fuel MERCEDES-BENZ SPRINTER 2006 Owners Manual

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

ENGINE OIL SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20GY/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
FUEL INJECTOR NO. 1 - BLACKCAV CIRCUIT FUNCTION
1 14BK/BL (EXCEPT OBD) FUEL INJECTOR NO. 1 CONTROL
1 16BK/RD (OBD) FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16BL (OBD) FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
FUEL INJECTOR NO. 2 - BLACKCAV CIRCUIT FUNCTION
1 14BK/VT (EXCEPT OBD) FUEL INJECTOR NO. 2 CONTROL
1 16BK/BL (OBD) FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
2 14BL (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 2
2 16BK (OBD) FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
FUEL INJECTOR NO. 3 - BLACKCAV CIRCUIT FUNCTION
1 14BK/RD (EXCEPT OBD) FUEL INJECTOR NO. 3 CONTROL
1 16BK/DG (OBD) FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16DG (OBD) FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
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CONNECTOR PINOUTS

FUEL INJECTOR NO. 4 - BLACKCAV CIRCUIT FUNCTION
1 14BK/YL (EXCEPT OBD) FUEL INJECTOR NO. 4 CONTROL
1 16BK/VT (OBD) FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16BL/WT (OBD) FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL
FUEL INJECTOR NO. 5 - BLACKCAV CIRCUIT FUNCTION
1 14BK/DG (EXCEPT OBD) FUEL INJECTOR NO. 5 CONTROL
1 16BK/YL (OBD) FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
2 14BL (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 2
2 16BK/WT (OBD) FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL
FUEL PRESSURE SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20BR/GY FUEL PRESSURE SENSOR GROUND
2 20DG/VT FUEL PRESSURE SENSOR SIGNAL
3 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
FUEL PRESSURE SOLENOIDCAV CIRCUIT FUNCTION
1 20BK/WT FUEL PRESSURE SOLENOID CONTROL
2 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
FUEL PUMP (OBD)CAV CIRCUIT FUNCTION
1 14BK FUEL PUMP RELAY OUTPUT
2 14BR GROUND
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CONNECTOR PINOUTS

FUEL PUMP RELAY (OBD)CAV CIRCUIT FUNCTION
30 14RD/BK FUSED B(+)
85 18BR/RD FUEL PUMP RELAY CONTROL
86 18BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
87 14BK FUEL PUMP RELAY OUTPUT
87A - -
FUEL QUANTITY CONTROL VALVE (OBD)CAV CIRCUIT FUNCTION
1 20BK/WT FUEL QUANTITY SOLENOID CONTROL
2 18RD/BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY
FUEL TEMPERATURE SENSORCAV CIRCUIT FUNCTION
1 18DG/BK FUEL TEMPERATURE SENSOR GROUND
2 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
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CONNECTOR PINOUTS

FUSED IGNITION SWITCH RUN-START RELAY (RELAY BLOCK)CAV CIRCUIT FUNCTION
30 14RD FUSED B(+)
85 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
86 16BR GROUND
87 14BK/YL FUSED IGNITION SWITCH RUN-START RELAY OUTPUT
87A --
SPEED CONTROL SWITCHCAV CIRCUIT FUNCTION
1 18GY OFF SIGNAL
2 18BK VERIFICATION SIGNAL
3 18BL RESUME SIGNAL
4 18YL DECEL/SET SIGNAL
5 18DG ACCEL/SET SIGNAL
6 18RD S/C SWITCH 12 VOLT SUPPLY
WATER IN FUEL SENSOR - BLACKCAV CIRCUIT FUNCTION
1 18BR WATER IN FUEL SENSOR GROUND
2 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
3 18BK/YL WATER IN FUEL SENSOR SIGNAL
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CONNECTOR PINOUTS

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
7Cooling
8AAudio/Video
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
VAINTRODUCTION 3

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID..........................2
BRAKE FLUID.........................2
HOAT COOLANT.......................2
ENGINE OIL - DIESEL ENGINES...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......5FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........7
MAINTENANCE SCHEDULES
DESCRIPTION..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VALUBRICATION & MAINTENANCE 0 - 1

DaimlerChrysler
Approved En-
gine OilSAE Rating MB Sheet
Number
Mobil Delvac 1 5W-40 228.5
Mobil Delvac
1300 Super (1)15W-40 228.3
Mobil SHC For-
mula MB5W-30 229.5
MOPARTPart
No.
04798231AD15W-40 228.3
Motul 8100 E-
Tech 0W-400W-40 229.3
Motul 8100 X-
cess 5W-405W-40 229.3
Panolin Indy SV 5W-40 229.3
Pennzoil Euro-
pean Formula
Ultra5W-30 229.5
Pennzoil Syn-
thetic European
Formula5W-40 229.3
Premium Syn-
thetik Motorenæl5W-30 229.5
QS Superfleet 15W-40 228.3
Quaker State
European For-
mula Ultra5W-30 229.5
Quaker State
Full Synthetic
European For-
mula5W-40 229.3
Quaker State
Super Series III
(1)15W-40 228.3
Raloy Diesel
Turbo MX15W-40 228.3
Raloy Motor
Diesel15W-40 228.3
Repsol Turbo
UHPD10W-40 228.5
Roshfrans Vol-
tro Diesel (1)15W-40 228.3
Shell Helix Ultra 5W-30 229.3
Shell Helix Ultra 5W-40 229.3
Shell Rimula X
CH-415W-40 228.3
Shell Rimula X
CH-420W-50 228.3DaimlerChrysler
Approved En-
gine OilSAE Rating MB Sheet
Number
Shell Rotella T
Multigrade (1)15W-40 228.3
Super Diesel
Oil MB-315W-40 228.3
Supreme Duty
Diesel Engine
Oil Multi- grade15W-40 228.3
Unoil GX-7 5W-40 229.3
Ursa Premium
TDX10W-30 228.3
Ursa Premium
TDX15W-40 228.3
Valvoline Syn-
Power MXL0W-30 229.3
(1) Engine oil also meets API classification CI-4.
Other oils may meet requirements - see oil label to
determine
Use of the approved fluid is required if the
ASSYST Oil Service Reminder is followed. Use of a
lower quality oil on this service schedule may cause
severe engine damage.
FUEL REQUIREMENTS - DIESEL ENGINE
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use only commercially available vehicular diesel
fuels No. 2 or No. 1 (ASTM D 975 No. 2-D or No.
1-D).
NOTE: Because of its better quality, the manufac-
turer recommends the use of commercially avail-
able vehicular diesel fuel No. 2.
DIESEL FUELS FOR USE AT VERY LOW TEMPERA-
TURE
At very low temperatures, the fluidity of No. 2 die-
sel fuel may become insufficient due to paraffin sep-
eration. For this reason, the vehicle comes equipped
with a fuel preheater. It permits trouble free engine
operation to a temperature of approximately 14ÉF
(-10ÉC) when using No. 2 diesel fuel.
To avoid malfunctions, No. 2 diesel fuel of a low-
ered cloud point is marketed during the cold season.
At temperatures below 14 ÉF (-10 ÉC) use winter-
ized or No. 1 diesel fuel only.
0 - 4 LUBRICATION & MAINTENANCEVA

Do not blend other specific fuel additives with die-
sel fuel. They only result in unnecessary cost, and
may be harmful to the engine operation.
POWER STEERING FLUID
No fluid service required. Filled with Power Steer-
ing Fluid approved to MB 236.3, such as Mobil
ATF-D (Exxon Mobil Corporation) or equivalent.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L without Filter Re-
placement9.5 Quarts with Filter
Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of inter-
nal cooler, length and inside diameter of cooler lines,
or use of an auxiliary cooler, these figures may vary.
(Refer to appropriate 21 - TRANSMISSION/AUTO-
MATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE  .03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to manufac-
turing tolerance and refill procedure
DESCRIPTION SPECIFICATION
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cool-
er options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed proce-
dures.
FLUID FILL / CHECK LOCA-
TIONS
INSPECTION - FLUID FILL / CHECK LOCA-
TIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle. Support the vehicle in the raised
position with jack stands at the front and rear ends
of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
VALUBRICATION & MAINTENANCE 0 - 5