ABS MERCEDES-BENZ SPRINTER 2006 Service Manual

(2) Remove the screw that secures the park brake
switch and the ground eyelet terminal to the park
brake lever.
(3) Disengage the park brake switch from the park
brake lever.
(4) Disconnect the vehicle wire harness connector
for the park brake switch from the switch terminal.
(5) Remove the park brake switch from the park
brake lever.
INSTALLATION
(1) Position the park brake switch near the park
brake lever (Fig. 38).
(2) Reconnect the vehicle wire harness connector
for the park brake switch to the switch terminal.
(3) Engage the park brake switch into the park
brake lever.
(4) Install and tighten the screw that secures the
park brake switch and the ground eyelet terminal to
the park brake lever.
(5) Reinstall the trim cover onto the park brake
lever. (Refer to 5 - BRAKES/PARKING BRAKE/LE-
VER - INSTALLATION).
REAR SIDE MARKER LAMP
BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is so equipped, remove the trim
from the inside of the right or left rear corner pillar.
(3) From inside the vehicle, use hand pressure to
push the two latch tabs toward the center of the tail
lamp unit socket plate and pull the socket plate
straight out from the inner rear pillar (Fig. 39).(4) Pull the socket plate away from the inner rear
pillar far enough to access the side marker lamp bulb
(Fig. 40).
(5) Remove the side marker lamp bulb from the
tail lamp socket plate.INSTALLATION
(1) Install the side marker lamp bulb into the tail
lamp socket plate (Fig. 40).
(2) Align the socket plate with the mounting hole
in the inner rear pillar.
Fig. 38 Park Brake Switch Remove/Install
1 - LEVER
2 - SWITCH
3 - WIRE HARNESS
4 - SCREW
Fig. 39 Tail Lamp Socket Plate Remove/Install
1 - SOCKET PLATE
2 - INNER REAR PILLAR
3 - LATCH TAB (2)
Fig. 40 Tail Lamp Bulb Remove/Install
1 - BRAKE/PARK LAMP BULB
2 - BACKUP LAMP BULB
3 - TURN SIGNAL LAMP BULB
4 - SIDE MARKER LAMP BULB
5 - TAIL LAMP SOCKET PLATE
8L - 22 LAMPS/LIGHTING - EXTERIORVA

(3) Using hand pressure, push the socket plate
gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged (Fig. 39).
(4) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
(5) Reconnect the battery negative cable.
REAR TURN LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is so equipped, remove the trim
from the inside of the right or left rear corner pillar.
(3) From inside the vehicle, use hand pressure to
push the two latch tabs toward the center of the tail
lamp unit socket plate and pull the socket plate
straight out from the inner rear pillar (Fig. 41).
(4) Pull the socket plate away from the inner rear
pillar far enough to access the turn signal lamp bulb
(Fig. 42).(5) Remove the turn signal lamp bulb from the tail
lamp socket plate.
INSTALLATION
(1) Install the turn signal lamp bulb into the tail
lamp socket plate (Fig. 42).
(2) Align the socket plate with the mounting hole
in the inner rear pillar.
(3) Using hand pressure, push the socket plate
gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged (Fig. 41).
(4) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
(5) Reconnect the battery negative cable.
REPEATER LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the small or large style repeater lamp
unit from its mounting location, but do not discon-
nect it from the vehicle wire harness. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/RE-
PEATER LAMP - REMOVAL).
(3) Remove the bulb holder from the lens (small
type) (Fig. 43), or the lens from the lamp housing
(large type) (Fig. 44).
Fig. 41 Tail Lamp Socket Plate Remove/Install
1 - SOCKET PLATE
2 - INNER REAR PILLAR
3 - LATCH TAB (2)
Fig. 42 Tail Lamp Bulb Remove/Install
1 - BRAKE/PARK LAMP BULB
2 - BACKUP LAMP BULB
3 - TURN SIGNAL LAMP BULB
4 - SIDE MARKER LAMP BULB
5 - TAIL LAMP SOCKET PLATE
VALAMPS/LIGHTING - EXTERIOR 8L - 23

(3) Pull the repeater lamp lens and housing out-
ward to disengage the unit from the mounting hole.
(4) Disconnect the vehicle wire harness connector
from the connector receptacle on the back of the
repeater lamp unit.
(5) Remove the repeater lamp unit from the vehi-
cle.
INSTALLATION
SMALL
(1) Position the repeater lamp unit to the mount-
ing hole on the fender panel (Fig. 45).
(2) Reconnect the vehicle wire harness connector
to the connector receptacle of the bulb holder on the
back of the repeater lamp unit.
(3) Engage the front edge of the repeater lamp
unit into the front edge of the mounting hole.
(4) Using hand pressure, press the rear edge of the
repeater lamp lens/housing toward the front of the
vehicle against the spring pressure of the retaining
clip, then push the rear edge of the lamp into the
rear of the mounting hole.
(5) Reconnect the battery negative cable.
LARGE
(1) Position the repeater lamp unit near the
mounting hole on the fender panel (Fig. 46).
(2) Reconnect the vehicle wire harness connector
to the connector receptacle on the back of the
repeater lamp unit.
(3) Position the repeater lamp lens and housing to
the mounting hole as a unit.(4) Install and tighten the screw that secures the
lens and the repeater lamp housing to the fender
panel.
(5) Reconnect the battery negative cable.
TAIL LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is so equipped, remove the trim
from the inside of the right or left rear corner pillar.
(3) From inside the vehicle, use hand pressure to
push the two latch tabs toward the center of the tail
lamp unit socket plate and pull the socket plate
straight out from the inner rear pillar (Fig. 47).
(4) Pull the socket plate away from the inner rear
pillar far enough to access the tail lamp unit mount-
ing nuts (Fig. 48).
Fig. 46 Large Repeater Lamp Unit Remove/Install
1 - LAMP HOUSING
2 - BULB
3 - LENS
4 - SCREW
Fig. 47 Tail Lamp Socket Plate Remove/Install
1 - SOCKET PLATE
2 - INNER REAR PILLAR
3 - LATCH TAB (2)
VALAMPS/LIGHTING - EXTERIOR 8L - 25

(5) From the inside of the vehicle, remove the four
nuts that secure the tail lamp unit housing to the
vehicle.
(6) Remove the tail lamp unit housing and gasket
from the outside of the vehicle.
INSTALLATION
(1) Position the tail lamp unit housing and gasket
to the outside of the vehicle (Fig. 48).
(2) From the inside of the vehicle, install and
tighten the four nuts that secure the tail lamp unit
housing to the vehicle.
(3) Align the socket plate with the mounting hole
in the inner rear pillar.
(4) Using hand pressure, push the socket plate
gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged.
(5) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
(6) Reconnect the battery negative cable.
TURN SIGNAL RELAY
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-tem. Failure to take the proper precautions could
result in accidental airbag deployment.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse access panel from the steering
column opening cover below the steering column on
the instrument panel.
(3) Reach through and below the inboard side of
the fuse access opening to access the turn signal
relay (Fig. 49).
(4) Remove the turn signal relay by grasping it
firmly, releasing the latches and pulling it straight
down from the receptacle on the bottom of the fuse
block.
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
(1) Position the turn signal relay to the receptacle
on the bottom of the fuse block (Fig. 49).
(2) Align the turn signal relay terminals with the
terminal cavities in the fuse block receptacle.
Fig. 48 Tail Lamp Unit Remove/Install
1 - SOCKET PLATE
2 - NUT (4)
3 - LAMP HOUSING
4 - GASKET
Fig. 49 Turn Signal Relay
1 - STEERING COLUMN OPENING COVER
2 - FUSE BLOCK
3 - LOWER INSTRUMENT PANEL
4 - TURN SIGNAL RELAY
5 - ENGINE CONTROL MODULE RELAY
6 - WIPER RELAY
8L - 26 LAMPS/LIGHTING - EXTERIORVA

and to the supplemental restraint system compo-
nents through the use of a combination of soldered
splices, splice block connectors, and many different
types of wire harness terminal connectors and insu-
lators. Refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, 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.
OPERATION
ACTIVE RESTRAINTS
The primary passenger restraints in this or any
other vehicle are the standard equipment factory-in-
stalled seat belts. Seat belts are referred to as an
active restraint because the vehicle occupants are
required to physically fasten and properly adjust
these restraints in order to benefit from them. See
the owner's manual in the vehicle glove box for more
information on the features, use and operation of all
of the factory-installed active restraints.
PASSIVE RESTRAINTS
The passive restraints are referred to as a supple-
mental restraint system because they were designed
and are intended to enhance the protection for the
occupants of the vehicleonlywhen used in conjunc-
tion with the seat belts. They are referred to as pas-
sive restraints because the vehicle occupants are not
required to do anything to make them operate; how-
ever, the vehicle occupants must be wearing their
seat belts in order to obtain the maximum safety
benefit from the factory-installed supplemental
restraint system.
The supplemental restraint system electrical cir-
cuits are continuously monitored and controlled by a
microprocessor and software contained within the
Airbag Control Module (ACM). An airbag indicator in
the ElectroMechanical Instrument Cluster (EMIC)
illuminates for about four seconds as a bulb test each
time the ignition switch is turned to the On or Start
positions. Following the bulb test, the airbag indica-
tor is turned on or off by the ACM to indicate the
status of the supplemental restraint system. If the
airbag indicator comes on either solid or flashing at
any time other than during the bulb test, it indicates
that there is a problem in the supplemental restraint
system electrical circuits. Such a problem may cause
airbags not to deploy when required, or to deploy
when not required.
Deployment of the supplemental restraints
depends upon the angle and severity of an impact.
Deployment is not based upon vehicle speed; rather,
deployment is based upon the rate of deceleration as
measured by the forces of gravity (G force) upon the
impact sensor(s). When an impact is severe enough,the microprocessor in the ACM signals the inflator of
the appropriate airbag units to deploy their airbag
cushions. The front seat belt tensioners are provided
with a deployment signal by the ACM in conjunction
with the driver and passenger airbags.
During a frontal vehicle impact, the knee blockers
work in concert with properly fastened and adjusted
seat belts to restrain both the driver and the front
seat passenger in the proper position for an airbag
deployment. The knee blockers also absorb and dis-
tribute the crash energy from the driver and the
front seat passenger to the structure of the instru-
ment panel. The seat belt tensioners remove the
slack from the front seat belts to provide further
assurance that the driver and front seat passenger
are properly positioned and restrained for an airbag
deployment.
Typically, the vehicle occupants recall more about
the events preceding and following a collision than
they do of an airbag deployment itself. This is
because the airbag deployment and deflation occur so
rapidly. In a typical 48 kilometer-per-hour (30 mile-
per-hour) barrier impact, from the moment of impact
until the airbags are fully inflated takes only a few
milliseconds. Within one to two seconds from the
moment of impact, the airbags are almost entirely
deflated. The times cited for these events are approx-
imations, which apply only to a barrier impact at the
given speed. Actual times will vary somewhat,
depending upon the vehicle speed, impact angle,
severity of the impact, and the type of collision.
When the ACM monitors a problem in any of the
airbag system circuits or components, including the
seat belt tensioners, it stores a fault code or Diagnos-
tic Trouble Code (DTC) in its memory circuit and
sends a hard wired output to the EMIC to turn on
the airbag indicator. If the EMIC detects a problem
in the airbag indicator or airbag indicator circuit, the
cluster will flash the seatbelt indicator on and off.
Proper testing of the supplemental restraint system
components as well as the retrieval or erasure of a
DTC from the ACM requires the use of a diagnostic
scan tool. Refer to the appropriate diagnostic infor-
mation.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the factory-installed passive restraints.
8O - 4 RESTRAINTSVA

(1) Reconnect and latch the vehicle wire harness
connector for the ACM to the ACM connector recep-
tacle located on the left facing side of the module
(Fig. 12).
(2) Carefully position the ACM cover base plate
onto the mounting bracket that is welded onto the
floor panel under the driver side front seat (Fig.
13).
(3) Carefully position the ACM onto the ACM cover
base plate. When the ACM is correctly positioned, the
three ACM mounting tabs will be aligned with the
holes in the cover base plate and the mounting
bracket, and the orientation arrow on the ACM label
will be pointed forward in the vehicle.
(4) Install and tighten the three screws that secure
the ACM to the mounting bracket that is welded onto
the floor panel within the driver side front seat riser.
Be certain that the ground eyelet terminal is
installed under the screw for the left rear mounting
tab. Tighten the screws to 12 N´m (105 in. lbs.).
(5) Position the ACM cover over the ACM and
press it down firmly and evenly until it snaps into
position over the ACM cover base plate (Fig. 11).
(6) Position the control module bracket onto the
top of the driver side seat riser (Fig. 10).
(7) Install and tighten the two screws that secure
the control module bracket to the top of the seat riser
under the driver side front seat. Tighten the screws
to 2 N´m (18 in. lbs.).
(8) Position the cover panel onto the top of the
driver side seat riser (Fig. 9).
(9) Install and tighten the two screws that secure
the cover panel to the top of the seat riser under the
driver side front seat. Tighten the screws to 2 N´m
(18 in. lbs.).(10) Move the driver side front seat back to its
driving position.
(11) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
NOTE: If the Airbag Control Module (ACM) has been
replaced with a new unit, it will be necessary to ini-
tialize the new ACM. In order to function properly,
the ACM must be programmed for the correct stan-
dard and optional supplemental restraint system
components installed in the vehicle. To initialize the
ACM, a diagnostic scan tool is required. Refer to
the appropriate diagnostic information.
CLOCKSPRING
DESCRIPTION
The clockspring assembly is secured with two
screws onto the multi-function switch housing near
the top of the steering column directly below the
steering wheel (Fig. 14). The clockspring consists of a
flat, round molded plastic case that contains a spool-
like molded plastic rotor with a large exposed hub
covering the entire upper surface of the case. The
rotor hub has a large center hole that is internally
ribbed to engage splines on the upper steering col-
umn shaft, and two small clearance holes that pro-
vide access to the case mounting screws. The lower
Fig. 13 ACM Cover Base Plate
1 - BASE PLATE
2 - SEAT RISER
3 - GROUND EYELET TERMINAL
4 - ACM CONNECTOR
5 - FLOOR PANEL
Fig. 14 Clockspring
1 - PIGTAIL WIRE CONNECTOR (2)
2 - CASE
3 - CANCEL CAM
4 - ROTOR
5 - SCREW (2)
6 - HORN SWITCH CONNECTOR (2)
7 - AIRBAG CONNECTOR
8O - 12 RESTRAINTSVA

CONTROLLER ANTILOCK BRAKE
CAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
3- -
4- -
5 14BR GROUND
6 14RD FUSED B(+)
7- -
8 20BK/DG SENSOR SIGNAL
9 20YL/WT SENSOR SIGNAL
10 20YL/RD SENSOR SIGNAL
11 18BL/BK K-ABS/SHIFTER ASSEMBLY
12 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
13 - -
14 20WT LEFT REAR WHEEL SPEED SENSOR (+)
15 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)
16 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
17 - -
18 - -
19 - -
20 20WT BRAKE SWITCH OUTPUT
21 20BR GROUND
22 - -
23 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
24 20DG/WT CAN C BUS (+)
25 20BR SENSOR GROUND
26 20WT/GY BRAKE PRESSURE SENSOR SIGNAL
27 18BK/BL TCS SWITCH (ASR) SENSE
28 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
29 20BR LEFT REAR WHEEL SPEED SENSOR (-)
30 20BR RIGHT REAR WHEEL SPEED SENSOR (-)
31 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
32 18BK/RD BRAKE LAMP SWITCH OUTPUT
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 20RD/BL POWER INPUT
40 20DG CAN C BUS (-)
41 20DG/YL SENSOR SIGNAL
42 20WT/RD 5 VOLT SUPPLY
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTSVA

CYLINDER LOCK SWITCH-DRIVER
CAV CIRCUIT FUNCTION
1 16BK DRIVER CYLINDER UNLOCK SENSE
2- -
3 16BR GROUND
4 16RD DRIVER CYLINDER LOCK SENSE
DATA LINK CONNECTOR - BLACK
CAV CIRCUIT FUNCTION
1 20WT/DG K-SKREEM
2- -
3 20DG/YL ENGINE RPM
4 20BR GROUND
5 20BR GROUND
6- -
7 20BL/YL K-ECM
8 20BK/BL/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 20BL/BK K-ABS/SHIFTER ASSEMBLY
10 - -
11 20BL K-TCM/RADIO
12 20GY/DG/RD K-CTM/SSM
13 20BK/RD K-ACM
14 - -
15 20WT/GY K-IC/ATC/HBM/CHM
16 20RD/YL FUSED B(+)
DIFFERENTIAL LOCK SOLENOID VALVE
CAV CIRCUIT FUNCTION
1 18VT/YL DIFFERENTIAL LOCK SOLENOID CONTROL
2 18BR GROUND
DOME LAMP
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT FRONT COURTESY LAMPS CONTROL
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

SENTRY KEY REMOTE ENTRY MODULE (SKREEM)
CAV CIRCUIT FUNCTION
1 18YL RKE ANTENNA
2 16BR GROUND
3 16RD/YL FUSED B(+)
4 16BK/WT LEFT TURN SIGNAL
5 20DG/WT CAN C BUS (+)
6 20DG CAN C BUS (-)
7 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20WT/DG K-SKREEM
9 16WT/BL/RD (EXCEPT VTSS) RKE INTERFACE
9 16WT/BL/RD (VTSS) SECURITY SYSTEM INTERFACE
10 18DG/YL TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT/
RIGHT CONTROL
11 20BR TRANSPONDER COIL (+)
12 - TRANSPONDER COIL (-)
SHIFTER ASSEMBLY - BLACK
CAV CIRCUIT FUNCTION
1- -
2 20GY/DG/RD LAMP DRIVER
3 20BL/DG K-ABS/SHIFTER ASSEMBLY
4 18BR GROUND
5 20BK/BL/RD BRAKE LAMP SWITCH
6 20DG/WT CAN C BUS (+)
7 20DG CAN C BUS (-)
8 18BK/DG TRANSMISSION RELAY OUTPUT
9 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 16WT/RD BACK-UP LAMP
SIREN - BLACK
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSVA

a variable resistor track (card).
REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the fuel pump
module (4) (Fig. 30).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) Unplug sensor's 2±wire harness from pump
module electrical connector.
(3) Before disconnecting wiring from 2±wire har-
ness electrical connector, note position of each wire in
the connector. Record this position.
(4) Disconnect wiring from 2±wire harness electri-
cal connector using a terminal pick / removal tool.
Refer to Special Tools in 8W, Wiring for tool part
numbers.
(5) To remove sending unit from pump module,
press on plastic locking tabs (1) (Fig. 30) while slid-
ing sending unit (4) on its tracks.
INSTALLATION
(1) Noting their previous positions, connect wires
from 2±wire harness into its connector.
(2) Plug 2±wire harness connector into pump mod-
ule electrical connector.
(3) Position sending unit (4) (Fig. 31) to tracks on
fuel pump module. Slide and snap into place.
(4) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
Fig. 29 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
Fig. 30 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
Fig. 31 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
VAFUEL DELIVERY 14 - 29