2006 MERCEDES-BENZ SPRINTER OBD port

ENGINE CONTROL MODULE C2 (EXCEPT OBD) - BLACKCAV CIRCUIT FUNCTION
1- -
2- -
3 18BR/WT HIGH IDLE ON SIGNAL
4- -
5- -
6- -
7 18BR/DG KICKDOWN SWITCH SIGNAL
8- -
9 18BR SENSOR GROUND
10 - -
11 20DG/WT CAN C BUS (+)
12 20DG CAN C BUS (-)
13 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 18DG ACCEL/SET SIGNAL
15 - -
16 18YL DECEL/SET SIGNAL
17 20DG ENHANCED ACCIDENT REPORT DRIVER
18 - -
19 18RD S/C SWITCH 12 VOLT SUPPLY
20 18BL RESUME SIGNAL
21 18BK VERIFICATION SIGNAL
22 18GY OFF SIGNAL
23 - -
24 - -
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C2 (OBD)CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
2 14BR GROUND
3 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
6 14BR GROUND
7 18RD S/C SWITCH 12 VOLT SUPPLY
8 18BR/WT HIGH IDLE ON SIGNAL
10 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
11 18WT/DG BOOST PRESSURE SENSOR SIGNAL
12 18BR/WT SENSOR GROUND
13 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
14 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
17 18BR/DG KICKDOWN SWITCH SIGNAL
18 20DG/YL ENGINE RPM
19 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
25 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
26 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
28 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
31 20BL/YL K-ECM
32 20DG ENHANCED ACCIDENT REPORT DRIVER
36 18VT IGNITION SWITCH OUTPUT (START)
37 18DG ACCEL/SET SIGNAL
38 18BK VERIFICATION SIGNAL
42 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
43 18BK/RD GLOW PLUG MODULE CONTROL
44 18YL/BL ENGINE CONTROL RELAY CONTROL
50 18YL DECEL/SET SIGNAL
51 18GY OFF SIGNAL
52 18BL RESUME SIGNAL
53 20DG/WT CAN C BUS (+)
54 20DG CAN C BUS (-)
55 18BR/RD FUEL PUMP RELAY CONTROL
58 18VT/DG STARTER MOTOR RELAY CONTROL
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CONNECTOR PINOUTS

9.0 CONNECTOR PINOUTS
ACCELERATOR PEDAL POSITION SENSOR (OBD)CAV CIRCUIT FUNCTION
1 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
2 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
3 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
4 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
5 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
AIRBAG CONTROL MODULE - YELLOWCAV CIRCUIT FUNCTION
1 20BL DRIVER SEAT BELT TENSIONER LINE 2
2 20BR/YL DRIVER SEAT BELT TENSIONER LINE 1
3 20BL PASSENGER SEAT BELT TENSIONER LINE 2
4 20BR PASSENGER SEAT BELT TENSIONER LINE 1
5 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 20BR GROUND
7 20YL AIRBAG WARNING INDICATOR DRIVER
8- -
9 20BK/RD K-ACM
10 20DG DRIVER AIRBAG SQUIB 1 LINE 2
11 20VT DRIVER AIRBAG SQUIB 1 LINE 1
12 - -
13 20BL/DG PASSENGER AIRBAG SQUIB 1 LINE 2
14 20BR/DG PASSENGER AIRBAG SQUIB 1 LINE 1
15 - -
16 - -
17 - -
18 - -
19 - -
20 20DG ENHANCED ACCIDENT REPORT DRIVER
21 -
22 -
23 -
24 -
25 -
BOOST PRESSURE SENSOR (OBD)CAV CIRCUIT FUNCTION
1 18BR/WT SENSOR GROUND
2 18WT/DG BOOST PRESSURE SENSOR SIGNAL
3 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C2 (OBD)CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
2 14BR GROUND
3 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
6 14BR GROUND
7 18RD S/C SWITCH 12 VOLT SUPPLY
8 18BR/WT HIGH IDLE ON SIGNAL
10 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
11 18WT/DG BOOST PRESSURE SENSOR SIGNAL
12 18BR/WT SENSOR GROUND
13 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
14 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
17 18BR/DG KICKDOWN SWITCH SIGNAL
18 20DG/YL ENGINE RPM
19 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
25 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
26 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
28 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
31 20BL/YL K-ECM
32 20DG ENHANCED ACCIDENT REPORT DRIVER
36 18VT IGNITION SWITCH OUTPUT (START)
37 18DG ACCEL/SET SIGNAL
38 18BK VERIFICATION SIGNAL
42 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
43 18BK/RD GLOW PLUG MODULE CONTROL
44 18YL/BL ENGINE CONTROL RELAY CONTROL
50 18YL DECEL/SET SIGNAL
51 18GY OFF SIGNAL
52 18BL RESUME SIGNAL
53 20DG/WT CAN C BUS (+)
54 20DG CAN C BUS (-)
55 18BR/RD FUEL PUMP RELAY CONTROL
58 18VT/DG STARTER MOTOR RELAY CONTROL
ENGINE COOLANT TEMPERATURE SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
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CONNECTOR PINOUTS

For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the recommended battery maintenance schedules and
for the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
this service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all ofthe components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
8F - 2 BATTERY SYSTEMVA

STARTING SYSTEM
TABLE OF CONTENTS
page page
STARTING SYSTEM
DESCRIPTION.........................28
OPERATION...........................28
DIAGNOSIS AND TESTING - STARTING
SYSTEM............................29
SPECIFICATIONS
TORQUE - STARTER - DIESEL...........33
SPECIFICATIONS - STARTER MOTOR -
DIESEL.............................33STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR .............................33
REMOVAL.............................34
INSTALLATION.........................35
STARTER MOTOR RELAY
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................36
STARTING SYSTEM
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Park/neutral position switch (automatic trans-
mission)
²Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Engine Control Module
(ECM). Use of an induction-type milliampere amme-
ter, volt/ohmmeter, battery charger, carbon pile rheo-
stat (load tester), and 12-volt test lamp may be
required.
Certain starting system components are monitored
by the ECM and may produce a Diagnostic Trouble
Code (DTC).
OPERATION
The starting system components form two separate
circuits. A high-amperage feed circuit that feeds the
starter motor high-amperage, and a low-amperagecontrol circuit that operates on less than 20 amperes.
The high-amperage feed circuit components include
the battery, the battery cables, the contact disc por-
tion of the starter solenoid, and the starter motor
itself. The low-amperage control circuit components
include the ignition switch, the park/neutral position
switch (automatic transmission), the starter relay,
the electromagnetic windings of the starter solenoid,
and the connecting wire harness components.
If the vehicle is equipped with an automatic trans-
mission, battery voltage is supplied through the low-
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is
turned to the momentary Start position. The park/
neutral position switch is installed in series between
the starter relay coil ground terminal and ground.
This normally open switch prevents the starter relay
from being energized and the starter motor from
operating unless the automatic transmission gear
selector is in the Neutral or Park positions.
When the starter relay coil is energized, the nor-
mally open relay contacts close. The relay contacts
connect the relay common feed terminal to the relay
normally open terminal. The closed relay contacts
energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls in the sole-
noid plunger. The solenoid plunger pulls the shift
lever in the starter motor. This engages the starter
overrunning clutch and pinion gear with the starter
ring gear on the manual transmission flywheel or on
the automatic transmission torque converter or
torque converter drive plate.
As the solenoid plunger reaches the end of its
travel, the solenoid contact disc completes the high-
amperage starter feed circuit and energizes the sole-
noid plunger hold-in coil. Current now flows between
the solenoid battery terminal and the starter motor,
energizing the starter.
Once the engine starts, the overrunning clutch pro-
tects the starter motor from damage by allowing the
8F - 28 STARTING SYSTEMVA

CAMSHAFT POSITION SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 18RD/BL (EXCEPT OBD) CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
3 20RD/BL (OBD) CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
CENTER HIGH MOUNTED STOP LAMP
CAV CIRCUIT FUNCTION
1 16BK/RD BRAKE LAMP SWITCH OUTPUT
2 16BR GROUND
CENTRAL TIMER MODULE C1 - PINK
CAV CIRCUIT FUNCTION
1 16DG/BK DRIVER DOOR UNLOCK SENSE
2 16BL/RD DRIVER DOOR LOCK DRIVER
3 16BK/RD DRIVER DOOR UNLOCK DRIVER
4 16YL/BK DRIVER DOOR LOCK SENSE
5 16DG/BL/WT PASSENGER FRONT DOOR UNLOCK SENSE
6 16YL/BL PASSENGER FRONT DOOR LOCK SENSE
7 16WT/YL MASTER DOOR LOCK SWITCH SENSE-ALL DOORS
8 16RD/BK FUSED D(+) RELAY NO. 1 OUTPUT
9 16WT/BL (EXCEPT VTSS) RKE INTERFACE
9 16WT/BL/RD (VTSS) RKE INTERFACE
10 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
11 16DG ENHANCED ACCIDENT REPORT DRIVER
12 20DG/WT/BL K-CTM/SSM
13 14RD/WT FUSED B(+)
14 14BR GROUND
15 16WT/BK DRIVER DOOR AJAR INDICATOR DRIVER
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29

ENGINE CONTROL MODULE C2 (EXCEPT OBD) - BLACK
CAV CIRCUIT FUNCTION
1- -
2- -
3 18BR/WT HIGH IDLE ON SIGNAL
4- -
5- -
6- -
7 18BR/DG KICKDOWN SWITCH SIGNAL
8- -
9 18BR SENSOR GROUND
10 - -
11 20DG/WT CAN C BUS (+)
12 20DG CAN C BUS (-)
13 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 18DG ACCEL/SET SIGNAL
15 - -
16 18YL DECEL/SET SIGNAL
17 20DG ENHANCED ACCIDENT REPORT DRIVER
18 - -
19 18RD S/C SWITCH 12 VOLT SUPPLY
20 18BL RESUME SIGNAL
21 18BK VERIFICATION SIGNAL
22 18GY OFF SIGNAL
23 - -
24 - -
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTSVA