sensor MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Dome Lamp Dome Area 20
Door Jamb Switch-Driver Driver Door 21
Door Jamb Switch-Left
SlidingLeft Sliding Door N/S
Door Jamb Switch-Passenger Passenger Door 21
Door Jamb Switch-Right
SlidingRight Sliding Door N/S
Door Jamb Switch-Tailgate Tailgate N/S
Door Lock Motor/Ajar Switch
Assembly - Driver C1Driver Door 21
Door Lock Motor/Ajar Switch
Assembly - Driver C2Driver Door 21
Door Lock Motor/Ajar Switch
Assembly - Left Sliding C1Left Sliding Door 22
Door Lock Motor/Ajar Switch
Assembly - Left Sliding C2Left Sliding Door 22
Door Lock Motor/Ajar Switch
Assembly - Passenger C1Passenger Door 22
Door Lock Motor/Ajar Switch
Assembly - Passenger C2Passenger Door 22
Door Lock Motor/Ajar Switch
Assembly - Right Sliding C1Right Sliding Door N/S
Door Lock Motor/Ajar Switch
Assembly - Right Sliding C2Right Sliding Door N/S
Door Lock Motor/Ajar Switch
Assembly-Rear C1Cargo Door 25
Door Lock Motor/Ajar Switch
Assembly-Rear C2Cargo Door 25
Dosing Pump Engine Compartment N/S
EGR Valve Engine Compartment 8
Engine Control Module C1 Instrument Panel 12
Engine Control Module C2 Instrument Panel 12
Engine Control Module C3 Instrument Panel 12
Engine Control Module C4 Instrument Panel 12
Engine Control Module C5 Instrument Panel 12
Engine Coolant Level Switch Engine Compartment 2, 3
Engine Coolant Temperature
SensorEngine Compartment 7
Engine Oil Pressure Sensor Engine Compartment 8
Evaporator Temperature
SensorInstrument Panel-Right 15
Fan Stage 1 Relay (Relay
Block)Under Driver Seat N/S
Fog Lamp Relay (Relay
Block)Under Driver Seat N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Fog Lamp Switch Instrument Panel N/S
Fuel Injector No. 1 Engine Compartment 7
Fuel Injector No. 2 Engine Compartment 6,7
Fuel Injector No. 3 Engine Compartment 6,7
Fuel Injector No. 4 Engine Compartment 6,7
Fuel Injector No. 5 Engine Compartment 7
Fuel Level Sensor Underbody-Middle 24
Fuel Pressure Sensor Engine Compartment 6
Fuel Pressure Solenoid Engine Compartment-Rear 5
Fuel Temperature Sensor Engine Compartment 7
Fuse Block No.1 C1 Under Fuse Block No.1 N/S
Fuse Block No.1 C2 Under Fuse Block No.1 N/S
Fuse Block No.1 C3 Under Fuse Block No.1 N/S
Fuse Block No.1 C4 Under Fuse Block No.1 N/S
Fuse Block No.1 C5 Under Fuse Block No.1 N/S
Fuse Block No.1 Control
ModuleUnder Driver Seat N/S
Fuses (Fuse Block No. 1) Steering Column 13
Fuses (Fuse Block No. 2) Under Driver Seat 17
Fuses (Fuse Block No. 3) Under Driver Seat N/S
Fuses (Fuse/Relay Block) Under Driver Seat 17,18
Fuses (PDC) Battery Area 3
Generator No.1 Engine Compartment N/S
Generator No.2 Engine Compartment-Right 2,8
Glow Plug Control Module C1 Engine Compartment-Left Front 1
Glow Plug Control Module C2 Engine Compartment-Left Front 1
Glow Plug No. 1 On Engine N/S
Glow Plug No. 2 On Engine N/S
Glow Plug No. 3 On Engine N/S
Glow Plug No. 4 On Engine N/S
Glow Plug No. 5 On Engine N/S
Headlamp Adjust Switch Instrument Panel N/S
Headlamp Assembly-Left On Front Of Vehicle (Left Side) N/S
Headlamp Assembly-Right On Front Of Vehicle (Right Side) N/S
Heat Exchanger Connector Instrument Panel N/S
Heat Exchanger Switch Engine Compartment N/S
Heated Seat Module-Driver Under Driver Seat N/S
Heated Seat Module-
PassengerUnder Passenger Seat N/S
Heated Seat Switch-Driver On Driver Seat N/S
Heated Seat Switch-
PassengerOn Passenger Seat N/S
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Heater Relay-Auxiliary Under Driver Seat N/S
Heater Timer-Auxiliary Under Driver Seat N/S
High Pressure Pump Shutoff
ValveEngine Compartment 6
Hood Ajar Switch Engine Compartment N/S
Horn Engine Compartment N/S
Horn C1 Engine Compartment N/S
Horn C2 Engine Compartment N/S
Horn Relay (Relay Block) Under Driver Seat N/S
Horn-Switch Steering Wheel 10
Ignition Lock Switch Steering Column N/S
Instrument Cluster C1 Instrument Panel 10
Instrument Cluster C2 Instrument Panel 10
Instrument Panel Socket Instrument Panel N/S
Intake Air Temperature
SensorEngine Compartment-Left 5
Interior Lamp No. 1 Headliner-Front 20
Interior Lamp No. 2 Headliner-Front 20
Interior Lamp No. 3 Headliner-Front 20
Interior Lamp No. 4 Headliner-Front 20
Interior Lamp No. 5 Headliner-Front 20
Interior Lamp-Left Left Upper Side 20
Interior Lamp-Middle Front Headliner-Front 20
Interior Lamp-Middle Rear Headliner Middle Rear N/S
Interior Lamp-Rear No. 1 Headliner-Rear 20
Interior Lamp-Rear No. 2 Headliner-Rear 20
Interior Lamp-Right Right Upper Side 20
Interior Lamp-Right Center Headliner-Rear 20
Interior Light Switch Instrument Panel N/S
Interior Light Switch-Driver Driver Side Of Vehicle N/S
Interior Light Switch-
Passenger SidePassenger Side Of Vehicle N/S
Interior Light Switch-Rear Rear Side Of Vehicle N/S
Interior Lighting Connector Instrument Panel N/S
Intrusion Sensor No. 1 Headliner-Front Body 23
Intrusion Sensor No. 2 Headliner-Front Body 23
Intrusion Sensor No. 3 Headliner-Rear Body 23
K138 Relay (Relay Block) Under Driver Seat N/S
K78 Relay (Relay Block) Under Driver Seat N/S
K79 Relay (Relay Block) Under Driver Seat N/S
Kick Down Switch Instrument Panel N/S
Lamp Relay-Left Under Driver Seat N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Lamp Relay-Right Under Driver Seat N/S
License Plate Lamp No. 1 On Rear Of Vehicle N/S
License Plate Lamp No. 2 On Rear Of Vehicle N/S
Locker Switch No. 1 Under Body-Front N/S
Locker Switch No. 2 Under Body-Rear 24
Low Fuel Pressure Sensor Engine Compartment 6,8
Map/Reading Lamp Switch Instrument Panel N/S
Marker Lamp No.1-Left Front Front Of Vehicle-Left Side N/S
Marker Lamp No.2-Left Front Front Of Vehicle-Left Side N/S
Marker Lamp-Left Center Front Of Vehicle-Center Left Side N/S
Marker Lamp-Left Rear Rear Of Vehicle-Left Side N/S
Marker Lamp-Right Center Front Of Vehicle-Center Right Side N/S
Marker Lamp-Right Rear Rear Of Vehicle -Right Side N/S
Mass Air Flow Sensor Engine Compartment 5
Master Door Lock Switch Center Of Instrument Panel N/S
Metering Pump Instrument Panel N/S
Microphone Connector Instrument Panel N/S
Multi-Function Switch Steering Wheel 11
Optional Equipment Relay
(Relay Block)Under Driver Seat N/S
Panic Alarm Switch Instrument Panel N/S
Parking Brake Switch Under Instrument Panel 23
Power Mirror Motor-Driver In Driver Door N/S
Power Mirror Motor-
PassengerIn Passenger Door N/S
Power Mirror Switch On Driver Door N/S
Power Mirror-Driver On Driver Door N/S
Power Mirror-Master On Driver Door N/S
Power Mirror-Passenger On Passenger Door N/S
Power Window Motor-Driver In Driver Door N/S
Power Window Motor-
PassengerIn Passenger Door N/S
Power Window Switch-Driver On Driver Door N/S
Power Window Switch-Master On Driver Door N/S
Power Window Switch-
PassengerOn Passenger Door N/S
Radio Antenna Behind Radio N/S
Radio C1 Behind Radio N/S
Radio C2 Behind Radio N/S
Radio/Cellular Antenna Behind Radio N/S
Reading Lamp Connector Instrument Panel N/S
Recirculated Air Solenoid
ValveUnderhood Right (To The
Instrument Panel)4
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Refrigerant Pressure Sensor Engine Compartment-Left Front 3,4
Relay Block Under Driver Seat 18
Remote Keyless Entry
AntennaNear Remote Keyless Entry
ModuleN/S
Remote Keyless Entry
ModuleInstrument Panel N/S
Roof Fan Motor In Headliner N/S
S165 Middle Of Vehicle N/S
Seat Belt Switch Driver Seat Belt Lock N/S
Seat Belt Tensioner-Driver Driver Seat-Back 16
Seat Belt Tensioner-
PassengerPassenger Seat-Back 16
Security System Module C1 Instrument Panel N/S
Security System Module C2 Instrument Panel N/S
Sentry Key Remote Entry
Module (SKREEM)Instrument Panel N/S
Shifter Assembly Center Console 12
Side Marker Lamp Connector Engine Compartment N/S
Siren Engine Compartment-Left 1
Speaker-Left Front Door
Assembly C1Engine Compartment-Left N/S
Speaker-Left Front Door
Assembly C2In Left Front Door N/S
Speaker-Left Rear Rear Of Vehicle On Left Side N/S
Speaker-Right Front Door In Right Front Door N/S
Speaker-Right Rear Rear Of Vehicle On Right Side N/S
Speed Control Switch Steering Wheel Controls 10
Starter Motor On Engine N/S
Starter Motor Relay
(Fuse/Relay Block)In Fuse/Relay Block N/S
Tail Lamp Assembly-Left Rear Of Vehicle On Left Side N/S
Tail Lamp Assembly-Right Rear Of Vehicle On Right Side N/S
TCS Switch (ASR) Center Of Instrument Panel N/S
Temperature Switch Instrument Panel N/S
Time Delay Relay Under Driver Seat N/S
Towing/Interior Motion Sensor Instrument Panel N/S
Trailer Tow Connector Under Rear Of Vehicle N/S
Trailer Tow Control Module
C1Rear Of Vehicle N/S
Trailer Tow Control Module
C2Rear Of Vehicle N/S
Transmission Control Module
C1Engine Compartment N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Transmission Control Module
C2Engine Compartment N/S
Transmission Control Relay
(Fuse Block No. 1)In Fuse Block No.1 N/S
Transmission Solenoid
AssemblyTransmission 9
Turn Signal Lamp No.1-Left
FrontFront Of Vehicle On Left Side N/S
Turn Signal Lamp No.1-Right
FrontFront Of Vehicle On Right Side N/S
Turn Signal Lamp No.2-Left
FrontFront Of Vehicle On The Left Side N/S
Turn Signal Lamp No.2-Right
FrontFront Of Vehicle On The Right
SideN/S
Turn Signal Relay (Fuse
Block No. 1)In Fuse Block No.1 N/S
Turn Signal/Anti-Theft Alarm
Relay-Left (Relay Block)Under Driver Seat N/S
Turn Signal/Anti-Theft Alarm
Relay-Right (Relay Block)Under Driver Seat N/S
Warm Air Auxiliary Heater
Assembly C1Instrument Panel 15
Warm Air Auxiliary Heater
Assembly C2Instrument Panel 15
Washer Pump Motor-Front Engine Compartment N/S
Wastegate Solenoid Engine Compartment N/S
Water Cycle Valve Underhood (To The Instrument
Panel)4
Water In Fuel Sensor Engine Compartment 8
Wheel Speed Sensor-Left
FrontLeft Front Wheel 2
Wheel Speed Sensor-Left
RearLeft Rear Wheel 2
Wheel Speed Sensor-Right
FrontRight Front Wheel N/S
Wheel Speed Sensor-Right
RearRight Rear Wheel N/S
Window Defogger Module -
RearRear Of Vehicle N/S
Window Defogger Relay-Left
Rear (Relay Block)Under Driver Seat N/S
Window Defogger Relay-
Right Rear (Relay Block)Under Driver Seat N/S
Window Defogger Switch -
RearInstrument Panel N/S
Window Defogger-Left Rear On Left Rear Window N/S
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S305 Near Power Window Motor-Driver N/S
S306 Near Locker Switch No.2 N/S
S307 Near Fuse/Relay Block N/S
S308 Near Interior Lamp No.3 N/S
S309 Near Interior Lamp-Right N/S
S310 Near Fuse Block No.2 N/S
S311 Under Drivers Seat 19
S312 Near Wheel Speed Sensor-Left Rear N/S
S313 Near Wheel Speed Sensor-Left Rear N/S
S314 Near Wheel Speed Sensor-Right Rear N/S
S315 Near Wheel Speed Sensor-Right Rear N/S
S316 Near Headlamp Assembly-Left N/S
S317 Engine Compartment N/S
S318 Near Marker Lamp-Left Rear N/S
S319 Near Tail Lamp Assembly-Left N/S
S320 Under Body-Rear Center 24
S321 Near Power Window Switch-Passenger N/S
S322 Instrument Panel N/S
S323 Near Brake Wear Sensor-Left Rear N/S
S324 Near Interior Lamp No.3 N/S
S325 Near Map/Reading Lamp Switch N/S
S326 Top Body- Front Center 20
S327 Near Security System Module N/S
S328 Near Central Timer Module N/S
S329 Near Central Timer Module N/S
S330 Near Security System Module N/S
S331 Near Security System Module N/S
S332 Near Brake Wear Sensor-Left Rear N/S
S332 Near K26 N/S
S350 Near Trailer Tow Connector N/S
S351 Near Trailer Tow Control Module N/S
S352 Near Trailer Tow Control Module N/S
S353 Near Dome Lamp N/S
S354 Body-Upper Right Center 20
S355 Near Window Defogger Module-Rear N/S
S356 Near Headlamp Assembly-Left N/S
S356 Near Central Timer Module N/S
S357 Near Central Timer Module N/S
S358 Near Trailer Tow Control Module N/S
S359 Near Interior Light Switch-Passenger N/S
S360 Near Interior Light Switch-Rear N/S
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

LEFT MOUNT
REMOVAL.............................49
INSTALLATION.........................49
RIGHT MOUNT
REMOVAL.............................49
INSTALLATION.........................49
OIL
REMOVAL - OIL SEPARATOR..............50
INSTALLATION - OIL SEPARATOR..........50
OIL COOLER & LINES
REMOVAL.............................50
INSTALLATION.........................50
OIL FILTER
REMOVAL.............................51
INSTALLATION.........................51
OIL JET
DESCRIPTION.........................51
REMOVAL.............................51
INSTALLATION.........................51
OIL PAN
REMOVAL.............................52
INSTALLATION.........................52
OIL PUMP
REMOVAL
REMOVAL...........................53
REMOVAL- OIL PUMP CHAIN............53
INSTALLATION
INSTALLATION.......................54
INSTALLATION - OIL PUMP CHAIN........54
OIL TEMPERATURE SENSOR
DESCRIPTION.........................56OPERATION...........................56
REMOVAL.............................57
INSTALLATION.........................57
INTAKE MANIFOLD
REMOVAL.............................57
INSTALLATION.........................58
EXHAUST MANIFOLD
REMOVAL.............................59
INSTALLATION.........................59
TIMING CHAIN COVER
REMOVAL.............................59
INSTALLATION.........................60
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TENSIONING AND SLIDE
RAILS..............................61
REMOVAL - INTERMEDIATE GEAR........61
REMOVAL - TIMING CHAIN TENSIONING
RAIL...............................63
REMOVAL - TIMING CHAIN..............63
INSTALLATION
INSTALLATION - TENSIONING AND SLIDE
RAIL...............................66
INSTALLATION - INTERMEDIATE GEAR....66
INSTALLATION - TIMING CHAIN
TENSIONING RAIL....................66
ADJUSTMENTS
INSTALLATION - TIMING CHAIN..........67
TIMING CHAIN TENSIONER
REMOVAL.............................70
INSTALLATION.........................71
ENGINE
DESCRIPTION
This 2.7 Liter five-cylinder Common Rail Diesel
Injection (CDI) engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has for valve per cylinder and dual overhead
camshafts (Fig. 1).
Fig. 1 2.7L CDI Engine
9 - 2 ENGINEVA

(15) Disconnect the coolant hose of the heater sup-
ply at the coolant pipe at the side of the cylinder
head (Fig. 3).
(16) Disconnect the vacuum hose at the turbo-
charger (Fig. 3).
(17) Disconnect the air inlet hose at the turbo-
charger (Fig. 3).
(18) Raise and support the vehicle.
(19) Disconnect the front exhaust at the turbo-
charger.
(20) Disconnect the electrical connector at the
transmission (Fig. 4).
(21) Disconnect the locking clamp, shifter cable
and the security catch for the shifter cable (Fig. 4)
(22) Remove the steering gear mounting bolts.
(23) Disconnect the transmission cooler lines at
transmission.
(24) Remove the torque converter access plate.
(25) Remove the torque converter bolts.
(26) Remove the crank position sensor.
(27) Remove the transmission housing to engine
mounting bolts.
(28) Remove the starter mounting bolts.
(29) Support the transmission with a transmission
jack.(30) Place a wood block between the transmission
housing and the front frame cross over.
(31) Remove the transmission jack.
(32) Remove the exhaust bracket (right side).
(33) Remove the engine ground strap (left side).
(34) Lower the vehicle.
(35) Remove the heater housing filter and lower
housing.
(36) Connect the engine lifting fixture to the lifting
eyes. (Fig. 5).
(37) Remove the engine mount bolts.
(38) Remove the transmission oil level indicator
tube mounting bolt.
NOTE: After removing the front cross plate, seal
metal with anti corrosion protection.
(39) Using tin snips, remove the front cross plate
at the cutting edges and deburr (Fig. 6).
(40) Connect and engine hoist and carefully lift
engine assembly from engine bay area (Fig. 7).
Fig. 4 TRANSMISSION CONNECTIONS
1 - TRANSMISSION CONNECTOR 4 - LOCKING CLAMP
2 - REAR ENGINE SUPPORT 5 - LINKAGE ROD
3 - BALL SOCKET 6 - BRACKET
9 - 6 ENGINEVA
ENGINE (Continued)

(11) Install the transmission cooler lines to trans-
mission.(Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(12) 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.
(13) 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.
(14) Install the crank sensor.
(15) Install the starter.
(16) Connect the ground strap (left side).
(17) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(18) Lower the vehicle.
(19) Install the air inlet hose at the turbocharger
(Fig. 3).
(20) Connect the vacuum hose at the turbocharger
(Fig. 3).
(21) Connect the coolant supply and return hoses
(Fig. 3).(22) Connect the brake booster vacuum hose at the
vacuum pump (Fig. 3).
(23) Connect the refrigerant lines (Fig. 3).
(24) Connect the fuel lines at the filter assembly
(Fig. 3).
(25) Connect the power steering hoses (Fig. 3).
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser.
(28) Install air cleaner housing, sensors, and hoses
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).
(29) Route the engine wiring harness inside the
vehicle and connect.
(30) Install the front grill assembly.
(31) Install and align the hood.
(32) Connect the negative battery cable.
(33) Check and fill engine oil.
(34) Fill cooling system to proper level with the
appropriate coolant.
(35) Evacuate and recharge air conditioning.
(36) Check and refill all ancillary system fluid lev-
els.
(37) Start engine and inspect for leaks.
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge
Distribution Pipe to Air
Charge Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to
Cylinder Head14 - 124
12m-Bolt-Cylinder Head to
Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44 -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque
angle)55, 90É 40 -
Bolt-End Cover to
Crankcase9-80
9 - 8 ENGINEVA
ENGINE (Continued)