2006 MERCEDES-BENZ SPRINTER ECU

As the dragging brake overheats, efficiency is so
reduced that fade occurs. Since the opposite brake
unit is still functioning normally, its braking effect is
magnified. This causes pull to switch direction in
favor of the normally functioning brake unit.
An additional point when diagnosing a change in
pull condition concerns brake cool down. Remember
that pull will return to the original direction, if the
dragging brake unit is allowed to cool down (and is
not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pull is usually caused by improperly
adjusted or seized parking brake cables, contami-
nated lining, bent or binding shoes and support
plates, or improperly assembled components. This is
particularly true when only one rear wheel is
involved. However, when both rear wheels are
affected, the master cylinder or proportioning valve
could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
This condition is generally caused by water soaked
lining. If the lining is only wet, it can be dried by
driving with the brakes very lightly applied for a
mile or two. However, if the lining is both soaked and
dirt contaminated, cleaning and/or replacement will
be necessary.
BRAKE LINING CONTAMINATION
Brake lining contamination is mostly a product of
leaking calipers or worn seals, driving through deep
water puddles, or lining that has become covered
with grease and grit during repair. Contaminated lin-
ing should be replaced to avoid further brake prob-
lems.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
produce a grab-like condition as the tire loses and
recovers traction. Flat-spotted tires can cause vibra-
tion and generate shudder during brake operation. A
tire with internal damage such as a severe bruise,
cut, or ply separation can cause pull and vibration.
BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfacesafter a few brake applications causing the noise to
subside.
BRAKE SQUEAK / SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material
embedded in the brake lining will also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brake pads in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors can become so scored that replacement is nec-
essary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP / CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use approved brake fluid (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES - DESCRIP-
TION). Use fresh, clean fluid from a sealed container
at all times.
(1) Remove reservoir filler caps and fill reservoir.
(2) If calipers, or wheel cylinders were overhauled,
open all caliper and wheel cylinder bleed screws.
Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more
before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
5 - 4 BRAKES - BASEVA

edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible.
(2) Disconnect the brake level switch electrical
connector.
(3) Remove the brake lines from the master cylin-
derSeal off the ends and bore holes with plugs.
(4) Remove the master cylinder from the booster.
(5) Remove the booster vacuum hose and check
valve (Fig. 23).
(6) Remove the pedal push rod clip (Fig. 23).
(7) Remove the booster mounting nuts (Fig. 23).
(8) Remove the booster from the vehicle.
INSTALLATION
(1) Install the brake booster to the vehicle.
(2) Install the booster mounting nuts (Fig. 23).
Tighten to 25 N´m (221 in.lbs.).
(3) Install the push rod pin & clip (Fig. 23).
(4) Install the brake booster vacuum line and
check valve (Fig. 23).
(5) Install the master cylinder to the brake
booster. Tighten to 28 N´m (248 in.lbs.).
(6) Install the brake lines to the master cylinder.
Tighten to 14 N´m (124 in.lbs.).
(7) Install the brake level switch electrical connec-
tor.(8) Bleed the base brake system (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
ROTORS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 24).
(4) Remove the caliper adapter (Fig. 24).
(5) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(6) Remove the locking bolt for the disc brake rotor
(Fig. 24).
(7) Remove the two lug nuts.
(8) Remove the disc brake rotor (Fig. 24).
REMOVAL - REAR (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 25).
(4) Remove the disc brake caliper adapter (Fig.
25).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 25).
(8) Remove the two lug nuts.
(9) Release the parking brake.
Fig. 23 POWER BRAKE BOOSTER
1 - VACUUM LINE & CHECK VALVE
2 - BRAKE BOOSTER
3 - GASKET
4 - MOUNTING NUTS (4)
5 - PUSH ROD PIN
6 - SECURING CLIP
Fig. 24 FRONT DISC BRAKE ROTOR
1 - CALIPER ADAPTER BOLT
2 - CALIPER ADAPTER
3 - GUIDE BOLT
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
5 - 20 BRAKES - BASEVA

(10) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 25).
(11) Remove the rear disc brake rotor.
REMOVAL - FRONT (DRW)
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Remove the front brake pads (Fig. 26).
(4) Remove the caliper adapter (Fig. 26).
(5) Remove the wheel flange ring (Fig. 26).
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 26).
(8) Remove the two lug nuts.
(9) Remove the disc brake rotor (Fig. 26).
REMOVAL - REAR (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 27).
(4) Remove the disc brake caliper adapter (Fig.
27).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the wheel flange ring (Fig. 27).
(8) Remove the locking bolt for the disc brake rotor
(Fig. 27).
(9) Remove the two lug nuts.
(10) Release the parking brake.
(11) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 27).
(12) Remove the rear disc brake rotor.
Fig. 25 REAR DISC BRAKE ROTOR
1-M8BOLT
2 - CALIPER ADAPTER
3 - DISC BRAKE ROTOR
4 - LOCKING BOLT
5 - DISC BRAKE PADS
6 - RATTLE SPRING
7 - DISC BRAKE CALIPER
8 - GUIDE BOLT
9 - COVER
10 - WEAR INDICATOR
Fig. 26 FRONT DISC BRAKE ROTOR WITH DUAL
REAR WHEELS
1 - ADAPTER BOLT
2 - ADAPTER
3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR WIRE
5 - DISC BRAKE CALIPER
6 - DISC BRAKE PADS
7 - WHEEL FLANGE RING MOUNTING BOLT
8 - WHEEL FLANGE RING
9 - LOCKING BOLT
10 - DISC BRAKE ROTOR
VABRAKES - BASE 5 - 21

(3) Remove the cover below the drivers seat (Fig.
8).
(4) Remove the bracket for the control modules
and set aside with the control modules (Fig. 9).
(5) Remove the screws securing the Yaw rate/lat-
eral Acceleration Sensor (Fig. 10).(6) Remove the metal cover over the sensor.
(7) Disconnect the electrical connector (Fig. 11).
(8) Remove the Yaw rate/lateral Acceleration Sen-
sor.
INSTALLATION
(1) Reconnect the yaw rate/lateral acceleration
sensor electrical connector (Fig. 11).
(2) Install the yaw rate/lateral acceleration sensor.
(3) Install the metal cover over top of the sensor.
(4) Install the screws securing the yaw rate/lateral
acceleration sensor (Fig. 10). Tighten to 6 N´m (53
in.lbs).
Fig. 8 COVER
1 - SCREWS
2 - COVER
Fig. 9 CONTROL MODULE BRACKET
1 - SEAT FRAME
2 - BRACKET FOR THE CONTROL MODULES
Fig. 10 SENSOR REMOVE/INSTALL
1 - SCREWS
2 - YAW RATE/LATERAL ACCELERATION SENSOR
Fig. 11 ELECTRICAL CONNECTOR
1 - YAW RATE/ATERAL ACCELERATION SENSOR
2 - ELECTRICAL CONNECTOR
5 - 34 BRAKES - ABSVA

(5) Install the bracket with the control modules
(Fig. 9).
(6) Install the cover for the drivers seat (Fig. 8).
(7) Return the drivers seat to normal position.
(8) Reconnect the battery.
(9) Perform diagnosis quick check and road test
the vehicle.
YAW RATE SENSOR
DESCRIPTION
The Yaw Rate and Lateral Acceleration Sensor is
housed into one unit (Fig. 12)(each individual sen-
sor can not be replaced separately the whole
housing unit must be replaced when servicing).
The sensor is used to measure side to side (Lateral)
motion and vehicle rotational sensing (how fast the
vehicle is turning). This is a 6±wire sensor with all
six wires connected to the ESP/ABS module.
REMOVAL
(1) Disconnect the battery.
(2) Move the drivers seat forward and upwards.(3) Remove the cover below the drivers seat (Fig.
13).
(4) Remove the bracket for the control modules
and set aside with the control modules (Fig. 14).
(5) Remove the screws securing the Yaw rate/lat-
eral Acceleration Sensor (Fig. 15).
Fig. 12 YAW/LATERAL ACCELERATION SENSOR
1 - SEAT BOX
2 - YAW RATE/ LATERAL ACCELERATION SENSOR
Fig. 13 COVER
1 - SCREWS
2 - COVER
Fig. 14 CONTROL MODULE BRACKET
1 - SEAT FRAME
2 - BRACKET FOR THE CONTROL MODULES
VABRAKES - ABS 5 - 35

(6) Remove the metal cover over the sensor.
(7) Disconnect the electrical connector (Fig. 16).
(8) Remove the Yaw rate/lateral Acceleration Sen-
sor.
INSTALLATION
(1) Reconnect the yaw rate/lateral acceleration
sensor electrical connector (Fig. 16).
(2) Install the yaw rate/lateral acceleration sensor.
(3) Install the metal cover over top of the sensor.
(4) Install the screws securing the yaw rate/lateral
acceleration sensor (Fig. 15). Tighten to 6 N´m (53
in.lbs).(5) Install the bracket with the control modules
(Fig. 14).
(6) Install the cover for the drivers seat (Fig. 13).
(7) Return the drivers seat to normal position.
(8) Reconnect the battery.
(9) Perform diagnosis quick check and road test
the vehicle.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor, low
pressure accumulators, inlet valves, outlet valves and
noise attenuators.
REMOVAL
NOTE: Store the Hydraulic Control Unit in an
upright position only.
(1) Disconnect the ground cable at the battery.
The ignition switch must be switched to the off
position when disconnecting the battery cable.
(2) Disconnect the multiplug from the control mod-
ule (Fig. 17).
(3) Disconnect the brake lines from the hydraulic
control unit (Fig. 17).Mark the brake lines for
reinstallation, also seal off the connections and
lines to prevent contamination.
(4) Remove the hydraulic control unit from the
bracket (Fig. 17).
(5) Check the rubber mounts on the bracket.
(Replace if necessary) (Fig. 17).
Fig. 15 SENSOR REMOVE/INSTALL
1 - SCREWS
2 - YAW RATE/LATERAL ACCELERATION SENSOR
Fig. 16 ELECTRICAL CONNECTOR
1 - YAW RATE/ATERAL ACCELERATION SENSOR
2 - ELECTRICAL CONNECTOR
Fig. 17 HYDRAULIC CONTROL UNIT (ABS)
1 - BRAKE LINES
2 - HCU WITH CONTROL MODULE
3 - ABS/ABD CONTROL MODULE MULTIPLUG
4 - RUBBER SUPPORT
5 - 36 BRAKES - ABSVA

(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

(8) Unplug wiring connector at coolant level sensor
(Fig. 9).
(9) Detach coolant hose at bottom right of radiator
(Fig. 9).
(10) Detach transmission cooler lines at radiator
(Fig. 9).
(11) Remove the radiator trim from the left and
right (Fig. 9).
(12) Remove radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL).
(13) Remove bolts securing intercooler to radiator.
(14) Remove screws and upper radiator trim from
radiator.
(15) Move condenser/intercooler/power steering
cooler assembly forward.
(16) Lift the radiator assembly up and out of the
rubber grommets (Fig. 9).
Fig. 9 RADIATOR ASSEMBLY
1 - COOLANT HOSE 8 - ATF LINE
2 - SENSOR HARNESS CONNECTOR 9 - LEFT RADIATOR TRIM PANEL
3 - HYDRAULIC HOSE 10 - RIGHT RADIATOR TRIM PANEL
4 - CHARGE AIR HOSE 11 - RADIATOR
5 - HYDRAULIC HOSE 12 - ATF LINE
6 - RUBBER GROMMET 13 - COOLANT HOSE
7 - COOLANT HOSE 14 - COOLANT RESERVOIR
7 - 18 ENGINEVA