MERCEDES-BENZ SPRINTER 2006 Service Manual

8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
HOW TO USE WIRING DIAGRAMS.........1
CIRCUIT INFORMATION.................5
SECTION IDENTIFICATION AND
INFORMATION........................5
CONNECTOR, GROUND, AND SPLICE
INFORMATION........................5
WARNINGS - GENERAL...................6
DIAGNOSIS AND TESTING
WIRING HARNESS.....................6
STANDARD PROCEDURE
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES...................7
TESTING FOR VOLTAGE POTENTIAL.......7
TESTING FOR CONTINUITY..............7
TESTING FOR A SHORT TO GROUND......8TESTING COMPONENTS FOR A SHORT TO
GROUND ON A FUSE POWERING
SEVERAL LOADS......................8
TESTING FOR A VOLTAGE DROP.........8
CONNECTOR
REMOVAL.............................9
INSTALLATION..........................9
DIODE
REMOVAL.............................9
INSTALLATION..........................9
TERMINAL
REMOVAL.............................10
INSTALLATION.........................10
WIRE
STANDARD PROCEDURE
WIRE SPLICING......................10
WIRING DIAGRAM INFORMA-
TION
DESCRIPTION
HOW TO USE WIRING DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are
designed to provide information regarding the vehi-
cles wiring content. In order to effectively use the
wiring diagrams to diagnose and repair
DaimlerChrysler Corporation vehicles, it is important
to understand all of their features and characteris-
tics.
Diagrams are arranged such that the power (B+)
side of the circuit is placed near the top of the page,
and the ground (B-) side of the circuit is placed near
the bottom of the page (Fig. 1).
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition (Fig. 2).Components are shown two ways. A solid line
around a component indicates that the component is
complete. A dashed line around the component indi-
cates that the component is being shown is not com-
plete. Incomplete components have a reference
number to indicate the page where the component is
shown complete.
It is important to realize that no attempt is made
on the diagrams to represent components and wiring
as they appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. In
addition, switches and other components are shown
as simply as possible, with regard to function only.
SYMBOLS
International symbols are used throughout the wir-
ing diagrams. These symbols are consistent with
those being used around the world (Fig. 3).
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Fig. 1 WIRING DIAGRAM EXAMPLE 1
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Fig. 2 WIRING DIAGRAM EXAMPLE 2
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Fig. 3 Wiring Diagram Symbols
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TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD.................Left Hand Drive Vehicles
RHD ...............Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX . . . Manual Transmissions-Front Wheel Drive
AT....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC..........Double Over Head Cam Engine
Built-Up-Export....... Vehicles Built For Sale In
Markets Other Than North America
Except Built-Up-Export . Vehicles Built For Sale In
North America
CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies gage of wire, and color.
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
SECTION IDENTIFICATION AND INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections thesplices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru 8W-
09General information and Diagram
Overview
8W-10 thru 8W-
19Main Sources of Power and Ve-
hicle Grounding
8W-20 thru 8W-
29Starting and Charging
8W-30 thru 8W-
39Powertrain/Drivetrain Systems
8W-40 thru 8W-
49Body Electrical items and A/C
8W-50 thru 8W-
59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru 8W-
69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
CONNECTOR, GROUND, AND SPLICE INFOR-
MATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
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²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING
WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle's
electrical system can cause damage to the equip-
ment and provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 4). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
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INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly, check the following items.
²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully
seated into the connector/component and locked into
position
²Dirt or corrosion on the terminals. Any amount
of corrosion or dirt could cause an intermittent prob-
lem
²Damaged connector/component casing exposing
the item to dirt or moisture
²Wire insulation that has rubbed through causing
a short to ground
²Some or all of the wiring strands broken inside
of the insulation
²Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem area.(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.
STANDARD PROCEDURE
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 5) is used to indicate this. When han-
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part form it's protective
packing until it is time to install the part.
(5) Before removing the part from it's pakage,
ground the pakage to a known good ground on the
vehicle.
TESTING FOR VOLTAGE POTENTIAL
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 6).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the circuit being checked
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 7).
Fig. 4 Probing Tool
1 - SPECIAL TOOL 6801
2 - PROBING END
Fig. 5 ELECTROSTATIC DISCHARGE SYMBOL
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(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
TESTING COMPONENTS FOR A SHORT TO
GROUND ON A FUSE POWERING SEVERAL
LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting the items in the fused circuit
one at a time. When the fuse blows the component
with the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 8).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.Fig. 6 Testing for Voltage Potential
Fig. 7 Testing for Continuity
1 - FUSE REMOVED FROM CIRCUITFig. 8 Testing for Voltage Drop
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CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 9).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 9).
(5) Release the Secondary Terminal Lock, if
required.
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector.
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 10).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 11).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
Fig. 9 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
Fig. 10 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
Fig. 11 Diode Identification
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
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