relay MERCEDES-BENZ SPRINTER 2006 Service Manual

(3) Disconnect the front lamp unit wire harness
connector from the fog lamp bulb base (Fig. 14).
(4) Disengage the two fog lamp bulb retainers by
pushing them slightly toward the front lamp unit
housing, outward to each side of the bulb base, then
pivot the retainers off of the bulb base.
(5) Remove the fog lamp bulb from the integral
bulb holder on the front lamp unit reflector.
INSTALLATION
(1) Position the fog lamp bulb into the integral
bulb holder on the front lamp unit reflector. Be cer-tain that the lugs on the bulb base are engaged in
the recesses of the bulb holder (Fig. 14).
(2) Engage the two fog lamp bulb retainers by piv-
oting them over the bulb base, pressing them slightly
toward the front lamp unit housing, then inward on
each side of the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the fog lamp bulb base.
(4) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 13).
(5) Reconnect the battery negative cable.
FOG LAMP RELAY
REMOVAL
Fog lamps are optional equipment on this model.
On vehicles equipped with fog lamps, a fog lamp
relay is located in a dedicated connector of the vehi-
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat
riser just beneath the seat riser cover panel.
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) Move the driver side front seat to its most for-
ward position for easiest access to the seat riser
cover panel (Fig. 15).
Fig. 13 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT
Fig. 14 Fog Lamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB RETAINER
3 - CONNECTOR
4 - BULB BASE
VALAMPS/LIGHTING - EXTERIOR 8L - 11

(3) Remove the cover panel from the top of the
driver side seat riser.
(4) Remove the fog lamp relay by grasping it
firmly and pulling it straight out of the relay connec-
tor.
INSTALLATION
Fog lamps are optional equipment on this model.
On vehicles equipped with fog lamps, a fog lamp
relay is located in a dedicated connector of the vehi-
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat
riser just beneath the seat riser cover panel.
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 fog lamp relay to the relay connec-
tor.
(2) Align the fog lamp relay terminals with the
terminal cavities in the relay connector.
(3) Using hand pressure, push firmly and evenly
on the top of the fog lamp relay until the terminals
are fully seated in the relay connector.
(4) Position the cover panel onto the top of the
driver side seat riser (Fig. 15).(5) Install and tighten the two screws that secure
the cover panel to the top of the seat riser under the
driver side front seat.
(6) Move the driver side front seat back to its driv-
ing position.
(7) Reconnect the battery negative cable.
FOG LAMP SWITCH
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 cluster bezel from the instrument
panel (Fig. 16). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).
(3) From the back of the cluster bezel, squeeze the
two latches on the fog lamp switch body and push
the switch out through the face of the bezel (Fig.
17).
Fig. 15 Seat Riser Cover
1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
Fig. 16 Fog Lamp Switch
1 - FOG LAMP SWITCH
2 - SCREW (2)
3 - CLUSTER BEZEL
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTION AL)
5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)
8L - 12 LAMPS/LIGHTING - EXTERIORVA

(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

(3) Push firmly and evenly on the top of the turn
signal relay until the terminals are fully seated in
the terminal cavities in the receptacle of the fuse
block and both latches are fully engaged.
(4) Reinstall the fuse access panel onto the steer-
ing column opening cover below the steering column
on the instrument panel.
(5) Reconnect the battery negative cable.
VALAMPS/LIGHTING - EXTERIOR 8L - 27

LAMPS / LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
DESCRIPTION.........................28
OPERATION...........................29
SPECIFICATIONS - INTERIOR LIGHTING.....29
ASH RECEIVER/CIGAR LIGHTER LAMP UNIT
REMOVAL.............................30
INSTALLATION.........................30
CARGO/DOME LAMP BULB
REMOVAL.............................30
INSTALLATION.........................30
CARGO/DOME LAMP UNIT
REMOVAL.............................31
INSTALLATION.........................31
CARGO LAMP SWITCH
REMOVAL
REMOVAL - INSTRUMENT PANEL........31
REMOVAL - BULKHEAD................31
REMOVAL - REAR PILLAR..............31
INSTALLATION
INSTALLATION - INSTRUMENT PANEL.....32
INSTALLATION - BULKHEAD.............32
INSTALLATION - REAR PILLAR...........32
DOME/READING LAMP BULB
REMOVAL.............................32INSTALLATION.........................32
DOME/READING LAMP UNIT
REMOVAL.............................32
INSTALLATION.........................33
DOME LAMP/INTRUSION SENSOR BULB
REMOVAL.............................33
INSTALLATION.........................33
DOME LAMP/INTRUSION SENSOR
REMOVAL.............................33
INSTALLATION.........................34
DOOR JAMB SWITCH
REMOVAL.............................34
INSTALLATION.........................34
ENTRY/EXIT LAMP BULB
REMOVAL.............................34
INSTALLATION.........................35
ENTRY/EXIT LAMP UNIT
REMOVAL.............................35
INSTALLATION.........................35
TIME DELAY RELAY
REMOVAL.............................35
INSTALLATION.........................36
LAMPS / LIGHTING - INTERIOR
DESCRIPTION
The interior lighting for this model includes the
following standard and optional incandescent interior
lamps and controls:
²Ash Receiver/Cigar Lighter Lamp- An avail-
able ash receiver/cigar lighter lamp is secured by an
integral mount to the outside of the cigar lighter halo
ring. A single lamp serves to illuminate both the
translucent halo ring and the ash receiver.
²Cargo/Dome Lamp- Several cargo/dome lamp
units located overhead in both the front and rear of
the vehicle interior are standard equipment. These
lamps feature a single incandescent bulb. An optional
version of these lamps includes an integral three-po-
sition switch that protrudes through the lamp lens.
²Cargo Lamp Switch- Toggle-type remote
cargo lamp switches located in the accessory switch
bezel in the center of the instrument panel, on the
back side of the cargo compartment bulkhead panel,
and on the rear cargo door pillar are an available
option on all van models. The instrument panel
switch has two Light-Emitting Diode (LED) units,one for illumination and a second that provides an
indication. The switches mounted in the cargo com-
partment also have two LED units, but only the indi-
cation LED unit is functional in this application.
²Dome/Reading Lamp- An optional equipment
dome/reading lamp unit is located in the windshield
header area between the driver and passenger sun
visors. This lamp features two incandescent bulbs,
one dome lamp bulb and a second, dedicated reading
lamp bulb. An integral four-position switch protrudes
through the lamp lens.
²Dome Lamp/Intrusion Sensor- An optional
equipment dome lamp/intrusion sensor unit is
located overhead in the vehicle interior. This lamp
features four incandescent bulbs, two for dome lamps
and two for dedicated right and left reading lamps.
This lamp has two integral three-position switches,
one to control interior lamp operation and one to con-
trol reading lamp operation. This lamp also houses
three intrusion sensors that are part of an optional
vehicle theft security system.
²Door Jamb Switch- A door jamb switch for
each front door is standard equipment on all models.
A door jamb switch for each sliding side door and the
8L - 28 LAMPS/LIGHTING - INTERIORVA

right rear door is standard equipment on wagon mod-
els. The sliding and rear door jamb switches are not
available for van models.
²Entry/Exit Lamp- An entry/exit lamp to illu-
minate each front and sliding side door step well is
optional equipment on wagon models.
²Time Delay Relay- Vehicles equipped with the
optional remote cargo lamp switches also have a time
delay relay located in the electrical center within the
driver side front seat riser.
Hard wired circuitry connects the interior lighting
system components to the electrical system of the
vehicle. These hard wired circuits are integral to sev-
eral wire harnesses, which are routed throughout the
vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the interior lighting
system components through the use of a combination
of soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
OPERATION
The interior lighting systems can be divided into
two general classifications based upon the circuit
that controls their operation: The interior lighting
circuit, or the exterior lighting circuit. The hard
wired circuits and components of the interior lighting
systems may be diagnosed and tested using conven-
tional diagnostic tools and procedures.
INTERIOR LIGHTING CIRCUIT
Depending upon the vehicle model (van or wagon)
and the selected vehicle options the interior lighting
circuit may include dome/cargo lamps located over-
head in the front and rear of the vehicle, a dome/
reading lamp located in the header area above the
windshield between the sun visors, and entry/exit
lamps located in the front and sliding side door step
wells.
WAGON MODELS
In all wagon models, the lamps in the interior
lighting circuit are provided with battery current at
all times by a fuse in the fuse block beneath the
steering column. The front, side, and rear door jamb
switches control a ground path for each of these
lamps, except for the optional reading lamp. If the
lamp has an optional integral switch, that switch has
three separate positions. The first position provides a
ground path independent of the door jamb switches
to turn the lamp On. The second, or center position
allows the door jamb switches to control the lamp.The third position segregates that lamp from the
door jamb switch input, turning the lamp Off. In the
case of the optional dome/reading lamp, the integral
lamp switch has a fourth position which will illumi-
nate only the reading lamp bulb.
VAN MODELS
Unless a van model is equipped with an optional
remote cargo lamp switch, all of the lamps in the
interior lighting circuit operate the same way as the
wagon models except that there are only two door
jamb switches, one for each front door. If the vehicle
is equipped with an optional remote cargo lamp
switch, the lamps in the rear of the vehicle on the
interior lighting circuit are provided with battery
current by the time delay relay. The time delay relay
is a smart relay containing active electronic elements
that comprise an electronic timer logic circuit. When
the remote cargo lamp switches provide the proper
input to the time delay relay, the relay logic responds
by energizing the relay control coil. The energized
relay control coil provides battery current to all of
the lamps on the rear interior lighting circuit and to
the indicator Light-Emitting Diode (LED) units in
the remote cargo switches causing each to illuminate.
If a remote cargo lamp switch remains On for more
than about fifteen minutes, the time delay relay will
then automatically de-energize the rear interior
lighting circuits until the remote cargo lamp switch
is cycled Off and then back On.
EXTERIOR LIGHTING CIRCUIT
The exterior lighting circuit provides battery cur-
rent to the optional ash receiver/cigar lighter lamp
and to the illumination Light-Emitting Diode (LED)
unit within the remote cargo lamp switch in the
instrument panel accessory switch bezel whenever
the exterior lamps are turned On.
SPECIFICATIONS - INTERIOR LIGHTING
VALAMPS/LIGHTING - INTERIOR 8L - 29

(4) Remove the bulb from the bulb holder.
INSTALLATION
(1) Insert the bulb into the entry/exit lamp bulb
holder (Fig. 10).
(2) Grasp the entry/exit lamp housing firmly in
one hand, then insert the bulb holder into the hous-
ing and rotate it clockwise to lock it in place with the
other hand.
(3) Reinstall the entry/exit lamp unit into its
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/ENTRY/EXIT
LAMP UNIT - INSTALLATION).
(4) Reconnect the battery negative cable.
ENTRY / EXIT LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the tip of a small flat-bladed screwdriver
into the notch on one edge of the entry/exit lamp
housing to depress the retainer clip and pull that
edge of the lamp away from its mounting location
(Fig. 11).
(3) Pull the entry/exit lamp unit from its mounting
location far enough to access and disconnect the vehi-
cle wire harness from the lamp connector receptacle.(4) Remove the entry/exit lamp unit from its
mounting location.
INSTALLATION
(1) Position the entry/exit lamp unit to its mount-
ing location.
(2) Reconnect the vehicle wire harness connector
to the entry/exit lamp connector receptacle (Fig. 11).
(3) Position the edge of the entry/exit lamp hous-
ing opposite from the retainer clip into the mounting
hole.
(4) Push firmly and evenly on the notched edge of
the entry/exit lamp housing until the retainer clip
latches into place.
(5) Reconnect the battery negative cable.
TIME DELAY 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) Move the driver side front seat to its most for-
ward position for easiest access to the seat riser
cover panel.
(3) Remove the two screws that secure the cover
panel to the top of the seat riser under the driver
side front seat (Fig. 12).
Fig. 10 Entry/Exit Lamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB HOLDER
3 - CONNECTOR
Fig. 11 Entry/Exit Lamp Unit Remove/Install
1 - STEP WELL SCUFF PAD
2 - NOTCH
3 - ENTRY/EXIT LAMP UNIT
VALAMPS/LIGHTING - INTERIOR 8L - 35

(4) Remove the cover panel from the top of the
driver side seat riser.
(5) Remove the time delay relay from its vehicle
wire harness connector by grasping it firmly and
pulling it straight out from the connector within the
driver side seat riser.
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 time delay relay to its vehicle wire
harness connector within the driver side seat riser.
(2) Align the time delay relay terminals with the
terminal cavities in the vehicle wire harness connec-
tor.
(3) Push firmly and evenly on the top of the time
delay relay until the terminals are fully seated in the
terminal cavities in the vehicle wire harness connec-
tor.
(4) Position the cover panel onto the top of the
driver side seat riser (Fig. 12).
(5) 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.).(6) Move the driver side front seat back to its driv-
ing position.
(7) Reconnect the battery negative cable.
Fig. 12 Seat Riser Cover
1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
8L - 36 LAMPS/LIGHTING - INTERIORVA

WIPERS / WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................2
OPERATION............................3
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM.....................6
CLEANING - WIPER & WASHER SYSTEM.....9
INSPECTION - WIPER & WASHER SYSTEM . . 10
CHECK VALVE
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
RAIN SENSOR
DESCRIPTION.........................12
OPERATION...........................12
STANDARD PROCEDURE
RAIN SENSOR BRACKET REPLACEMENT . . 12
REMOVAL.............................14
INSTALLATION.........................14
RAIN SENSOR CONTROL MODULE
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................16
WASHER FLUID LEVEL SWITCH
DESCRIPTION.........................16
OPERATION...........................16
WASHER HOSES/TUBES
DESCRIPTION.........................18
OPERATION...........................18
WASHER NOZZLE
DESCRIPTION.........................18
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19WASHER PUMP/MOTOR
DESCRIPTION.........................19
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
WASHER RESERVOIR
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
WIPER ARM
DESCRIPTION.........................23
OPERATION...........................24
REMOVAL.............................24
INSTALLATION.........................24
WIPER BLADE
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................27
WIPER LINKAGE
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................28
INSTALLATION.........................31
WIPER MOTOR
DESCRIPTION.........................31
OPERATION...........................32
REMOVAL.............................32
INSTALLATION.........................33
WIPER RELAY
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................35
INSTALLATION.........................35
VAWIPERS/WASHERS 8R - 1

WIPERS/WASHERS
DESCRIPTION
An electrically operated intermittent wiper and
washer system is standard factory-installed safety
equipment on this model (Fig. 1). The wiper and
washer system includes the following major compo-
nents, which are described in further detail else-
where in this service information:
²Check Valve- The washer system check valve
is integral to the plumbing fitting located in the
washer plumbing between the cowl plenum washer
hose and the two washer nozzle hoses, and is locatedbeneath the cowl top panel at the base of the wind-
shield in the engine compartment.
²Multi-Function Switch- The multi-function
switch is secured to the top of the steering column,
just below the steering wheel. Only the left (lighting)
control stalk, right (wiper) control stalk and the haz-
ard warning switch button for the multi-function
switch are visible, the remainder of the switch is con-
cealed beneath the steering column shrouds. The
multi-function switch contains all of the switches for
Fig. 1 Wiper & Washer System
1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL SWITCH 4 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH
2 - WIPER MOTOR, LINKAGE & PIVOTS MODULE 5 - RAIN SENSOR (W/AUTOMATIC WIPERS ONLY)
3 - WIPER RELAY 6 - RAIN SENSOR CONTROL MODULE (W/AUTOMATIC WIPERS
ONLY)
8R - 2 WIPERS/WASHERSVA