Dash MERCEDES-BENZ SPRINTER 2006 User Guide

WASHER RESERVOIR
DESCRIPTION
The molded plastic washer fluid reservoir is
located in the right rear corner of the engine com-
partment (Fig. 19). Two integral mounting posts, one
on the bottom and one at the rear of the reservoir,
each are engaged in rubber mounting grommets, one
in the dash panel and one in the top of the right
front wheel house. A single nut and washer secures
an integral mounting hole near the top of the reser-
voir to a stud nut on the right inner fender shield.
Also near the upper inboard side of the reservoir are
two integral hose routing troughs, one for the stan-
dard washer supply hose and the second for the
optional vent hose used when the washer pump/mo-
tor is equipped with an integral washer fluid level
switch.
A molded blue plastic filler cap with an integral
retainer ring and tether strap snaps over the open
end of the filler neck, and hangs from the tether
when it is removed for inspecting or adjusting the
fluid level in the reservoir. There is a sump area near
the bottom inboard side of the reservoir with a dedi-
cated hole provided for the mounting of the washer/
pump motor unit and rubber grommet seal.
The washer reservoir cannot be repaired and, if
faulty or damaged, it must be replaced. The washer
reservoir, the mounting grommets, the grommet seal
for the washer pump/motor unit, and the filler cap
are each available for service replacement.
OPERATION
The washer fluid reservoir provides a secure,
on-vehicle storage location for a large reserve ofwasher fluid for operation of the washer system. The
washer reservoir filler neck provides a clearly
marked and readily accessible point from which to
add washer fluid to the reservoir. The washer/pump
motor unit is located in a sump area near the bottom
of the reservoir to be certain that washer fluid will
be available to the pump as the fluid level in the res-
ervoir becomes depleted. The optional washer fluid
level switch is designed to provide adequate warning
to the vehicle operator that the washer fluid level is
low, before the washer system will no longer operate.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the upper turbocharger heat shield
and the upper air cleaner housing from the engine
compartment (Fig. 20).
(3) Disconnect the vehicle wire harness connector
for the washer pump/motor unit from the motor con-
nector receptacle.
(4) Disengage the vehicle wire harness from the
routing clip integral to the front of the washer reser-
voir (Fig. 21).
Fig. 19 Washer Reservoir
1 - CAP
2 - TROUGH (2)
3 - MOUNTING POST (2)
4 - WASHER PUMP/MOTOR
5 - RESERVOIR
6 - MOUNTING HOLE
Fig. 20 Heat Shield & Air Cleaner Housing
1 - UPPER AIR CLEANER HOUSING
2 - VEHICLE WIRE HARNESS CONNECTOR
3 - CLAMP
4 - UPPER TURBO HEAT SHIELD
5 - SCREW
6 - NUT (2)
VAWIPERS/WASHERS 8R - 21

(5) Remove the washer supply hose from the
barbed outlet nipple of the washer pump/motor and
allow the washer fluid to drain into a clean container
for reuse.
(6) Disengage the washer supply hose from the
routing trough integral to the top of the washer res-
ervoir.
(7) Remove the nut and washer that secures the
top of the washer reservoir to the stud nut on the
right inner fender.
(8) Pull the washer reservoir inboard far enough to
disengage the reservoir from the stud nut.
(9) Tilt the washer reservoir forward far enough to
disengage the rear mounting post from the grommet
in the dash panel.
(10) Lift the washer reservoir upward far enough
to disengage the lower mounting post from the grom-
met in the top of the right front wheel house.
(11) Remove the washer reservoir from the engine
compartment.
INSTALLATION
(1) Position the washer reservoir into the engine
compartment.
(2) Engage the lower mounting post of the washer
reservoir into the grommet in the top of the right
front wheel house (Fig. 22).(3) Engage the rear mounting post of the washer
reservoir into the grommet in the dash panel.
(4) Position the washer reservoir mounting hole
over the stud nut on the right inner fender (Fig. 21).
(5) Install and tighten the nut and washer that
secures the top of the washer reservoir to the stud
nut on the right inner fender. Tighten the nut to 6
N´m (50 in. lbs.).
(6) Reconnect the washer supply hose to the
barbed outlet nipple of the washer pump/motor.
(7) Engage the washer supply hose into the rout-
ing trough integral to the top of the washer reservoir.
(8) Reconnect the vehicle wire harness connector
for the washer pump/motor unit to the motor connec-
tor receptacle.
(9) Engage the vehicle wire harness into the rout-
ing clip integral to the front of the washer reservoir.
(10) Reinstall the upper turbocharger heat shield
and the upper air cleaner housing into the engine
compartment (Fig. 20).
(11) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(12) Reconnect the battery negative cable.
Fig. 21 Washer Reservoir Remove/Install
1 - RIGHT INNER FENDER
2 - WASHER RESERVOIR
3 - NUT & WASHER
4 - ROUTING CLIP
Fig. 22 Washer Reservoir Mounting
1 - RIGHT INNER FENDER
2 - STUD NUT
3 - DASH PANEL
4 - RIGHT FRONT WHEEL HOUSE
5 - GROMMET (2)
6 - HOOD PROP
8R - 22 WIPERS/WASHERSVA

(2) Remove the wiper arms from the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - REMOVAL).
(3) Remove the five nuts that secure the ventila-
tion housing to the dash panel and the underside of
the cowl top panel (Fig. 29).
VAWIPERS/WASHERS 8R - 29

(4) Pull the ventilation housing forward far enough
to disengage the housing from the studs on the dash
panel, then lower the housing until it rests on the
top of the engine.
(5) Disconnect the wiper motor pigtail wire connec-
tor from the vehicle wire harness connector.
(6) Remove the nut and washer that secures each
wiper pivot housing to the outside of the cowl top
panel (Fig. 30).
Fig. 29 Ventilation Housing
1 - NUT (5) 3 - CABIN FILTER HOUSING
2 - WASHER (5) 4 - VENTILATION HOUSING
8R - 30 WIPERS/WASHERSVA

(7) Remove the two screws that secure the wiper
linkage module motor bracket to the flange on the
underside of the cowl top panel.
(8) Remove the wiper linkage module and wiper
motor from the underside of the cowl top panel as a
unit.
(9) Remove the wiper motor from the wiper link-
age module. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MOTOR - REMOVAL).
INSTALLATION
(1) Reinstall the wiper motor onto the wiper link-
age module. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/FRONT WIPER MOTOR -
INSTALLATION).
(2) Carefully position the wiper linkage module
and wiper motor to the underside of the cowl top
panel as a unit (Fig. 30).
(3) Install and tighten the two screws that secure
the wiper linkage module motor bracket to the flange
on the underside of the cowl top panel. Tighten the
screws to 6 N´m (50 in. lbs.).
(4) Install and tighten the nut and washer that
secures each wiper pivot housing to the outside of the
cowl top panel.
(5) Reconnect the wiper motor pigtail wire connec-
tor to the vehicle wire harness connector.
(6) Reinstall the ventilation housing onto the dash
panel and the underside of the cowl top panel (Fig.
29).
(7) Reinstall the wiper arms onto the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).
(8) Reconnect the battery negative cable.
WIPER MOTOR
DESCRIPTION
The wiper motor is secured with three screws to a
motor bracket integral to the wiper linkage module
bracket located below the cowl top panel in the
engine compartment (Fig. 31). The wiper motor out-
put shaft passes through a hole in the motor bracket,
where a nut secures the wiper motor crank arm to
the motor output shaft. The two-speed permanent
magnet wiper motor features an integral transmis-
sion, an internal park switch, and an internal Posi-
tive Temperature Coefficient (PTC) circuit breaker.
The wiper motor cannot be adjusted or repaired. If
any component of the motor is faulty or damaged, the
entire wiper motor unit must be replaced.
Fig. 30 Wiper Linkage Module Remove/Install
1 - NUT & WASHER (2) 4 - COWL TOP PANEL
2 - PIVOT (2) 5 - MOTOR BRACKET
3 - SCREW (2)
Fig. 31 Wiper Motor
1 - TRANSMISSION
2 - PIGTAIL WIRE
3 - MOTOR
4 - SCREW (3)
5 - OUTPUT SHAFT
VAWIPERS/WASHERS 8R - 31

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).
VA8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1

C102 (EXCEPT OBD) - (GENERATOR SIDE)
CAV CIRCUIT
A 18WT/BL
B-
C103 (OBD) - (GENERATOR SIDE)
CAV CIRCUIT
1 18WT/BL
2 14BK/YL
3-
4-
5-
6 16YL/RD
C103 (OBD) - (MAIN BODY)
CAV CIRCUIT
1 20BL
2 12BK/YL
3-
4-
5-
6 16YL/RD
C200 - BLACK (DASH SIDE)
CAV CIRCUIT
1 16GY
2 16GY/DG
3 16BK/YL
4 16DG/BL/WT
5 16YL/BK
6 16BL/RD
7 16BK/RD
8 16WT/BK
9 16WT/DG
10 16WT/YL
11 16WT/RD
12 16BK/RD
13 16VT/YL
14 16BR/WT
15 16YL
16 16BR/WT
17 16GY/RD
18 16BK/YL/DG
19 16BK/YL
20 -
21 -
22 -
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTSVA

C200 - BLACK (MAIN BODY SIDE)
CAV CIRCUIT
1 16GY
2 16GY/DG
3 16BK/YL
4 16DG/BL/WT
5 16YL/BL
6 16BL/RD
7 16BK/RD
8 16WT/BK
9 16WT/DG
10 16WT/YL
11 16WT/RD
12 16BK/RD
13 18VT/YL
14 16BR/BK
15 16YL
16 16BR/WT
17 16GY/RD
18 16BK/YL/DG
19 16BK/YL
20 -
21 -
22 -
C201 - (DASH SIDE)
CAV CIRCUIT
1-
2 16GY/DG/RD
3 16RD/BL
4 20BL/VT
4 16RD/YL/WT
5 16VT/WT
6 20BL/RD/WT
7 16BK/RD
8 16RD/YL
9 18BK/RD
10 18BK/BL
11 16YL
12 -
13 16RD
14 -
15 18RD/BK
16 -
17 -
18 -
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15

C201 - BLACK (MAIN BODY SIDE)
CAV CIRCUIT
1-
2 16GY/DG/RD
3 16RD/BL
4 16RD/YL/WT
4 20BL/VT
5 16VT/WT
6 20BL/RD/WT
7 16BK/RD
8 16RD/YL
9 16BK/RD
10 18BK/BL
11 16YL
12 -
13 16RD
14 -
15 18RD/BK
16 -
17 -
18 -
19 -
20 -
21 -
22 -
C202 - (DASH SIDE)
CAV CIRCUIT
1 16WT/RD
2 16WT/BL/RD
3 20BK/BL/RD
4 20BL/DG
5-
6 18BK/DG
7 20DG/WT
8 20DG
9-
10 -
11 20YL
12 -
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTSVA

C202 - BLACK (MAIN BODY SIDE)
CAV CIRCUIT
1 16WT/RD
2 16WT/BL/RD
3 20BK/BL/RD
4 20BL/DG
5-
6 18BK/DG
7 20DG/WT
8 20DG
9-
10 -
11 20YL
12 -
C203 - (DASH SIDE)
CAV CIRCUIT
1 18GY/YL
2 18GY/BR
3 18GY/WT
4-
5-
6-
7-
8-
9-
10 18VT/DG
11 16RD
12 -
C203 - BLACK (MAIN BODY SIDE)
CAV CIRCUIT
1 18GY/YL
2 18GY/BR
3 18GY/WT
4-
5-
6-
7-
8-
9-
10 18VT/DG
11 16RD
12 -
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17