trailer MERCEDES-BENZ SPRINTER 2006 Owner's Manual

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.
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

SPLICE NUMBER LOCATION FIG.
S210 Near Radio 21
S211 Near Heater Timer-Auxiliary 21
S212 Near Security System Module 50
S213 Instrument Panel 18, 50
S214 Near Security System Module 18
S215 Instrument Panel 18
S216 Instrument Panel 18
S217 Near Engine Control Module 18
S218 Instrument Panel 21
S219 Instrument Panel 18
S220 Near Central Timer Module 18
S221 Instrument Panel 18
S222 Near Security System Module 18
S223 Instrument Panel 18
S224 Instrument Panel 18
S225 Instrument Panel 18
S226 Near Turn Signal/Anti-Theft Alarm Relay-Left 18
S227 Near Sentry Key Remote Entry Module 18
S228 Instrument Panel 18
S229 Near C202 9
S230 Center Instrument Panel 23, 25
S231 Left Plenum 27
S232 Left Plenum 27
S250 Near Turn Signal/Anti-Theft Alarm Relay-Left 18
S251 Near Trailer Tow Control Module 9
S252 Near Trailer Tow Control Module 21
S253 Instrument Panel 21, 22
S254 Near Interior Lamp No.5 9
S255 Near Control Timer Module 27
S256 Near A/C Roof-Switch 18, 21
S257 Near Data Link Connector 18
S258 Near Transmission Control Module 18
S259 Under Drivers Seat 18
S260 Under Drivers Seat 18
S261 Near Data Link Connector 18
S262 Under Drivers Seat 18
S299 Instrument Panel N/S
S300 Near Heated Seat Switch-Driver 21
S301 Near Heated Seat Switch-Passenger 21
S302 Under Drivers Seat 18
S303 Near Power Window Switch-Driver 21
S304 Near Power Window Motor-Driver 21
S305 Near Power Window Motor-Driver 21
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11

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

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT BUMPER - STEPS
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER - STEP
REMOVAL.............................2
INSTALLATION..........................3
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 3
SPECIFICATIONS - TORQUE.............8
ENGINE CRADLE CROSSMEMBER
REMOVAL.............................8
INSTALLATION.........................10
REAR CROSSMEMBER - TRANSMISSION
REMOVAL.............................11
INSTALLATION.........................11
TRAILER HITCH
REMOVAL.............................11
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FRONT BUMPER - STEPS BOLTS 20 15 Ð
FRONT FASCIA SCREWS 23 17 Ð
REAR BUMPER STEP FRAME BOLTS/
NUTS38 17 Ð
REAR BUMPER STEP SUPPORT BOLTS 90 66 Ð
REAR FASCIA BOLTS 23 17 Ð
VAFRAME & BUMPERS 13 - 1

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake line nuts 14 10 Ð
Brake pads wear
indicator caliper
bolt10 7 89
Engine cradle bolts 125 92 Ð
Engine mount bolt
to engine bracket83 61 Ð
Engine mount nuts
to engine cradle45 33 Ð
Power steering line
nuts37 27 Ð
Steering gear
mounting bolts -
1st stage25 18 Ð
Steering Gear
mounting bolts -
2nd stage45 33 Ð
Steering Gear
mounting bolts -
3rd stage90ÉÐÐ
Steering gear u-
joint bolt24 18 Ð
Sway bar bushing
bolts30 22 Ð
Trailer hitch angle
bracket bolts/nuts50*
See
Warning37*
See
WarningÐ
Trailer hitch frame
bolts11 0 8 1 Ð
Transmission cross-
member nuts45 33 Ð
Transmission
mount bolts/nuts45 33 Ð
WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
ENGINE CRADLE CROSSMEM-
BER
REMOVAL
(1) Install engine support tool 8534 or equivalent.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Remove engine mount nuts. (Fig. 8)
(4) Remove front spring. (Refer to 2 - SUSPEN-
SION/FRONT/SPRING - REMOVAL)
(5) Remove calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) (Fig. 9)
Fig. 8 ENGINE MOUNT
1 - ENGINE MOUNT
2 - SHIELD
3 - NUTS (2 PER MOUNT)
13 - 8 FRAME & BUMPERSVA

(18) Install calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION)
(19) Install new tie straps holding wheel speed
sensors and brake pad wear sensors wire harness to
cradle.
(20) Check and align vehicle to specifications.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
REAR CROSSMEMBER -
TRANSMISSION
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support transmission with a suitable lifting
device.
(3) Remove the bolts/nuts and remove transmis-
sion mount cover. (Fig. 16)
(4) Remove crossmember nuts and crossmember.
INSTALLATION
(1) Install crossmember and install nuts.
(2) Tighten crossmember nut to 45 N´m (33 ft.
lbs.).
(3) Remove transmission support.
(4) Install transmission mount bracket.
(5) Install transmission mount bolts/nuts and
tighten to 45 N´m (33 ft. lbs.).
TRAILER HITCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(3) Disconnect electrical connector. (Fig. 17)
Fig. 16 TRANSMISSION CROSSMEMBER
1 - TRANSMISSION MOUNT BOLTS (2)
2 - TRANSMISSION MOUNT COVER
3 - TRANSMISSION CROSSMEMBER NUTS (4)
4 - TRANSMISSION MOUNT NUTS (2)
5 - TRANSMISSION SUPPORT
6 - CROSSMEMBER
7 - TRANSMISSION MOUNT
VAFRAME & BUMPERS 13 - 11

WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
(4) Remove and discard microencapsulated angle
bracket bolts/nuts. (Fig. 18)
(5) Support hitch and remove frame bolts. (Fig. 19)
(6) Lower hitch.
INSTALLATION
WARNING: Do not oil or grease the bolts and nuts.
if the bolts and nuts are greased, the trailer hitch
may become detached from the vehicle, possibly
resulting in a serious risk of injury and/or damage
to property, including damage to the vehicle.
(1) Raise hitch into position.
(2) Install the mounting plate and new frame
bolts/nuts and hand tighten bolts.
Fig. 17 TRAILER HITCH ELECTRICAL CONNECTION
1 - TRAILER CONNECTION SOCKET
2 - ELECTRICAL CONNECTOR TAB
3 - SUPPORT BRACKET
4 - ELECTRICAL CONNECTOR
5 - SCREWS (4)
Fig. 18 TRAILER HITCH MOUNTING
1 - LOCK NUTS (8)
2 - MOUNTING PLATE
3 - BOLTS (8)
4 - ANGLE BRACKETS (2)
5 - BOLTS (4)
6 - HITCH
7 - BRACKET BOLTS/NUTS
Fig. 19 TRAILER HITCH
1 - FRAME BOLTS (8)
2 - MOUNTING PLATES (2)
3 - LOCK NUTS (8)
4 - TRAILER HITCH
5 - BRACKET TO STEP BOLTS (4)
6 - ANGLE BRACKETS (2)
7 - BRACKET BOLTS (4)
13 - 12 FRAME & BUMPERSVA

WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
(3) Install the angle bracket microencapsulated
bolts/nuts and hand tighten.
(4) Align trailer hitch.
(5) Tighten the frame mounting bolts to 110 N´m
(81 ft. lbs.).
(6) Tighten microencapsulated angle bracket bolts
to 50 N´m (37 ft. lbs.)
(7) Connect trailer socket electrical connector.
VAFRAME & BUMPERS 13 - 13

CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
1. Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
2. A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged oil cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
3. Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever
a failure generates sludge and debris. This is neces-
sary because normal converter flushing procedures
will not remove all contaminants.
STANDARD PROCEDURE
CHECK OIL LEVEL
(1) Verify that the vehicle is parked on a level sur-
face.
(2) Remove locking pin (1) (Fig. 149). Remove the
plate of the locking pin with a suitable tool and press
out the pin remaining in the cap downwards.
(3) Remove cap (2).
WARNING: Risk of accident from vehicle starting off
by itself when engine running. Risk of injury from
contusions and burns if you insert your hands into
the engine when it is started or when it is running.
Secure vehicle to prevent it from moving off by
itself. Wear properly fastened and close-fitting work
clothes. Do not touch hot or rotating parts.
(4) Actuate the service brake. Start engine and let
it run at idle speed in selector lever position ªPº.
(5) Shift through the transmission modes several
times with the vehicle stationary and the engine
idling
(6) Warm up the transmission, wait at least 2 min-
utes and check the oil level with the engine running.
Push the Oil Dipstick 8863A in up to the stop on the
electrohydraulic unit and pull out again, read off oil
level, repeat if necessary.
NOTE: The dipstick will protrude from the fill tube
approximately 75mm (3 inches) when installed.
Fig. 149 Remove Dipstick Tube Cap Lock
1 - LOCKING PIN
2 - TUBE CAP
3 - DIPSTICK TUBE
21 - 132 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA