MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED SEATS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - HEATED SEATS . . 2
DRIVER HEATED SEAT SWITCH
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH.........................2
REMOVAL.............................3
INSTALLATION..........................3
HEATED SEAT ELEMENT
DESCRIPTION..........................3
OPERATION............................3
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENT............................3
HEATED SEAT RELAY
DESCRIPTION..........................4OPERATION............................4
DIAGNOSIS AND TESTING - HEATED SEAT
RELAY...............................4
REMOVAL.............................4
INSTALLATION..........................4
HEATED SEAT SENSOR
DESCRIPTION..........................4
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR.............................4
PASSENGER HEATED SEAT SWITCH
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH.................5
REMOVAL.............................5
INSTALLATION..........................5
HEATED SEATS
DESCRIPTION
Individually controlled, electrically heated front
seats are available factory-installed optional equip-
ment on this model. Vehicles with this option can be
visually identified by the two separate heated seat
switches mounted in the instrument panel. The
heated seat system allows the front seat driver and
passenger to select from two different levels of sup-
plemental electrical seat heating, or no seat heating
to suit their individual comfort requirements. The
heated seat system for this vehicle includes the fol-
lowing major components, which are described in fur-
ther detail later in this section:
²Heated Seat Elements- Four heated seat ele-
ments are used per vehicle, two for each front seat.
One heating element in the seat back and one in the
seat cushion. The heated seat sensor is integral to
the seat cushion heating element. The heated seat
elements are integral to the front seat and seat back
cushions. Refer to heated seat elements later in this
section for additional information.²Heated Seat Relay- One heated seat relay is
used per vehicle. The relay is located in the fuse
block and is responsible for distributing the voltage
(B+) to the heated seat elements.
²Heated Seat Sensors- Two heated seat sen-
sors are used per vehicle, one for each front seat. The
heated seat sensors are integral to each of the heated
seat element assemblies. Refer to heated seat sensor
later in this section for additional information.
²Heated Seat Switches- Two heated seat
switches are used per vehicle, one for each front seat.
The switches are mounted in the instrument panel.
Refer to heated seat switches later in this section for
additional information.
Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. Refer to Wiring for additional
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce-
dures, further details on wire harness routing and
retention, as well as pin-out and location views for
the various wire harness connectors, splices and
grounds.
VAHEATED SYSTEMS 8G - 1

OPERATION
The heated seat system is designed to provide indi-
vidually controlled, supplemental heat to the seat
cushion and seat back surfaces of both front seats.
Because this system converts electrical current to
heat, the heated seat system can provide a measure
of warm comfort almost immediately upon entering a
cold vehicle, rather than having to wait for the
engine coolant to reach sufficient temperature to
deliver heat through the conventional heater system.
This system allows each front seat occupant to indi-
vidually select one of two comfort levels, Hi or Lo, or
to turn the heater for their seat off.
The heated seat system components operate on
battery current received through a fuse in the Fuse
Block on a fused ignition switch output (run-acc) cir-
cuit so that the system will only operate when theignition switch is in the On or Accessory positions.
The heated seat system will be turned Off automati-
cally whenever the ignition switch is turned to any
position except On or Accessory. Also, the heated seat
system will not operate when the surface tempera-
ture of the seat cushion cover at either heated seat
sensor is above the designed temperature set points
of the system.
DIAGNOSIS AND TESTING - HEATED SEATS
Refer toWiringfor the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
HEATED SEAT SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO HEATED SEAT SWITCH
ILLUMINATION WITH
IGNITION ON1. Faulty fuse. 1. Check heated seat fuse in Fuse Block.
Replace fuse, if required.
2. Wiring faulty. 2. Check fused ignition switch output (run-acc)
circuit from heated seat switch connector to
ignition switch. Repair, if required.
3. Ground faulty. 3. Check for ground at heated seat switch
connector. Repair, if required.
4. Faulty switch. 4. Refer to Heated Seat Switch for the proper
switch diagnosis and testing procedures.
DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are located on the instru-
ment panel, in the accessory switch bezel. The two,
momentary rocker type switches provide a signal to
the Heated Seat Relay through separate hard wired
circuits. Each switch contains two light emitting
diodes (LED), one for each High and Low setting to
let the occupant know that the seat heater system is
on.
The heated seat switches and their LED's cannot
be repaired. If either switch is faulty or damaged the
entire switch must be replaced.
OPERATION
There are three modes that can be selected with
each of the heated seat switches: Off, Low, and High.
When the top of the switch rocker is depressed, the
low mode is selected and the low mode LED indicator
illuminates. Depressing the top of the switch rocker asecond time will turn the heated seat to Off. This
same process is repeated for High heat setting. The
heated seats will automatically return to the Off
mode anytime the vehicle ignition switch is turned
Off.
Both switches provide separate hard wire inputs to
the Heated Seat Relay to indicate the selected mode.
The Heated Seat Relay responds to the heated seat
switch messages by controlling the output to the seat
heater elements of the selected seat.
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
For circuit description and diagrams, refer toWir-
ing.
(1) Inspect the Heated Seat Switches for apparent
damage or sticking/binding and replace if required.
Refer to Heated Seat Switch Removal and Installa-
tion in this section.
(2) Replace the heated seat switch with a known
good unit and retest the heated seat system.
8G - 2 HEATED SYSTEMSVA
HEATED SEATS (Continued)

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the gear selector bezel trim. Refer to
the Body section for the procedure.
(3) Remove the storage bin. Refer to the Body sec-
tion for the procedure.
(4) Remove the switch bezel retaining screw and
remove the switch bezel from the instrument panel.
Refer to the Body section for the procedure.
(5) Disconnect electrical connections.
(6) Working from the underside of the switch, gen-
tly rock the switch back and forth out of its mounting
location in the switch bezel.
INSTALLATION
(1) Install the heated seat switch in its mounting
location in the switch bezel.
(2) Connect electrical connections.
(3) Position the switch bezel and install the retain-
ing screw. Refer to the Body section for the proce-
dure.
(4) Install the storage bin. Refer to the Body sec-
tion for the procedure.
(5) Install the gear selector bezel trim. Refer to the
Body section for the procedure.
(6) Connect the negative battery cable.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system includes two seat heating
elements in each front seat, one for the seat cushion
(Fig. 1) and the other for the seat back. All models
use two resistor wire heating elements for each seat
that are connected in series with the Heated Seat
Relay. The temperature sensor is a Negative Temper-
ature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is located in the
seat cushion heating element for all models.
The seat heating elements are glued onto the seat
and seat back cushions. The heated seat elements
and the temperature sensor cannot be adjusted or
repaired and, if faulty or damaged a new seat assem-
bly must be installed.
OPERATION
The heated seat elements resist the flow of electri-
cal current. When battery current is passed through
the elements, the energy lost by the resistance of the
elements is released in the form of heat. The heated
seat temperature sensor is a NTC thermistor. When
the temperature of the seat cushion cover rises, the
resistance of the sensor decreases. The heated seat
relay uses this temperature sensor input to monitorthe temperature of the seat, and regulates the cur-
rent flow to the seat heating elements accordingly.
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENT
For complete circuit diagrams, refer toWiring.
NOTE: When checking heated seat elements for
continuity, be certain to move the heating element
being checked. Moving the element, such as sitting
in the seat will eliminate the possibility of an inter-
mittent open in the element which would only be
evident if the element was in a certain position.
Failure to check the element in various positions
could result in an incomplete test.
(1) Disconnect and isolate the battery negative
cable. Disconnect the heated seat element wire har-
ness connector from under the seat cushion. Check
for continuity between the seat heater driver circuit
and ground. There should be continuity, less than 7
ohms. If OK, go to Step 2. If not OK, replace the seat
assembly.
(2) Check for continuity between the seat heater
B+ driver circuit cavity and the seat back frame.
There should benocontinuity. If OK, heating ele-
ment is OK at this time. If not OK, replace the seat
assembly.
Fig. 1 Heated Seat Element - Typical
1 - Seat Back Wire Harness
2 - Heated Seat Wire Harness Connector
3 - Heated Seat Cushion Element
VAHEATED SYSTEMS 8G - 3
DRIVER HEATED SEAT SWITCH (Continued)

HEATED SEAT RELAY
DESCRIPTION
The heated seat relay is an electromechanical
device that switches 12v battery current to the
heated seat elements when the relay control coil is
energized. The heated seat relay is located in the
Fuse Block, under the drivers seat. The heated seat
relay is a International Standards Organization
(ISO) relay. Relays conforming to the ISO specifica-
tions have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
The heated seat relay cannot be repaired or
adjusted and, if faulty or damaged, it must be
replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact. When the electromagnetic coil is de-ener-
gized, spring pressure returns the movable contact to
the normally closed position. The resistor or diode is
connected in parallel with the electromagnetic coil in
the relay, and helps to dissipate voltage spikes that
are produced when the coil is de-energized.
DIAGNOSIS AND TESTING - HEATED SEAT
RELAY
The heated seat relay is located in the Fuse Block,
under the drivers seat. Refer toWiringfor the loca-
tion of complete heated seat system wiring diagrams.
(1) Remove the heated seat relay from the fuse
block.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, check the relay supply circuits. If not
OK, replace the faulty relay.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) The heated seat relay is located in the fuse
block, under the drivers seat. Refer to wiring for
detailed location.
(3) Grasp the heated seat relay firmly and pull it
straight out from the fuse block. A slight rocking
motion will aid in removal.
INSTALLATION
(1) Grasp the heated seat relay firmly and push it
straight in the fuse block.
(2) Reconnect the battery negative cable.
HEATED SEAT SENSOR
DESCRIPTION
The heated seat temperature sensor is a Negative
Temperature Coefficient (NTC) thermistor. One tem-
perature sensor is used for each seat. The sensor is
located in the seat cushion heating element for all
models.
The heated seat sensor cannot be adjusted or
repaired and if it is found to be faulty, the complete
heated seat element must be replaced.
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring.
NOTE: Any resistance values (ohmsV) given in the
following text are supplied using the automatic
range generated by a FLUKETautomotive meter. If
another type of measuring device is used the val-
ues generated may not be the same as the results
shown here, or may have to be converted to the
range used here.
(1) Backprobe the heated seat relay wire harness
connector, do not disconnect. Using an voltmeter,
check the voltage of the seat temperature sensor
input cavity of the heated seat relay wire harness
connector. The seat sensor input voltage should be
between 1.7 volts and 3.0 volts with the system ON.
If OK, sensor is OK at this time. If not OK, replace
the faulty seat cushion heating element and sensor
assembly.
8G - 4 HEATED SYSTEMSVA

PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are located on the instru-
ment panel, in the accessory switch bezel. The two,
momentary rocker type switches provide a signal to
the Heated Seat Relay through separate hard wired
circuits. Each switch contains two light emitting
diodes (LED), one for each High and Low setting to
let the occupant know that the seat heater system is
on.
The heated seat switches and their LED's cannot
be repaired. If either switch is faulty or damaged the
entire switch must be replaced.
OPERATION
There are three modes that can be selected with
each of the heated seat switches: Off, Low, and High.
When the top of the switch rocker is depressed, the
low mode is selected and the low mode LED indicator
illuminates. Depressing the top of the switch rocker a
second time will turn the heated seat to Off. This
same process is repeated for High heat setting. The
heated seats will automatically return to the Off
mode anytime the vehicle ignition switch is turned
Off.
Both switches provide separate hard wire inputs to
the Heated Seat Relay to indicate the selected mode.
The Heated Seat Relay responds to the heated seat
switch messages by controlling the output to the seat
heater elements of the selected seat.
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH
For circuit description and diagrams, refer toWir-
ing.
(1) Inspect the Heated Seat Switches for apparent
damage or sticking/binding and replace if required.
Refer to Heated Seat Switch Removal and Installa-
tion in this section.
(2) Replace the heated seat switch with a known
good unit and retest the heated seat system.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the gear selector bezel trim. Refer to
the Body section for the procedure.
(3) Remove the storage bin. Refer to the Body sec-
tion for the procedure.
(4) Remove the switch bezel retaining screw and
remove the switch bezel from the instrument panel.
Refer to the Body section for the procedure.
(5) Disconnect electrical connections.
(6) Working from the underside of the switch, gen-
tly rock the switch back and forth out of its mounting
location in the switch bezel.
INSTALLATION
(1) Install the heated seat switch in its mounting
location in the switch bezel.
(2) Connect electrical connections.
(3) Position the switch bezel and install the retain-
ing screw. Refer to the Body section for the proce-
dure.
(4) Install the storage bin. Refer to the Body sec-
tion for the procedure.
(5) Install the gear selector bezel trim. Refer to the
Body section for the procedure.
(6) Connect the negative battery cable.
VAHEATED SYSTEMS 8G - 5

HORN
TABLE OF CONTENTS
page page
HORN
REMOVAL.............................1
INSTALLATION..........................1HORN SWITCH
REMOVAL.............................1
INSTALLATION..........................1
HORN
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connectors.
(3) Remove the mounting fastener and horns.
INSTALLATION
(1) Position horns and install mounting fasteners.
(2) Connect wire harness connector.
(3) Connect battery negative cable.
HORN SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.(2) Remove the drivers side airbag (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
REMOVAL).
(3) Remove the electrical harness connector.
(4) Remove the mounting fasteners and horn
switch.
INSTALLATION
(1) Connect the wire harness connector.
(2) Position the horn switch and install the mount-
ing fasteners.
(3) Install the drivers side airbag (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
(4) Connect the battery negative cable.
VAHORN 8H - 1

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
SPECIAL TOOLS........................1
GLOW PLUG
REMOVAL.............................1
INSTALLATION..........................1GLOW PLUG RELAY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - GLOW PLUG
RELAYS..............................2
IGNITION CONTROL
SPECIAL TOOLS
GLOW PLUG
REMOVAL
(1) Disconnect the negative battery cable.
(2) Use special tool #9286 pliers to unplug the
glow plug wiring harness connector(s).
(3) Remove the glow plug(s) (Fig. 1).
INSTALLATION
(1) Screw glow plug(s) into cylinder head and
tighten to 12 N´m (115 lbs. in) (Fig. 1).
(2) Connect the glow plug wiring harness connec-
tor(s)
(3) Connect negative battery cable.
GLOW PLUG PLIERS
VAIGNITION CONTROL 8I - 1

GLOW PLUG RELAY
DESCRIPTION
The glow plug relay supplies battery voltage to the
glow plug through a timed cycle that is related to
coolant temperature. The glow plug relay is located
under the battery. The purpose of a glow plug system
is to improve combustion for low emissions and to
achieve easy starting at low temperatures.
OPERATION
When the ignition key is turned to the ON position,
the glow plug output stage and pre-glow indicator
lamp are actuated by the ECM. The duration of the
signal depends on the coolant temperature. The glow
plug relay has processing that communicates with the
ECM. If no data exchange occurs at the triggering
stage, the preheating is switched off after 2 seconds.
Start glowing is initiated when the key is in the
start position. The glow plugs (R13±R17) continue to
be supplied with voltage. This makes it possible to
stabilize the cold starting speed. (After glowing is ini-
tiated when the starter reject speed is reached).
After the engine starts, the ECM determines the
afterglow period in line with coolant temperature. If
no signal is received from the coolant temperature
sensor, afterglow is maintained for thirty seconds.
The following aims are reached by the afterglow :²Improvement in warming-up properties
²
Prevention of white exhaust smoke after cold start
²Stabilizing of the cold starting speed
The glow plug output stage constantly signals the
current operating state and faults. The following are
faults detected and transmitted to the ECM :
²Open circuit at one or several glow plugs
²Short circuit in the glow plug circuit
²Relay fault
If the Glow plug relay detects an open circuit at a
glow plug, it is stored and indicated only once the
engine is running by the preglow indicator lamp com-
ing on for about one minute and a fault is stored in
the ECM. If a short circuit, a glow plug output stage
faulty or a temperature related switching off of out-
put stages is detected, the fault is stored and indi-
cated immediately by the preglow indicator lamp
coming on. Once the fault is no longer current, the
indicator is immediately switched off, but the fault is
stored in the ECM. If the fault is constantly current,
the preglow indicator lamp remains on until the igni-
tion is switched off.
DIAGNOSIS AND TESTING - GLOW PLUG
RELAYS
Refer to the appropriate Diesel Powertrain Diagno-
sis Manual for information on diagnosing the glow
plug relays.
Fig. 1 GLOW PLUG(S)
1 - GLOW PLUG
2 - WIRING HARNESS CONNECTOR3 - INTAKE MANIFOLD
4 - CYLINDER HEAD COVER
8I - 2 IGNITION CONTROLVA
GLOW PLUG (Continued)