fuel MERCEDES-BENZ SPRINTER 2006 Service Manual

LOCKER SWITCH NO. 1
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2- -
3 16BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
4 16BR/BK LOCKER SWITCH NO. 2 OUTPUT
5- -
6- -
7 16VT/YL DIFFERENTIAL LOCK SOLENOID CONTROL
8- -
9- -
10 20BR GROUND
LOCKER SWITCH NO. 2
CAV CIRCUIT FUNCTION
1 16BR/BK LOCKER SWITCH NO. 2 OUTPUT
2 16BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
LOW FUEL PRESSURE SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 18GY/DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY
2 18GY/YL LOW FUEL PRESSURE SENSOR GROUND
3 18GY/RD LOW FUEL PRESSURE SENSOR SIGNAL
MAP/READING LAMP SWITCH
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2- -
3 16RD/YL FUSED B(+)
4- -
5- -
6- -
7 16RD/YL MAP/READING LAMP SWITCH OUTPUT
8- -
9- -
10 16BR GROUND
8W - 80 - 62 8W-80 CONNECTOR PIN-OUTSVA

WATER IN FUEL SENSOR - BLACK
CAV 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
WHEEL SPEED SENSOR-LEFT FRONT
CAV CIRCUIT FUNCTION
1 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
2 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
WHEEL SPEED SENSOR-LEFT REAR
CAV CIRCUIT FUNCTION
1 18WT LEFT REAR WHEEL SPEED SENSOR (+)
2 18BR LEFT REAR WHEEL SPEED SENSOR (-)
WHEEL SPEED SENSOR-RIGHT FRONT
CAV CIRCUIT FUNCTION
1 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
2 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)
WHEEL SPEED SENSOR-RIGHT REAR
CAV CIRCUIT FUNCTION
1 18BK RIGHT REAR WHEEL SPEED SENSOR (+)
2 18BR RIGHT REAR WHEEL SPEED SENSOR (-)
8W - 80 - 84 8W-80 CONNECTOR PIN-OUTSVA

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Fuel Injector No. 1 BK Engine Compartment 13
Fuel Injector No. 2 BK Engine Compartment 12,13
Fuel Injector No. 3 BK Engine Compartment 12,13
Fuel Injector No. 4 BK Engine Compartment 12,13
Fuel Injector No. 5 BK Engine Compartment 13
Fuel Level Sensor BK Underbody-Middle 51
Fuel Pressure Sensor BK Engine Compartment 12
Fuel Pressure Solenoid (Except OBD) BK Engine Compartment-Rear 11
Fuel Pump BK 4
Fuel Pump Relay BK N/S
Fuel Quantity Control Valve N/S
Fuel Quanitity Control Valve (OBD) 11
Fuel Shutdown SolenoidN/S
Fuel Temperature Sensor Engine Compartment 13
Fuse Block No.1 C1 Under Fuse Block No.1 31
Fuse Block No.1 C2 BK Under Fuse Block No.1 31
Fuse Block No.1 C3 BK Under Fuse Block No.1 31
Fuse Block No.1 C4 BK Under Fuse Block No.1 31
Fuse Block No.1 C5 BK Under Fuse Block No.1 31
Fuses (Fuse Block No. 1) Steering Column 28
Fuses (Fuse Block No. 2) Under Driver Seat 35
Fuses (Fuse Block No. 3) Under Driver Seat N/S
Fuses (Fuse/Relay Block) Under Driver Seat 35,36
Fuses (PDC) Battery Area 8
Generator No.1 Engine Compartment 15
Generator No.2 Engine Compartment-Right 2,14
Glow Plug Control Module C1 BK Engine Compartment-Left
Front1
Glow Plug Control Module C2 BK Engine Compartment-Left
Front1
Glow Plug No. 1 On Engine 15
Glow Plug No. 2 On Engine 15
Glow Plug No. 3 On Engine 15
Glow Plug No. 4 On Engine 15
Glow Plug No. 5 On Engine 15
Headlamp Adjust Switch BK Instrument Panel 25
Headlamp Assembly-Left BK On Front Of Vehicle (Left
Side)3
Headlamp Assembly-Right BK On Front Of Vehicle (Right
Side)3
Heat Exchanger Switch BK Engine Compartment N/S
Heated Seat Module-Driver BK Under Driver Seat 4
Heated Seat Module-Passenger BK Under Passenger Seat 4
Heated Seat Switch-Driver BK On Driver Seat 20
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
License Plate Lamp No. 2 On Rear Of Vehicle 53
Locker Switch No. 1 BK Under Body-Front N/S
Locker Switch No. 2 BK Under Body-Rear 51
Low Fuel Pressure Sensor BK Engine Compartment 12,14
Low Pressure Switch Roof A/C Unit 39
Map/Reading Lamp Switch BK Instrument Panel N/S
Marker Lamp Connector K NS
Marker Lamp No.1-Left Front BK Front Of Vehicle-Left Side N/S
Marker Lamp No.1-Right Front BK Front Of Vehicle-Left Side N/S
Marker Lamp No.2-Left Front BK 5
Marker Lamp No.2-Right Front BK 5
Marker Lamp-Left Center BK Front Of Vehicle-Center Left
Side53
Marker Lamp-Left Rear BK Rear Of Vehicle-Left Side 53
Marker Lamp-Right Center BK Front Of Vehicle-Center
Right Side53
Marker Lamp-Right Rear BK Rear Of Vehicle -Right Side 53
Mass Air Flow Sensor BK Engine Compartment 11
Master Door Lock Switch BK Center Of Instrument Panel 20
Metering Pump BK Instrument Panel 27
Microphone Connector Instrument Panel N/S
Multi-Function Switch Steering Wheel 24
Optional Equipment Relay (Relay Block) Under Driver Seat 23
Oxygen Sensor (OBD) BK 6
Panic Alarm Switch BK Instrument Panel 20
Parking Brake Switch BK Under Instrument Panel N/S
Power Mirror Motor-Driver BK In Driver Door 27
Power Mirror Motor-Passenger BK In Passenger Door 27
Power Mirror Switch BK 23
Power Window Motor-Driver BK 44
Power Window Motor-Passenger BK 44
Power Window Switch-Driver BK 23
Power Window Switch-Master BK 23
Power Window Switch-Passenger BK 6
Radio Antenna Behind Radio 48
Radio C1 BK Behind Radio 20
Radio C2 BK Behind Radio 20
Radio/Cellular Antenna Behind Radio 48
Rain Sensor Front Center Roof 25
Reading Lamp Connector WT Instrument Panel N/S
Recirculated Air Solenoid Valve BK Underhood Right (To The
Instrument Panel)10
Refrigerant Pressure Sensor Engine Compartment-Left
Front8,10
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
TCS Switch (ASR) BK Center Of Instrument Panel 20
Temperature Sensor WT Center Roof A/C Unit 40
Thermotronic Control Module BK N/S
Thermotronic Diode Center Roof A/C Unit 39
Time Delay Relay Under Driver Seat N/S
Towing/Intrusion Sensor ON/OFF Switch BK Instrument Panel 20
Trailer Tow Connector Under Rear Of Vehicle N/S
Trailer Tow Control Module C1 BK Rear Of Vehicle N/S
Trailer Tow Control Module C2 BK Rear Of Vehicle N/S
Transmission Control Module C1 BK Engine Compartment 3
Transmission Control Module C2 BK Engine Compartment 3
Transmission Relay (Relay Block) In Fuse Block No.1 N/S
Transmission Solenoid Assembly BK Transmission 16
Turn Signal Lamp No.1-Left Front BK Front Of Vehicle On Left
SideN/S
Turn Signal Lamp No.1-Right Front BK Front Of Vehicle On Right
SideN/S
Turn Signal Lamp No.2-Left Front BK Front Of Vehicle On The
Left Side45
Turn Signal Lamp No.2-Right Front BK Front Of Vehicle On The
Right Side45
Turn Signal Relay (Fuse Block No.1) In Fuse Block No.1 N/S
Turn Signal/Anti-Theft Alarm Relay-Left (Re-
lay Block)BK Under Driver Seat N/S
Turn Signal/Anti-Theft Alarm Relay-Right
(Relay Block)BK Under Driver Seat N/S
Warm Air Auxiliary Heater Assembly C1 Instrument Panel 33
Warm Air Auxiliary Heater Assembly C2 Instrument Panel 33
Washer Pump Motor-Front WT Engine Compartment 25
Water Cycle Valve BK Underhood (To The Instru-
ment Panel)10
Water In Fuel Sensor Engine Compartment 14
Wheel Speed Sensor-Left Front Left Front Wheel 2
Wheel Speed Sensor-Left Rear Left Rear Wheel 2
Wheel Speed Sensor-Right Front Right Front Wheel 49
Wheel Speed Sensor-Right Rear Right Rear Wheel 49
Window Defogger Module - Rear BK Rear Of Vehicle N/S
Window Defogger Relay-Left Rear (Relay
Block)BK Under Driver Seat N/S
Window Defogger Relay-Right Rear (Relay
Block)BK Under Driver Seat N/S
Window Defogger Switch - Rear BK Instrument Panel 25
Window Defogger-Left Rear On Left Rear Window 53
Window Defogger-Right Rear On Right Rear Window 53
Wiper Motor-Front BK Underhood (To The Window) 8
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9

Fig. 11 FUEL AND AIR COMPONENTS
8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

DESCRIPTION SPECIFICATION
Engine 2.7L CDI
Engine Description 5 Cylinder In-Line En-
gine With 4-Valve Tech-
nology
Air Intake Turbo-Charged Engine
with Charge Air Cooling
Fuel Injection System 2 nd. Generation Com-
mon Rail Direct Injection
(CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE
(1) Warm up engine to operating temperature
(approx. 80 ÉC, 176ÉF).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
COMPRESSION SPECIFICATIONS
Maximum Compression 29-35 bar (420-507 psi)
Minimum Compression 18bar (261 psi)
Permissible Difference
Between Cylinders  3bar (  44 psi)
STANDARD PROCEDURE - CYLINDER LEAK
DOWN TEST
(1) Warm engine to operating temperature.
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194ÉF). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT
WHICH SPLASHES OUT. RISK OF POISONING
FROM SWALLOWING COOLANT. OPEN CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine possible cause
(Refer to 9 - ENGINE - STANDARD PROCEDURE).
VAENGINE 9 - 3

REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90ÉC (194ÉF). OPEN CAP
SLOWLY TO RELEASE PRESSURE. STORE COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES, AND EYE WEAR.
(1) Disconnect the negative battery cable.
NOTE: REPLACE THE AIR CONDITIONING DRIER
WHEN EVER THE AIR CONDITIONING SYSTEM IS
OPENED.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Evacuate and recover air conditioning system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(4) Remove the front grille and fascia assembly.(5) Disconnect the engine wiring harness at the
cabin side and carefully guide though the cowl into
the engine area.
Fig. 2 ENGINE COVER
1 - ENGINE COVER
2 - FASTENERS
VAENGINE 9 - 5

(6) Remove the turbocharger heat shield (Fig. 3).
(7) Remove the engine cover (Fig. 3).
(8) Remove the air cleaner and hose at the turbo-
charger and air cleaner assembly.
(9) Disconnect the transmission lines at the radia-
tor.
(10) Disconnect the upper and lower radiator
hoses.
(11) Disconnect the A/C lines at the condenser.
(12) Disconnect the condenser fan harness connec-
tor.
(13) Disconnect the power steering cooler lines at
the cooler.
(14) Disconnect the charge air cooler hose at the
intake manifold (Fig. 3).
(15) Remove charge air hose fasteners at the radi-
ator closure panel.
(16) Remove the fasteners retaining the radiator to
the front crossmember.(17) Remove the change air cooler, A/C conderser
and fan as an assembly.
(18) Disconnect the charge air hose at the intake
manifold (Fig. 3).
(19) Remove the radiator assembly.
(20) Disconnect the high pressure and return
hoses at the power steering pump.
(21) Disconnect the fuel lines at the fuel filter.
(22) Disconnect the refrigerant line at the A/C
compressor.
(23) Disconnect the vacuum line for the brake
booster at the vacuum pump (Fig. 3).
(24) Disconnect the coolant hose of heating return
flow at the water pump.
(25) Disconnect the coolant hose of the heater sup-
ply at the coolant pipe at the side of the cylinder
head.
Fig. 3 ENGINE COVER
1 - ENGINE COVER 6 - HIGH PRESSURE FUEL PUMP
2 - FUEL RAIL 7 - VACUUM PUMP
3 - INTAKE MANIFOLD 8 - OIL LEVEL INDICATOR
4 - EGR VALVE 9 - HEAT SHIELD
5 - AIR INLET TUBE 10 - TRANSMISSION OIL LEVEL INDICATOR
9 - 6 ENGINEVA

(30) Disconnect the engine valley drain hose fas-
tener from the transmission (Fig. 5).
(31) Remove the steering gear mounting bolts.
(32) Disconnect the transmission cooler lines at
transmission and oil pan.
(33) Remove the torque converter access plate.
(34) Remove the torque converter bolts.
(35) Remove the crank position sensor.
(36) Remove the transmission housing to engine
mounting bolts.
(37) Remove the starter mounting bolts (Fig. 5).
(38) Support the transmission with a transmission
jack.
(39) Place a wood block between the transmission
housing and the front frame cross over.
(40) Remove the transmission jack.
(41) Remove the exhaust bracket (right side).
(42) Remove the engine ground strap (left side).
(43) Lower the vehicle.
(44) Remove the heater housing filter and lower
housing.(45) Connect the engine lifting fixture #9308 to the
engine lifting eyes.
(46) Remove the engine mount bolts.
(47) Remove the transmission oil level indicator
tube mounting bolt.
Fig. 5 2.7L CDI ENGINE
1 - INTAKE MANIFOLD 5 - FUEL FILTER
2 - ENGINE VALLEY DRAIN HOSE 6 - AIR CONDITIONING COMPRESSOR
3 - STARTER 7 - POWER STEERING PUMP
4 - ENGINE OIL LEVEL SENSOR 8 - EGR VALVE
9 - 8 ENGINEVA