 30, 39
Fuse 14.................... 8W-11-28, 29, 30, 38
Fuse 15....................... 8W-11-29, 31, 32
Fuse 18....................... 8W-11-14, 22, 39
Fuse 19............................ 8W-11-16
Fuse 20......................... 8W-11-29, 31
Fuse Block No. 1................ 8W-11-26, 33, 39
Fuse Block No. 2.............. 8W-11-4, 15, 17, 18,
25, 26, 28, 30, 31, 34, 38, 39
Fuse Block No. 3......... 8W-11-5, 16, 20, 21, 22, 24,
30, 31, 32, 33, 34, 36
Fuse/Relay Block......... 8W-11-2, 19, 20, 21, 23, 33
Fused Ignition Switch Run-Start Relay.... 8W-11-28, 39
G202................. 8W-11-16, 25, 33, 34, 38, 39
Headlamp Adjust Switch................ 8W-11-27
Headlamp Assembly-Left............. 8W-11-15, 25
Headlamp Assembly-Right............ 8W-11-15, 25
Headlamp Switch..................... 8W-11-26
Heated Seat Switch-Driver............ 8W-11-27, 32
Heated Seat Switch-Passenger.......... 8W-11-27, 32
Heater Timer-Auxiliary................. 8W-11-20
High Idle Switch................... 8W-11-27, 33
Component Page
Instrument Cluster................. 8W-11-18, 25
Instrument Panel Socket................ 8W-11-25
Interior Light Switch................ 8W-11-22, 27
Interior Light Switch-Driver.............. 8W-11-22
Interior Light Switch-Passenger........... 8W-11-22
Interior Light Switch-Rear............... 8W-11-22
Interior Lighting Connector.............. 8W-11-22
Intrusion Sensor No. 1.................. 8W-11-37
Intrusion Sensor No. 2.................. 8W-11-37
Intrusion Sensor No. 3.................. 8W-11-37
Lamp Relay-Left................... 8W-11-16, 17
Lamp Relay-Right.................. 8W-11-16, 17
License Plate Lamp No. 1............... 8W-11-25
License Plate Lamp No. 2............... 8W-11-25
Locker Switch No. 1................. 8W-11-27, 33
Locker Switch No. 2................... 8W-11-33
Map/Reading Lamp Switch............ 8W-11-22, 27
Master Door Lock Switch................ 8W-11-27
Multi-Function Switch.................. 8W-11-26
Optional Equipment Relay . . 8W-11-29, 30, 31, 32, 33, 34
Panic Alarm Switch.................... 8W-11-27
Power Distribution Center . . 8W-11-13, 17, 18, 19, 20, 21,
22, 23, 24, 25, 28, 29, 30, 31, 33, 36
Power Mirror Motor-Driver.............. 8W-11-35
Power Mirror Motor-Passenger............ 8W-11-35
Power Mirror Switch................... 8W-11-35
Power Window Switch-Driver............. 8W-11-30
Power Window Switch-Master............ 8W-11-31
Power Window Switch-Passenger.......... 8W-11-31
Radio.............................. 8W-11-27
Rear Window Defogger Relay............. 8W-11-19
Relay Block . . 8W-11-3, 14, 15, 16, 17, 19, 23, 24, 25, 28,
29, 30, 31, 32, 33, 34
Rollover Switch Assembly............. 8W-11-21, 34
Roof A/C Control Module................ 8W-11-20
Roof A/C Switch.................... 8W-11-16, 27
Roof A/C Temperature Setting Control....... 8W-11-27
Roof Fan Switch................... 8W-11-27, 31
Security System Module........... 8W-11-30, 36, 37
Sentry Key Remote Entry Module.......... 8W-11-23
Shifter Assembly...................... 8W-11-27
Siren.............................. 8W-11-37
Steering Angle Sensor.................. 8W-11-33
TCS Switch......................... 8W-11-27
Time Delay Relay..................... 8W-11-22
Towing/Intrusion Sensor On/Off Switch...... 8W-11-27
Trailer Tow Connector.................. 8W-11-24
Trailer Tow Control Module.............. 8W-11-24
Transmission Relay.................... 8W-11-17
Turn Signal/Anti-Theft Alarm Relay-Left..... 8W-11-23
Turn Signal/Anti-Theft Alarm Relay-Right.... 8W-11-23
Warm Air Auxiliary Heater Assembly....... 8W-11-20
Window Defogger Module-Rear......... 8W-11-16, 19
Window Defogger Switch-Rear............ 8W-11-27
VA8W-11 FUSE BLOCK 8W - 11 - 1

Page 1168 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 8W-15 GROUND DISTRIBUTION
Component PageA/C Auxiliary Fan..........................8W-15-4
A/C Auxiliary Fan Relay......................8W-15-12
A/C Compressor Clutch Relay...................8W-15-30

8W-15 GROUND DISTRIBUTION
Component PageA/C Auxiliary Fan..........................8W-15-4
A/C Auxiliary Fan Relay......................8W-15-12
A/C Compressor Clutch Relay...................8W-15-30
A/C Roof Auxiliary Fan......................8W-15-30
A/C Roof Auxiliary Fan Relay...................8W-15-30
Additional Heat Exchanger....................8W-15-12
Additional Heat Exchanger Relay.................8W-15-12
Additional Heat Exchanger Switch................8W-15-24
Airbag Control Module.......................8W-15-11
Ash Receiver Lamp........................8W-15-22
Automatic Temperature Control Module.............8W-15-24
Auxiliary Heater Control.....................8W-15-24
Battery................................8W-15-8
Battery Relay-Auxiliary......................8W-15-11
Battery-Auxiliary..........................8W-15-11
Blower Motor-Front.........................8W-15-9
Brake Fluid Level Switch......................8W-15-8
Brake Wear Sensor-Left Front...................8W-15-8
Brake Wear Sensor-Left Rear...................8W-15-28
Brake Wear Sensor-Right Front..................8W-15-8
Brake Wear Sensor-Right Rear..................8W-15-28
CTEL Connector..........................8W-15-21
Cabin Heater Module........................8W-15-3
Center High Mounted Stop Lamp.................8W-15-6
Central Timer Module.......................8W-15-15
Cigar Lighter............................8W-15-22
Cigar Lighter Lamp........................8W-15-22
Circulation Pump..........................8W-15-9
Circulation Pump Relay-Cabin Heater Module..........8W-15-12
Clockspring.............................8W-15-10
Controller Antilock Brake....................8W-15-2, 28
Crankcase Heater..........................8W-15-4
Cylinder Lock Switch-Driver...................8W-15-10
D+ Relay No. 1...........................8W-15-12
D+ Relay No. 2...........................8W-15-14
Data Link Connector........................8W-15-10
Daytime Running Lamp Relay-Left Side.............8W-15-13
Daytime Running Lamp Relay-Right Side............8W-15-13
Daytime Running Lamps Relay..................8W-15-13
Differential Lock Solenoid Valve..................8W-15-2
Dome Lamp.............................8W-15-6
Dosing Pump............................8W-15-2
Engine Control Module.......................8W-15-7
Engine Coolant Level Switch....................8W-15-2
Fan Stage 1 Relay.........................8W-15-11
Fog Lamp Relay..........................8W-15-11
Fog Lamp Switch.........................8W-15-22
Fuel Pump.............................8W-15-19
Fuse Block No. 1..........................8W-15-7
Fused Ignition Switch Run-Start Relay..............8W-15-14
G100...............................8W-15-2, 3
G101.................................8W-15-4
G102.................................8W-15-4
G103.................................8W-15-4
G200...........................8W-15-6, 7, 8, 9, 10
G201................................8W-15-11
G202................8W-15-11, 12, 13, 14, 15, 16, 17, 18, 19
G203......................8W-15-20, 21, 22, 23, 24, 25
G300............................8W-15-26, 27, 28
G301................................8W-15-28
G302................................8W-15-28
G303................................8W-15-31
G304................................8W-15-31
G305..............................8W-15-29, 30
Glow Plug Control Module.....................8W-15-2
Hazard Warning Switch.......................8W-15-7
Headlamp Adjust Switch.....................8W-15-22
Headlamp Assembly-Left......................8W-15-3
Headlamp Assembly-Right.....................8W-15-4
Heated Seat Module-Driver....................8W-15-19
Heated Seat Module-Passenger..................8W-15-19
Heated Seat Switch-Driver....................8W-15-25
Heated Seat Switch-Passenger..................8W-15-25
Heater Timer-Auxiliary......................8W-15-24
High Idle Switch..........................8W-15-25
Hood Ajar Switch..........................8W-15-4
Horn Relay.............................8W-15-11
Horn Switch............................8W-15-10
Ignition Lock Switch........................8W-15-10
Instrument Cluster........................8W-15-10
Instrument Panel Socket.....................8W-15-20
Interior Lamp No. 1.........................8W-15-6
Interior Lamp No. 2.........................8W-15-6
Interior Lamp No. 3.........................8W-15-6Component PageInterior Lamp No. 4.........................8W-15-6
Interior Lamp No. 5.........................8W-15-6
Interior Lamp-Left.........................8W-15-6
Interior Lamp-Middle Front...................8W-15-5, 6
Interior Lamp-Middle Rear...................8W-15-5, 6
Interior Lamp-Rear No. 2......................8W-15-5
Interior Lamp-Right.......................8W-15-5, 6
Interior Light Switch.......................8W-15-21
Interior Lighting Connector.....................8W-15-6
Intrusion Sensor No. 1.......................8W-15-6
Intrusion Sensor No. 2.......................8W-15-6
Intrusion Sensor No. 3.......................8W-15-6
Kickdown Switch..........................8W-15-8
Lamp Relay-Left..........................8W-15-13
Lamp Relay-Right.........................8W-15-13
License Plate Lamp No. 1.....................8W-15-27
License Plate Lamp No. 2.....................8W-15-27
Locker Switch No. 1........................8W-15-20
Map/Reading Lamp Switch....................8W-15-21
Marker Lamp Connector......................8W-15-17
Marker Lamp No. 1-Left Front..................8W-15-16
Marker Lamp No. 1-Right Front.................8W-15-16
Marker Lamp No. 2-Left Front..................8W-15-16
Marker Lamp No. 2-Right Front.................8W-15-16
Marker Lamp-Left Center.....................8W-15-17
Marker Lamp-Left Rear......................8W-15-27
Marker Lamp-Right Center....................8W-15-17
Marker Lamp-Right Rear.....................8W-15-27
Master Door Lock Switch.....................8W-15-25
Metering Pump...........................8W-15-18
Multi-Function Switch.......................8W-15-7
Optional Equipment Relay....................8W-15-19
Panic Alarm Switch........................8W-15-20
Parking Brake Switch.......................8W-15-15
Power Mirror Motor-Driver....................8W-15-23
Power Mirror Motor-Passenger..................8W-15-23
Power Mirror Switch........................8W-15-23
Power Window Switch-Driver...................8W-15-23
Power Window Switch-Master...................8W-15-23
Radio................................8W-15-21
Rain Sensor............................8W-15-31
Rain Sensor Control Module..................8W-15-19, 31
Reading Lamp Connector......................8W-15-6
Rear Window Defogger Relay...................8W-15-14
Recirculated Air Solenoid Valve...................8W-15-9
Rollover Switch Assembly......................8W-15-3
Roof A/C Blower..........................8W-15-29
Roof A/C Blower Stage I And Ii Relay...............8W-15-29
Roof A/C Blower Stage I Relay..................8W-15-29
Roof A/C Blower Stage Ii Relay..................8W-15-29
Roof A/C Control Module.....................8W-15-28
Roof A/C Switch..........................8W-15-24
Roof Fan Switch..........................8W-15-21
Roof Thermotronic Control Module................8W-15-30
Seat Belt Switch..........................8W-15-15
Security System Module......................8W-15-15
Sentry Key Remote Entry Module.................8W-15-7
Shifter Assembly..........................8W-15-20
Siren.................................8W-15-9
Steering Angle Sensor........................8W-15-7
TCS Switch.............................8W-15-25
Tail Lamp Assembly-Left.....................8W-15-26
Tail Lamp Assembly-Right.....................8W-15-26
Thermotronic Diode........................8W-15-30
Time Delay Relay.........................8W-15-17
Towing/Intrusion Sensor On/Off Switch..............8W-15-22
Trailer Tow Connector.......................8W-15-28
Trailer Tow Control Module....................8W-15-19
Transmission Control Module...................8W-15-19
Transmission Relay........................8W-15-19
Turn Signal No. 1-Left Front....................8W-15-3
Turn Signal No. 1-Right Front...................8W-15-4
Turn Signal No. 2-Left Front....................8W-15-3
Turn Signal No. 2-Right Front...................8W-15-4
Warm Air Auxiliary Heater Assembly...............8W-15-18
Washer Pump Motor-Front.....................8W-15-4
Water Cycle Valve..........................8W-15-9
Window Defogger Module-Rear..................8W-15-15
Window Defogger Switch-Rear..................8W-15-20
Window Defogger-Left Rear....................8W-15-26
Window Defogger-Right Rear...................8W-15-26
Wiper Motor-Front.........................8W-15-9
Wiper/Turn Signal/Engine Start Control Module.........8W-15-7
VA8W-15 GROUND DISTRIBUTION 8W - 15 - 1

Page 1200 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual 8W-18 BUS COMMUNICATIONS
Component Page
Airbag Control Module................ 8W-18-5
Automatic Temperature
Control Module.................. 8W-18-4, 6
Brake Lamp Switch.................. 8W-18-2
Brak

Page 1584 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual NOTE: After removing the front cross plate, seal
metal with anti corrosion protection.
(48) Using tin snips, remove the front cross plate
at the cutting edges and deburr (Fig. 6).
(49) Connect and eng

Page 1585 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transm

(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(13) Connect the engine valley drain hose to the
transmission (Fig. 5).
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(15) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and
CCV heater at the turbocharger (Fig. 4).
(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the
vacuum pump.(24) Connect the fuel lines at the filter assembly
(Fig. 9).
(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser and fan assemblies Con-
nect the fan harness connector.
(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).
(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-
tor.
(32) Install air cleaner housing and connect the air
inlet duct and air flow sensor.
(33) Connect the charge air cooler hose at intake
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).
(34) Route the engine wiring harness inside the
vehicle and connect.
(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
Fig. 8 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
Fig. 9 FUEL FILTER
1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
9 - 10 ENGINEVA

Page 1618 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller

(3) Install the retaining lock for the crankshaft/
ring gear.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the
puller. The groves of the puller MUST mesh fully
into the slots of the belt pulley.
NOTE: Inspect the running surface of the belt pulley
for wear.
(4) Remove the belt pully/vibration damper.
CAUTION: Care must be taken to prevent severe
damage to the crankshaft and mounting whole for
the front crankshaft seal.
(5) Using a suitable prying tool, remove the front
crankshaft seal from the timing cover (Fig. 34).
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
NOTE: Carefully position the front crankshaft seal
evenly onto the timing cover.(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(3) Remove the retaining lock for the crankshaft/
ring gear.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Fill the crankcase with the correct engine oil to
the proper level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(7) Start the engine and inspect for leaks.
FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: M6x90 bolts must be used with retaining
lock to prevent damage to rear end cover.
(2) Install retaining lock for crankshaft/starter
ring gear.
NOTE: Flywheel does not need balancing or should
it be interchanged.
(3) Remove flywheel with inner washer (Fig. 35).
Fig. 34 FRONT SEAL REMOVAL/INSTALLATION
1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
3 - WASHER
4 - RETAINING BOLT
VAENGINE 9 - 43

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