ECU MERCEDES-BENZ SPRINTER 2006 Service Manual

(5) If desired, a thin film coat of adhesive can be
applied to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)
away from edge of patch across from holes drilled
around cutout.
(7) Drill 3 mm (0.125 in.) holes in the support
squares 13 mm (0.5 in.) from the edge in the center
of one side.
(8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(9) Mix enough adhesive to cover one side of all
support squares.
(10) Apply adhesive to cover one side of all support
squares.
(11) Using number 8 sheet metal screws, secure
support squares to back side of body panel with
adhesive sandwiched between the panel and squares
(Fig. 9).(12) Position patch in cutout against support
squares and adjust patch until the gap is equal along
all sides (Fig. 10).
(13) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
(14) Apply a coat of adhesive to the exposed ends
of the support squares (Fig. 11).
(15) Install screws to hold the patch to support
squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.
(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.
(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 14).
(19) Mix enough adhesive to cover the entire patch
area.
(20) Apply adhesive over the mesh around patch,
and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 9 SECURE SUPPORT SQUARES TO BODY
PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
23 - 8 BODYVA

(7) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
(8) Adjust door if required. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
(9) Connect battery negative cable.
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
²During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door
with final torque of the fasteners occurring after
correct door positioning is achieved.
²A suitable body sealant should be used when
removing or moving the hinges.
(1) Check door alignment. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(2) If adjustment is required, remove latch striker.
(Refer to 23 - BODY/DOOR - FRONT/LATCH
STRIKER - REMOVAL)
(3) Remove side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - REMOVAL)
(4) Loosen hinge bolts and adjust door gap and
align ridge pattern as necessary.
(5) Tighten hinge bolts to 25 N´m (18 ft. lbs.).
(6) Install latch striker and adjust flush measure-
ment as necessary. (Refer to 23 - BODY/DOOR -
FRONT/LATCH STRIKER - INSTALLATION)
(7) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - INSTALLA-
TION)
DOOR GLASS
REMOVAL
(1) Remove the regulator. (Refer to 23 - BODY/
DOOR - FRONT/WINDOW REGULATOR - POWER
or MANUAL - REMOVAL)
(2) Remove reinforcement bolts. (Fig. 6)(3) Carefully lower glass into door and out of run
channel.
(4) Remove glass from door.
INSTALLATION
(1) Carefully place glass into door and slide up
into run channel.
(2) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 7)
(3) Install reinforcement and install the bolts.
Fig. 6 FRONT DOOR GLASS
1 - DOOR RUN CHANNEL
2 - DOOR GLASS
3 - REINFORCEMENT BOLTS
Fig. 7 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS
VADOOR - FRONT 23 - 15

(8) Slightly pull door trim upward and swing away
slightly.
(9) Unlock retainer clip and disconnect control
cable. (Fig. 21)
(10) Remove trim panel.
INSTALLATION
(1) Position trim panel and connect control cable.
(2) Install trim panel.(3) Position window frame molding and seat clips
fully.
(4) Close pocket door.
(5) Install window crank and mounting ring, if
equipped.
(6) Install handle screws.
(7) Connect electrical connectors and install switch
bezel.
(8) Install handle cover.
(9) Connect battery negative cable.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Lower front window approximately 2 cm (3/4
in.).
(2) Disconnect and isolate battery negative cable.
(3) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(4) Disconnect electrical connector. (Fig. 22)
(5) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 23)
Fig. 20 MANUAL REGULATOR ASSEMBLY
1 - DOOR
2 - CARRIER PLATE BOLTS
3 - CARRIER PLATE
4 - REGULATOR ASSEMBLY
5 - SEALING STRIP
6 - REGULATOR RIVETS (4)
7 - WINDOW CRANK/TRIM RING
8 - TRIM PANEL
9 - CLIPS
10 - WINDOW FRAME MOLDING
11 - REGULATOR
Fig. 21 CONTROL CABLE
1 - RETAINER CLIP
2 - CONTROL CABLE MOUNTING
Fig. 22 ELECTRICAL CONNECTOR
1 - ELECTRICAL CONNECTOR
2 - REGULATOR MOTOR
3 - WIRE TIE
23 - 20 DOOR - FRONTVA

(6) Remove tape securing wire harness to regula-
tor assembly. (Fig. 24)
(7) Remove carrier plate bolts.
(8) Disengage lift arm from glass guide rail and
remove regulator assembly. (Fig. 25)(9) Remove four rivets attaching regulator to car-
rier plate and remove regulator.
INSTALLATION
(1) Install regulator onto carrier plate and install
new rivets.
(2) Install regulator lift arm into glass guide rail
and install regulator assembly.
(3) Install carrier bolts and tighten to 10 N´m (89
in. lbs.).
(4) Replace tape securing wire harness to regulator
assembly.
(5) Remove glass support.
(6) Connect the electrical connector.
(7) Connect battery negative cable.
(8) Verify correct window operation.
(9) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
WINDOW REGULATOR - MAN-
UAL
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 26)
Fig. 23 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS
Fig. 24 REGULATOR ASSEMBLY MOUNTING
1 - CARRIER PLATE BOLTS (3)
2 - CARRIER PLATE
3 - REGULATOR MOTOR
4 - TAPE
Fig. 25 REGULATOR ASSEMBLY
1 - GUIDE RAIL
2 - REGULATOR
3 - CARRIER PLATE
4 - RIVETS (4)
5 - CARRIER PLATE BOLTS (3)
6 - WINDOW GLASS
VADOOR - FRONT 23 - 21

(9) Install instrument panel top cover and screws.
(Fig. 15)
(10) Install right outer and inner air nozzles. (Fig.
13)
(11) Install right side cover and screws.
(12) Wrap protective mat around connectors
behind instrument cluster.
(13) Install left outer and inner air nozzles.
(14) Install left side cover and screws.
(15) Install passenger side air nozzle cover and
bracket and install the screws. (Fig. 12)
(16) Position Power Distribution Center (PDC) in
vehicle and connect electrical connectors. (Fig. 11)
(17) Install PDC and install bolt and nut. (Fig. 10)
(18) Install PDC ground cable and nut.
(19) Install steering column shroud and install the
two screws and one nut. (Fig. 9)
(20) Install PDC cover and twist lock 1/4 turn to
secure in place. (Fig. 8)
(21) Connect electrical connectors and cables to air
conditioning push-button module and install. (Fig. 7)
(22) Install center bezel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL CEN-
TER BEZEL - INSTALLATION)
(23) Install left and right speakers. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - INSTALLATION)
(24) Install passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
INSTALLATION)
(25) Install instrument cluster. (Refer to 8 - ELEC-
TRICAL/INSTRUMENT CLUSTER - INSTALLA-
TION)
(26) Install cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - INSTALLA-
TION)
(27) Install glove compartment. (Refer to 23 -
BODY/INSTRUMENT PANEL/GLOVE BOX -
INSTALLATION)
(28) Install radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION)
(29) Connect battery negative cable.
TOP COVER - CLUSTER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the screws and using a trim stick
C-4755 or equivalent, remove the cover. (Fig. 23)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cover and install the screws.
Fig. 23 Instrument Cluster Remove/Install
1 - SCREW (2)
2 - COVER
3 - SCREW (2)
4 - INSTRUMENT CLUSTER
5 - LOOP (2)
23 - 64 INSTRUMENT PANELVA

(1) Twist cover lock 1/4 turn and remove Power
Distribution Center cover. (Fig. 27)
(2) Remove nut and screws and remove steering
column shroud. (Fig. 28)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install steering column shroud and install the
two screws and one nut.
(2) Install Power Distribution Center cover and
twist lock 1/4 turn to secure in place.
Fig. 27 ELECTRICAL CENTER COVER
1 - COVER LOCK
2 - COVER
Fig. 28 STEERING COLUMN SHROUD
1 - SHROUD
2 - SCREWS (2)
3 - NUT
VAINSTRUMENT PANEL 23 - 69

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION..........................8
OPERATION............................9
STANDARD PROCEDURE
A/C COMPRESSOR CLUTCH AIR GAP......9
A/C COMPRESSOR CLUTCH BREAK-IN.....9
REMOVAL.............................9
INSPECTION..........................11
INSTALLATION.........................11
A/C COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH COIL........12
A/C HEATER CONTROL
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................14
OPERATION...........................14
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER..........14
REMOVAL.............................15
INSTALLATION.........................15
AIR OUTLET TEMPERATURE SENSOR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
AMBIENT TEMPERATURE SENSOR
DESCRIPTION.........................17
OPERATION...........................17REMOVAL.............................17
INSTALLATION.........................17
BLOWER MOTOR RESISTOR
DESCRIPTION.........................17
OPERATION...........................18
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR............18
REMOVAL.............................18
INSTALLATION.........................18
BLOWER MOTOR SWITCH
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH..............19
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
IN-CAR TEMPERATURE SENSOR
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING
IN-CAR TEMPERATURE SENSOR.........21
MODE DOOR CABLES
REMOVAL.............................21
INSTALLATION.........................21
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
A / C COMPRESSOR CLUTCH
DESCRIPTION
The A/C compressor clutch assembly consists of a
stationary electromagnetic field coil, a hub bearing
and pulley assembly, and a clutch plate (Fig. 1). The
field coil and the hub bearing and pulley assembly
are each retained on the nose of the compressor front
housing with snap rings. The clutch plate is splined
to the compressor shaft and secured with a bolt.
The compressor clutch plate and pulley and the
clutch field coil are available for service replace-
ment.
24 - 8 CONTROLS-FRONTVA

OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is
part of the pulley.
The compressor clutch engagement is controlled by
several components:
²A/C switch on the A/C-heater control panel
²Evaporator temperature sensor
²A/C pressure transducer
²Air temperature sensor
²CAN bus messages
The compressor clutch is de-energized under any of
the following conditions:
²Blocked compressor (thermal fuse in the pulley)
²Low pressure in the system
²Low evaporator temperature
²Hard acceleration (WOT)
²High coolant temperatures
STANDARD PROCEDURE
A / C COMPRESSOR CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between specifications
(Refer to 24 - HEATING & AIR CONDITIONING -
SPECIFICATIONS), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
A / C COMPRESSOR CLUTCH BREAK - IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control in the
Recirculation Mode, the A/C button in the on posi-
tion, the blower motor switch in the highest speed
position, and the engine speed at 1500 to 2000 rpm.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher compressor
clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil
wire harness connector on the top of the compressor.
(4) Remove the retainer securing the compressor
clutch coil lead on the top of the compressor.
(5) Remove the bolt that secures the compressor
clutch to the compressor shaft (Fig. 2). If necessary, a
band-type oil filter wrench or strap wrench can be
placed around the clutch plate to aid in bolt
removal.
Fig. 1 A/C Compressor Clutch
1 - BOLT
2 - CLUTCH PLATE
3 - PULLEY AND BEARING
4 - FIELD COIL
5 - SNAP RING
6 - SNAP RING
7 - SHIM (2)
VACONTROLS-FRONT 24 - 9

(6) Tap the clutch plate lightly with a plastic mal-
let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3).Be certain not to lose
the shim or shims.
CAUTION: Do not pry between the clutch plate and
the pulley to remove it from the compressor shaft.
Prying may damage the clutch plate.
(7) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch pulley to the front of
the compressor, then slide the pulley off of the com-
pressor (Fig. 4).(8) Remove the screw that secures the clutch coil
wire harness connector bracket and ground clip to
the top of the compressor housing.
(9) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch coil to the front of the
compressor, then slide the clutch coil off of the com-
pressor (Fig. 5).
Fig. 2 Compressor Shaft Bolt and Clutch Plate
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
Fig. 3 Clutch Plate And Shim(s)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 4 Pulley Snap Ring
1 - SNAP RING
24 - 10 CONTROLS-FRONTVA

INSPECTION
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the fac-
tory using a burnishing operation. No attempt should
be made to separately replace the compressor clutch
pulley or clutch plate. The clutch coil may be serviced
separately.
(1) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for wear. The clutch pulley
and clutch plate should be replaced if there is exces-
sive wear or scoring.
(2) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for oil contamination. If the
friction surfaces are oily, the clutch pulley and clutch
plate should be replaced. Also inspect the shaft and
nose area of the compressor for oil. Remove the felt
packing from around the compressor shaft in the
compressor front cover. If the felt is saturated with
oil, the compressor front shaft seal is leaking and the
compressor will also have to be replaced.
(3) Check the clutch pulley bearing for roughness
or excessive leakage of grease. Replace the clutch
pulley and clutch plate if the bearing is faulty.
INSTALLATION
(1) Align the dowel pin on the back of the clutch
field coil with the hole in the compressor front cover,
and position the clutch coil onto the compressor. Be
certain that the cluch coil wire harness leads are
properly oriented and routed so that they are notpinched between the compressor front cover and the
clutch coil.
NOTE: A new snap ring must be used to secure the
clutch coil to the compressor. The bevel side of the
snap ring must face outward.
(2) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring that
secures the clutch coil to the front cover of the com-
pressor. The bevel side of the snap ring must be fac-
ing outward and both snap ring eyelets must be
oriented to the right or left of the clutch coil dowel
pin on the compressor. Be certain that the snap ring
is fully and properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the compressor front
cover.
(3) Install and tighten the screw that secures the
clutch coil wire harness connector bracket and
ground clip to the top of the compressor housing.
(4) Install the pulley onto the front of the compres-
sor. If necessary, place a block of wood on the friction
surface and tap gently with a hammer (Fig. 6).
CAUTION: Do not mar the friction surfaces of the
pulley.
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
Fig. 5 Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
Fig. 6 Pulley Assembly Install
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
VACONTROLS-FRONT 24 - 11