brake MERCEDES-BENZ SPRINTER 2006 Service Manual

TRAILER TOW CONNECTOR - BLACK
CAV CIRCUIT FUNCTION
1- -
2 16BK/DG/GY STOP/TURN SIGNAL-RIGHT
3 16BK/RD BACK-UP LAMP
4 14RD FUSED B(+)
5 16GY/RD RIGHT LAMP RELAY OUTPUT
6- -
7 14RD/BK ELECTRIC BRAKES
8 14BR GROUND
9- -
10 16BK/RD/WT STOP/TURN SIGNAL-LEFT
TRAILER TOW CONTROL MODULE C1 (EXCEPT RETROFIT) - BLACK
CAV CIRCUIT FUNCTION
A- -
B- -
C 16BK/RD/WT STOP/TURN SIGNAL-LEFT
D 16BK/DG/GY STOP/TURN SIGNAL-RIGHT
E- -
F 14RD/BK ELECTRIC BRAKES
TRAILER TOW CONTROL MODULE C1 (RETROFIT)
CAV CIRCUIT FUNCTION
2 16BK/DG/GY STOP/TURN SIGNAL-RIGHT
5 16BK/RD/WT STOP/TURN SIGNAL-LEFT
8 14RD FUSED B(+)
11 16BK/WT LEFT TURN SIGNAL
14 16BK/RD BRAKE LAMP SWITCH OUTPUT
17 16BR GROUND
20 16BK/DG RIGHT TURN SIGNAL
8W - 80 - 80 8W-80 CONNECTOR PIN-OUTSVA

TRAILER TOW CONTROL MODULE C2 (EXCEPT RETROFIT) - BLACK
CAV CIRCUIT FUNCTION
A 16BK/RD BRAKE LAMP SWITCH OUTPUT
B 16BK/DG RIGHT TURN SIGNAL
C 16BR GROUND
D 14RD FUSED B(+)
E 16BK/WT LEFT TURN SIGNAL
F- -
TRANSMISSION CONTROL MODULE C1 - BLACK
CAV CIRCUIT FUNCTION
1 20BL K-TCM/RADIO
2- -
3- -
4- -
5- -
6- -
7- -
8- -
9- -
10 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 16BK/DG TRANSMISSION RELAY OUTPUT
30 18BR GROUND
TRANSMISSION CONTROL MODULE C2 - BLACK
CAV CIRCUIT FUNCTION
12 20BL/GY N2 INPUT SPEED SENSOR
13 20BK/BL SENSOR SUPPLY VOLTAGE
14 16WT 1-2/4-5 SOLENOID CONTROL
15 16YL 3-4 SOLENOID CONTROL
16 16WT/BL 2-3 SOLENOID CONTROL
17 16YL/BL TCC SOLENOID CONTROL
33 20PK SENSOR GROUND
34 20GY/BL TEMPERATURE SENSOR-P/N SWITCH
35 20BL/DG N3 INPUT SPEED SENSOR
36 16BR/GY MODULATION PRESSURE SOLENOID CONTROL
37 16BK/RD SHIFT PRESSURE SOLENOID CONTROL
38 16BK SOLENOID SUPPLY VOLTAGE
H 20DG/WT CAN C BUS (+)
L 20DG CAN C BUS (-)
VA8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Blower Motor Resistor Block C3 Instrument Panel 33
Blower Motor-Front BK Underhood Right (To The
Instrument Panel)10
Blower Stage 1 Diode Center Roof A/C Unit 39
Body Plug Connector Under Driver Seat N/S
Boost Pressure Sensor (Except OBD) BK Engine Compartment-Left 11
Boost Pressure Sensor (OBD) BK NS
Boost Pressure Servomotor (OBD) BK NS
Boost Pressure Solenoid BK 48
Brake Fluid Level Switch BK Engine Compartment 8
Brake Lamp Switch C1 BK Pedals Area (Brake) 31, 32
Brake Lamp Switch C2 BK Pedals Area (Brake) 31, 32
Brake Wear Sensor-Left Front On Left Front Wheel 49
Brake Wear Sensor-Left Rear On Left Rear Wheel 49
Brake Wear Sensor-Right Front On Right Front Wheel 49
Brake Wear Sensor-Right Rear On Right Rear Wheel 49
C100 BK Under Driver Seat 36
C101 YL Under Instrument Panel-Left 31
C102 (Except OBD) BK NS
C103 BK Lower Left Instrument Panel 29
C200 BK Under Instrument Panel-Left 19
C201 BK Under Instrument Panel-Left 19
C202 BK Under Instrument Panel-Left 19
C203 BK Instrument Panel 29
C204 GY Upper Instrument Panel-Left 19
C205 YL Under Driver Seat 29
C206 BR Instrument Panel 29
C207 BR Near Interior Light Switch-
Driver29
C208 WT Near A/C Fan Switch N/S
C209 BK Instrument Panel 6
C210 BK Instrument Panel N/S
C211 BK Instrument Panel N/S
C214 BL Instrument Panel N/S
C215 BK Instrument Panel N/S
C216 BK Instrument Panel N/S
C217 BK Instrument Panel N/S
C218 BK Under Driver Seat 36
C219 BK Under Driver Seat 36
C220 WT Instrument Panel N/S
C221NS
C224 BK Left Rear Engine Compart-
ment29
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C225 BK Left Rear Engine Compart-
ment29
C226 BK Center Roof A/C Unit 39
C300 BK Front Center Headliner 24
C301 BK Left Lower Instrument Panel 29
C302 Center Roof A/C Unit 38
C303 Center Roof A/C Unit 39
C304 Center Roof A/C Unit 38
C305 Roof A/C Unit 39
C307 Center Roof A/C Unit 40
Cabin Heater Assembly C1 Instrument Panel 5
Cabin Heater Assembly C2 Instrument Panel 5
Camshaft Position Sensor BK Engine Compartment 13
Center High Mounted Stop Lamp Rear Vehicle 53
Central Timer Module C1 PK Instrument Panel 3
Central Timer Module C2 GR Instrument Panel 3
Cigar Lighter WT Near Ash Tray 30
Cigar Lighter Lamp WT Near Cigar Lighter N/S
Circulation Pump (Cabin Heater Module) BK Engine Compartment-Front 10
Circulation Pump (Rest System) NS
Circulation Pump Diode Under Driver Seat 29
Circulation Pump Relay (Relay Block) Under Driver Seat N/S
Clockspring C1 Steering Wheel 17
Clockspring C2 YL Steering Wheel 17,31
Contact Plate-Left Rear License Plate Rear Of Vehicle On Left N/S
Contact Switch Door-Right Rear Right Rear Door N/S
Controller Antilock Brake Engine Compartment-Left 2
Courtesy Lamp - Driver Door BK Driver Door 42
Courtesy Lamp - Left Sliding Door BK Left B-Pillar 42
Courtesy Lamp - Passenger Door BK Passenger Door 42
Courtesy Lamp - Right Sliding Door BK Right B-Pillar 42
Crankcase Heater BK Engine Compartment N/S
Crankshaft Position Sensor BK On Engine 15
CTEL Antenna Connector48
CTEL Connector BK Instrument Panel N/S
Cylinder Lock Switch-Driver Driver Door 43
D(+) Relay No.1 (Relay Block) BK Under Driver Seat N/S
D(+) Relay No.2 (Relay Block) BK NS
Data Link Connector BK Under Dash 29
Daytime Running Lamp Relay-Left Side (Re-
lay Block)BK Under Driver Seat N/S
Daytime Running Lamp Relay-Right Side
(Relay Block)BK Under Driver Seat N/S
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3

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.
Wiper On/Off Relay (Fuse Block No. 1) In Fuse Block No.1 N/S
Wiper/Turn Signal/Engine Start Control Mod-
ule (In Fuse Block 1)In Fuse Block No.1 N/S
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Underhood-Left Front 52
G101 Underhood-Right Front 52
G102 Underhood-Right Front 52
G200 Engine Compartment-Left 8,10, 52
G201 Under Driver Seat 52
G202 Under Driver Seat 36, 52
G203 Dash 19, 52
G300 Right Rear-Body 52
G301 Right Rear-Body Top 52
G302 Engine Compartment-Left Front 52
G303 Left Front Instrument Panel 5
G304 Front Center Headliner 5
SPLICES
SPLICE NUMBER LOCATION FIG.
S100 Under Drivers Seat 18
S101 Instrument Panel 18
S102 Under Drivers Seat 18
S103 Under Drivers Seat 18
S104 Near Headlamp Assembly-Left 27
S105 Engine Compartment-Left 7
S106 Near Wheel 48
S108 Instrument Panel 18
S175 Engine Compartment-Left 18
S176 Engine Compartment-Left 18
S177 Engine Compartment-Left 18
S178 Engine Compartment-Left 18
S180 Left Plenum 27
S200 Engine Compartment-Left 1, 9
S201 Instrument Panel 21
S202 Instrument Panel 21
S203 Instrument Panel 18
S204 Near Brake Lamp Switch 18
S205 Instrument Panel 18
S206 Instrument Panel 18
S207 Near Time Delay Relay 18
S208 Near Time Delay Relay 18
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

SPLICE NUMBER LOCATION FIG.
S306 Near Locker Switch No.2 18
S307 Near Fuse/Relay Block 18
S308 Near Interior Lamp No.3 50
S309 Near Interior Lamp-Right 50
S310 Near Fuse Block No.2 18, 21
S311 Under Drivers Seat 18
S312 Near Wheel Speed Sensor-Left Rear 47
S313 Near Wheel Speed Sensor-Left Rear 47
S314 Near Wheel Speed Sensor-Right Rear 47
S315 Near Wheel Speed Sensor-Right Rear 47
S316 Near Headlamp Assembly-Left 18
S317 Under Drivers Seat 18
S318 Near Marker Lamp-Left Rear 7
S319 Near Tail Lamp Assembly-Left 7
S320 Under Body-Rear Center 7
S321 Near Power Window Switch-Passenger 23, 25
S322 Instrument Panel 18
S323 Near Brake Wear Sensor-Left Rear 47
S324 Near Interior Lamp No.3 N/S
S325 Near Map/Reading Lamp Switch 21
S326 Top Body- Front Center 42
S327 Near Security System Module 18
S328 Near Central Timer Module 18
S329 Near Central Timer Module 18
S330 Near Security System Module 18
S331 Near Security System Module 18
S332 Near Brake Wear Sensor-Left Rear 47
S333 Instrument Panel 18
S350 Near Trailer Tow Connector 18
S351 Near Trailer Tow Control Module 18
S352 Near Trailer Tow Control Module 18
S353 Near Dome Lamp 21
S354 Body-Upper Right Center 42, 50
S355 Near Window Defogger Module-Rear 18, 23
S356 Near Headlamp Assembly-Left 18
S357 Near Central Timer Module 23
S358 Near Trailer Tow Control Module 18
S359 Near Interior Light Switch-Passenger 9
S360 Near Interior Light Switch-Rear 9
S361 Near Time Delay Relay 18
S362 Near Circulation Pump Diode 18
S363 Near Heated Seat Module-Passenger 47
S364 Near CTEL Connector 21
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

Fig. 49 BRAKE SENSORS
8W - 91 - 62 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

(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

(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(13) Connect the engine valley drain hose to the
transmission (Fig. 5).
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION) for correct sequence and torque
specification.
(15) Install the steering gear and tighten in two
stages. 25 N´m (18.5 lbs. ft.), then 45 N´m (33 lbs. ft.)
plus 90É.
(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and
CCV heater at the turbocharger (Fig. 4).
(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the
vacuum pump.(24) Connect the fuel lines at the filter assembly
(Fig. 9).
(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser and fan assemblies Con-
nect the fan harness connector.
(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).
(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-
tor.
(32) Install air cleaner housing and connect the air
inlet duct and air flow sensor.
(33) Connect the charge air cooler hose at intake
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).
(34) Route the engine wiring harness inside the
vehicle and connect.
(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
Fig. 8 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
Fig. 9 FUEL FILTER
1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
9 - 10 ENGINEVA