coolant level MERCEDES-BENZ SPRINTER 2006 Owner's Guide

8W-15 GROUND DISTRIBUTION
Component PageA/C Auxiliary Fan..........................8W-15-4
A/C Auxiliary Fan Relay......................8W-15-12
A/C Compressor Clutch Relay...................8W-15-30
A/C Roof Auxiliary Fan......................8W-15-30
A/C Roof Auxiliary Fan Relay...................8W-15-30
Additional Heat Exchanger....................8W-15-12
Additional Heat Exchanger Relay.................8W-15-12
Additional Heat Exchanger Switch................8W-15-24
Airbag Control Module.......................8W-15-11
Ash Receiver Lamp........................8W-15-22
Automatic Temperature Control Module.............8W-15-24
Auxiliary Heater Control.....................8W-15-24
Battery................................8W-15-8
Battery Relay-Auxiliary......................8W-15-11
Battery-Auxiliary..........................8W-15-11
Blower Motor-Front.........................8W-15-9
Brake Fluid Level Switch......................8W-15-8
Brake Wear Sensor-Left Front...................8W-15-8
Brake Wear Sensor-Left Rear...................8W-15-28
Brake Wear Sensor-Right Front..................8W-15-8
Brake Wear Sensor-Right Rear..................8W-15-28
CTEL Connector..........................8W-15-21
Cabin Heater Module........................8W-15-3
Center High Mounted Stop Lamp.................8W-15-6
Central Timer Module.......................8W-15-15
Cigar Lighter............................8W-15-22
Cigar Lighter Lamp........................8W-15-22
Circulation Pump..........................8W-15-9
Circulation Pump Relay-Cabin Heater Module..........8W-15-12
Clockspring.............................8W-15-10
Controller Antilock Brake....................8W-15-2, 28
Crankcase Heater..........................8W-15-4
Cylinder Lock Switch-Driver...................8W-15-10
D+ Relay No. 1...........................8W-15-12
D+ Relay No. 2...........................8W-15-14
Data Link Connector........................8W-15-10
Daytime Running Lamp Relay-Left Side.............8W-15-13
Daytime Running Lamp Relay-Right Side............8W-15-13
Daytime Running Lamps Relay..................8W-15-13
Differential Lock Solenoid Valve..................8W-15-2
Dome Lamp.............................8W-15-6
Dosing Pump............................8W-15-2
Engine Control Module.......................8W-15-7
Engine Coolant Level Switch....................8W-15-2
Fan Stage 1 Relay.........................8W-15-11
Fog Lamp Relay..........................8W-15-11
Fog Lamp Switch.........................8W-15-22
Fuel Pump.............................8W-15-19
Fuse Block No. 1..........................8W-15-7
Fused Ignition Switch Run-Start Relay..............8W-15-14
G100...............................8W-15-2, 3
G101.................................8W-15-4
G102.................................8W-15-4
G103.................................8W-15-4
G200...........................8W-15-6, 7, 8, 9, 10
G201................................8W-15-11
G202................8W-15-11, 12, 13, 14, 15, 16, 17, 18, 19
G203......................8W-15-20, 21, 22, 23, 24, 25
G300............................8W-15-26, 27, 28
G301................................8W-15-28
G302................................8W-15-28
G303................................8W-15-31
G304................................8W-15-31
G305..............................8W-15-29, 30
Glow Plug Control Module.....................8W-15-2
Hazard Warning Switch.......................8W-15-7
Headlamp Adjust Switch.....................8W-15-22
Headlamp Assembly-Left......................8W-15-3
Headlamp Assembly-Right.....................8W-15-4
Heated Seat Module-Driver....................8W-15-19
Heated Seat Module-Passenger..................8W-15-19
Heated Seat Switch-Driver....................8W-15-25
Heated Seat Switch-Passenger..................8W-15-25
Heater Timer-Auxiliary......................8W-15-24
High Idle Switch..........................8W-15-25
Hood Ajar Switch..........................8W-15-4
Horn Relay.............................8W-15-11
Horn Switch............................8W-15-10
Ignition Lock Switch........................8W-15-10
Instrument Cluster........................8W-15-10
Instrument Panel Socket.....................8W-15-20
Interior Lamp No. 1.........................8W-15-6
Interior Lamp No. 2.........................8W-15-6
Interior Lamp No. 3.........................8W-15-6Component PageInterior Lamp No. 4.........................8W-15-6
Interior Lamp No. 5.........................8W-15-6
Interior Lamp-Left.........................8W-15-6
Interior Lamp-Middle Front...................8W-15-5, 6
Interior Lamp-Middle Rear...................8W-15-5, 6
Interior Lamp-Rear No. 2......................8W-15-5
Interior Lamp-Right.......................8W-15-5, 6
Interior Light Switch.......................8W-15-21
Interior Lighting Connector.....................8W-15-6
Intrusion Sensor No. 1.......................8W-15-6
Intrusion Sensor No. 2.......................8W-15-6
Intrusion Sensor No. 3.......................8W-15-6
Kickdown Switch..........................8W-15-8
Lamp Relay-Left..........................8W-15-13
Lamp Relay-Right.........................8W-15-13
License Plate Lamp No. 1.....................8W-15-27
License Plate Lamp No. 2.....................8W-15-27
Locker Switch No. 1........................8W-15-20
Map/Reading Lamp Switch....................8W-15-21
Marker Lamp Connector......................8W-15-17
Marker Lamp No. 1-Left Front..................8W-15-16
Marker Lamp No. 1-Right Front.................8W-15-16
Marker Lamp No. 2-Left Front..................8W-15-16
Marker Lamp No. 2-Right Front.................8W-15-16
Marker Lamp-Left Center.....................8W-15-17
Marker Lamp-Left Rear......................8W-15-27
Marker Lamp-Right Center....................8W-15-17
Marker Lamp-Right Rear.....................8W-15-27
Master Door Lock Switch.....................8W-15-25
Metering Pump...........................8W-15-18
Multi-Function Switch.......................8W-15-7
Optional Equipment Relay....................8W-15-19
Panic Alarm Switch........................8W-15-20
Parking Brake Switch.......................8W-15-15
Power Mirror Motor-Driver....................8W-15-23
Power Mirror Motor-Passenger..................8W-15-23
Power Mirror Switch........................8W-15-23
Power Window Switch-Driver...................8W-15-23
Power Window Switch-Master...................8W-15-23
Radio................................8W-15-21
Rain Sensor............................8W-15-31
Rain Sensor Control Module..................8W-15-19, 31
Reading Lamp Connector......................8W-15-6
Rear Window Defogger Relay...................8W-15-14
Recirculated Air Solenoid Valve...................8W-15-9
Rollover Switch Assembly......................8W-15-3
Roof A/C Blower..........................8W-15-29
Roof A/C Blower Stage I And Ii Relay...............8W-15-29
Roof A/C Blower Stage I Relay..................8W-15-29
Roof A/C Blower Stage Ii Relay..................8W-15-29
Roof A/C Control Module.....................8W-15-28
Roof A/C Switch..........................8W-15-24
Roof Fan Switch..........................8W-15-21
Roof Thermotronic Control Module................8W-15-30
Seat Belt Switch..........................8W-15-15
Security System Module......................8W-15-15
Sentry Key Remote Entry Module.................8W-15-7
Shifter Assembly..........................8W-15-20
Siren.................................8W-15-9
Steering Angle Sensor........................8W-15-7
TCS Switch.............................8W-15-25
Tail Lamp Assembly-Left.....................8W-15-26
Tail Lamp Assembly-Right.....................8W-15-26
Thermotronic Diode........................8W-15-30
Time Delay Relay.........................8W-15-17
Towing/Intrusion Sensor On/Off Switch..............8W-15-22
Trailer Tow Connector.......................8W-15-28
Trailer Tow Control Module....................8W-15-19
Transmission Control Module...................8W-15-19
Transmission Relay........................8W-15-19
Turn Signal No. 1-Left Front....................8W-15-3
Turn Signal No. 1-Right Front...................8W-15-4
Turn Signal No. 2-Left Front....................8W-15-3
Turn Signal No. 2-Right Front...................8W-15-4
Warm Air Auxiliary Heater Assembly...............8W-15-18
Washer Pump Motor-Front.....................8W-15-4
Water Cycle Valve..........................8W-15-9
Window Defogger Module-Rear..................8W-15-15
Window Defogger Switch-Rear..................8W-15-20
Window Defogger-Left Rear....................8W-15-26
Window Defogger-Right Rear...................8W-15-26
Wiper Motor-Front.........................8W-15-9
Wiper/Turn Signal/Engine Start Control Module.........8W-15-7
VA8W-15 GROUND DISTRIBUTION 8W - 15 - 1

8W-30 FUEL/IGNITION SYSTEM
Component Page
Accelerator Pedal Position Sensor.... 8W-30-10, 21
Airbag Control Module................ 8W-30-9
Boost Pressure Sensor............. 8W-30-9, 25
Boost Pressure Servomotor............ 8W-30-24
Boost Pressure Solenoid.............. 8W-30-14
Camshaft Position Sensor.............. 8W-30-6
Central Timer Module................ 8W-30-9
Crankcase Heater................ 8W-30-17, 24
Crankshaft Position Sensor............ 8W-30-7
Data Link Connector................. 8W-30-4
Daytime Running Lamps Relay......... 8W-30-2
EGR Valve..................... 8W-30-17, 24
Engine Control Module . . . 8W-30-2, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24, 25
Engine Control Relay........... 8W-30-8, 17, 24
Engine Coolant Level Switch........... 8W-30-3
Engine Coolant Temperature Sensor..... 8W-30-6
Engine Oil Sensor................... 8W-30-17
Fuel Injector No. 1............... 8W-30-15, 22
Fuel Injector No. 2............... 8W-30-16, 23
Fuel Injector No. 3............... 8W-30-15, 22
Fuel Injector No. 4............... 8W-30-15, 22
Fuel Injector No. 5............... 8W-30-16, 23
Fuel Level Sensor.................... 8W-30-3
Fuel Pressure Sensor................. 8W-30-5
Fuel Pressure Solenoid................ 8W-30-7
Fuel Pump........................ 8W-30-18
Fuel Pump Relay................... 8W-30-18
Fuel Quantity Control Valve........... 8W-30-7
Fuel Shutdown Solenoid............... 8W-30-7
Fuel Temperature Sensor.............. 8W-30-5
Fuse 5......................... 8W-30-13, 19
Fuse 7............................ 8W-30-20
Fuse 12............................ 8W-30-2Component Page
Fuse 16............................ 8W-30-8
Fuse 17........................ 8W-30-17, 24
Fuse 18............................ 8W-30-9
Fuse 19........................... 8W-30-18
Fuse Block No. 1....... 8W-30-8, 9, 17, 18, 20, 24
Fuse Block No. 3.................... 8W-30-2
G100........................ 8W-30-3, 13, 19
G103............................. 8W-30-17
G200........................... 8W-30-8, 12
G202............................. 8W-30-18
G203.............................. 8W-30-2
Glow Plug Control Module......... 8W-30-13, 19
Glow Plug No. 1................. 8W-30-13, 19
Glow Plug No. 2................. 8W-30-13, 19
Glow Plug No. 3................. 8W-30-13, 19
Glow Plug No. 4................. 8W-30-13, 19
Glow Plug No. 5................. 8W-30-13, 19
High Idle Switch.................... 8W-30-2
Instrument Cluster................... 8W-30-3
Intake Air Pressure Sensor............ 8W-30-20
Intake Air Temperature Sensor...... 8W-30-10, 21
Kickdown Switch................... 8W-30-12
Low Fuel Pressure Sensor............ 8W-30-11
Mass Air Flow Sensor............. 8W-30-14, 20
Optional Equipment Relay............. 8W-30-2
Oxygen Sensor..................... 8W-30-24
Power Distribution Center......... 8W-30-13, 19
Relay Block........................ 8W-30-2
Speed Control Switch................ 8W-30-12
Starter Motor Relay.............. 8W-30-11, 18
Transmission Control Module........... 8W-30-4
Water In Fuel Sensor............. 8W-30-11, 25
Wiper/Turn Signal/Engine Start Control
Module.......................... 8W-30-8
VA8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-3
Ambient Temperature Sensor........... 8W-40-8
Automatic Temperature
Control Module.................. 8W-40-4, 8
Battery............................ 8W-40-2
Brake Fluid Level Switch.............. 8W-40-3
Brake Wear Sensor-Left Front.......... 8W-40-5
Brake Wear Sensor-Left Rear........... 8W-40-5
Brake Wear Sensor-Right Front......... 8W-40-5
Brake Wear Sensor-Right Rear......... 8W-40-5
Courtesy Lamp-Driver Door............ 8W-40-6
Courtesy Lamp-Passenger Door......... 8W-40-6
D+ Relay No. 1...................... 8W-40-8
Data Link Connector................. 8W-40-3
Dome Lamp........................ 8W-40-6
Door Jamb Switch-Driver.............. 8W-40-6
Door Jamb Switch-Passenger........... 8W-40-6
Engine Coolant Level Switch........... 8W-40-7
Fuel Level Sensor.................... 8W-40-3
Fuse 1............................ 8W-40-2
Fuse 6............................ 8W-40-3
Fuse 18............................ 8W-40-2Component Page
Fuse Block No. 1.................... 8W-40-2
Fuse Block No. 2.................... 8W-40-3
G100.............................. 8W-40-7
G200.......................... 8W-40-2, 3, 5
G202.......................... 8W-40-3, 7, 8
G300.............................. 8W-40-5
Generator.......................... 8W-40-2
Headlamp Assembly-Left.............. 8W-40-7
Headlamp Assembly-Right............. 8W-40-7
Ignition Lock Switch................. 8W-40-2
Instrument Cluster....... 8W-40-2, 3, 4, 5, 6, 7, 8
Parking Brake Switch................ 8W-40-3
Power Distribution Center............. 8W-40-2
Radio............................. 8W-40-8
Seat Belt Switch..................... 8W-40-7
Security System Module............... 8W-40-6
Sentry Key Remote Entry Module....... 8W-40-4
Turn Signal/Anti-Theft Alarm Relay-Left . . 8W-40-8
Turn Signal/Anti-Theft Alarm Relay-
Right........................... 8W-40-8
VA8W-40 INSTRUMENT CLUSTER 8W - 40 - 1

Component Page
Cigar Lighter...................... 8W-80-30
Cigar Lighter Lamp................. 8W-80-30
Circulation Pump (Cabin Heater
Module)........................ 8W-80-31
Circulation Pump (Rest System)........ 8W-80-31
Circulation Pump Diode.............. 8W-80-31
Clockspring C1..................... 8W-80-31
Clockspring C2..................... 8W-80-31
Controller Antilock Brake............. 8W-80-32
Courtesy Lamp-Driver Door........... 8W-80-33
Courtesy Lamp-Left Sliding Door....... 8W-80-33
Courtesy Lamp-Passenger Door........ 8W-80-33
Courtesy Lamp-Right Sliding Door...... 8W-80-33
Crankcase Heater................... 8W-80-34
Crankshaft Position Sensor........... 8W-80-34
CTEL Antenna Connector............. 8W-80-34
CTEL Connector.................... 8W-80-34
Cylinder Lock Switch-Driver.......... 8W-80-35
Data Link Connector................ 8W-80-35
Differential Lock Solenoid Valve........ 8W-80-35
Dome Lamp....................... 8W-80-35
Door Lock Motor/Ajar Switch
Assembly-Driver C1............... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Driver C2............... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C1........... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Left Sliding C2........... 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Passenger C1............ 8W-80-36
Door Lock Motor/Ajar Switch
Assembly-Passenger C2............ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Rear C1................ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Rear C2................ 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C1.......... 8W-80-37
Door Lock Motor/Ajar Switch
Assembly-Right Sliding C2.......... 8W-80-37
Dosing Pump...................... 8W-80-38
EGR Valve........................ 8W-80-38
Electrohydraulic Control Unit......... 8W-80-38
Engine Control Module C1 (Except
OBD).......................... 8W-80-38
Engine Control Module C1 (OBD)...... 8W-80-39
Engine Control Module C2 (Except
OBD).......................... 8W-80-40
Engine Control Module C2 (OBD)...... 8W-80-41
Engine Control Module C3 (Except
OBD).......................... 8W-80-42
Engine Control Module C4 (Except
OBD).......................... 8W-80-43Component Page
Engine Control Module C5 (Except
OBD).......................... 8W-80-44
Engine Coolant Level Switch.......... 8W-80-44
Engine Coolant Temperature Sensor.... 8W-80-44
Engine Oil Sensor................... 8W-80-44
Evaporator Temperature Sensor........ 8W-80-45
Fog Lamp Switch................... 8W-80-45
Fuel Injector No. 1.................. 8W-80-45
Fuel Injector No. 2.................. 8W-80-45
Fuel Injector No. 3.................. 8W-80-46
Fuel Injector No. 4.................. 8W-80-46
Fuel Injector No. 5.................. 8W-80-46
Fuel Level Sensor................... 8W-80-46
Fuel Pressure Sensor................ 8W-80-47
Fuel Pressure Solenoid............... 8W-80-47
Fuel Pump (OBD)................... 8W-80-47
Fuel Pump Relay (OBD).............. 8W-80-47
Fuel Quantity Control Valve (OBD)..... 8W-80-47
Fuel Shutdown Solenoid.............. 8W-80-48
Fuel Temperature Sensor............. 8W-80-48
Fuse Block No. 1 C1................. 8W-80-48
Fuse Block No. 1 C2................. 8W-80-49
Fuse Block No. 1 C3................. 8W-80-49
Fuse Block No. 1 C4................. 8W-80-49
Fuse Block No. 1 C5................. 8W-80-49
Glow Plug Control Module C1......... 8W-80-50
Glow Plug Control Module C2......... 8W-80-50
Headlamp Adjust Switch............. 8W-80-50
Headlamp Assembly-Left............. 8W-80-51
Headlamp Assembly-Right............ 8W-80-51
Heated Seat Module-Driver........... 8W-80-51
Heated Seat Module-Passenger........ 8W-80-52
Heated Seat Switch-Driver............ 8W-80-52
Heated Seat Switch-Passenger......... 8W-80-52
Heater Timer-auxiliary............... 8W-80-53
High Idle Switch.................... 8W-80-53
Hood Ajar Switch................... 8W-80-53
Horn............................. 8W-80-54
Horn (VTSS)....................... 8W-80-54
Ignition Lock Switch................. 8W-80-54
Instrument Cluster C1............... 8W-80-54
Instrument Cluster C2............... 8W-80-55
Instrument Panel Socket............. 8W-80-55
Intake Air Pressure Sensor (OBD)...... 8W-80-55
Intake Air Temperature Sensor........ 8W-80-56
Interior Lamp No. 1................. 8W-80-56
Interior Lamp No. 2................. 8W-80-56
Interior Lamp No. 3................. 8W-80-56
Interior Lamp No. 4................. 8W-80-56
Interior Lamp No. 5................. 8W-80-57
Interior Lamp-Left.................. 8W-80-57
Interior Lamp-middle Front........... 8W-80-57
Interior Lamp-middle Rear............ 8W-80-57
Interior Lamp-Rear No. 1............. 8W-80-58
Interior Lamp-Rear No. 2............. 8W-80-58
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSVA

ENGINE CONTROL MODULE C5 (EXCEPT OBD) - GRAY
CAV CIRCUIT FUNCTION
1- -
2 14BK COMMON INJECTOR DRIVER NO. 1
3 14BK/YL FUEL INJECTOR NO. 4 CONTROL
4 14BL COMMON INJECTOR DRIVER NO. 2
5 14BK/VT FUEL INJECTOR NO. 2 CONTROL
6- -
7 14BK/DG FUEL INJECTOR NO. 5 CONTROL
8 14BK/RD FUEL INJECTOR NO. 3 CONTROL
9 14BK/BL FUEL INJECTOR NO. 1 CONTROL
ENGINE COOLANT LEVEL SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
2 16BR GROUND
ENGINE COOLANT TEMPERATURE SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL SENSOR - BLACK
CAV CIRCUIT FUNCTION
1 20GY/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTSVA

HORN
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
HORN (VTSS)
CAV CIRCUIT FUNCTION
1 16BK/BR HORN RELAY OUTPUT
2 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
IGNITION LOCK SWITCH - BLACK
CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
INSTRUMENT CLUSTER C1
CAV CIRCUIT FUNCTION
1 20BR FUEL LEVEL SENSOR SIGNAL RETURN
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN
4 20WT/GY K-IC/ATC/HBM/CHM
5 20BR/BK PARK BRAKE INDICATOR SIGNAL
7 20BK/DG RIGHT TURN SIGNAL
10 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
11 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
14 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
15 20BR/WT FRONT COURTESY LAMPS CONTROL
16 20YL/RD SEAT BELT SWITCH SIGNAL
17 20DG CAN C BUS (-)
18 20DG/WT CAN C BUS (+)
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTSVA

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Daytime Running Lamps Relay (Relay
Block)BK Under Driver Seat N/S
Differential Lock Solenoid Valve BK Underbody 51
Dome Lamp BK Dome Area 42
Door Jamb Switch-Driver Driver Door 43
Door Jamb Switch-Left Sliding Left Sliding Door N/S
Door Jamb Switch-Passenger Passenger Door 43
Door Jamb Switch-Right Sliding Right Sliding Door 30
Door Jamb Switch-Tailgate Tailgate N/S
Door Lock Motor/Ajar Switch Assembly -
Driver C1Driver Door 43
Door Lock Motor/Ajar Switch Assembly -
Driver C2Driver Door 43
Door Lock Motor/Ajar Switch Assembly - Left
Sliding C1Left Sliding Door 46
Door Lock Motor/Ajar Switch Assembly - Left
Sliding C2Left Sliding Door 46
Door Lock Motor/Ajar Switch Assembly -
Passenger C1Passenger Door 46
Door Lock Motor/Ajar Switch Assembly -
Passenger C2Passenger Door 46
Door Lock Motor/Ajar Switch Assembly -
Rear C1Right Sliding Door 52
Door Lock Motor/Ajar Switch Assembly -
Rear C2Right Sliding Door 52
Door Lock Motor/Ajar Switch Assembly-Right
Sliding C1Cargo Door 45
Door Lock Motor/Ajar Switch Assembly-Right
Sliding C2Cargo Door 45
Dosing Pump Engine Compartment N/S
EGR Valve Engine Compartment 14
Engine Control Module C1 (Except OBD) BK Instrument Panel 22
Engine Control Module C1 (OBD) BK NS
Engine Control Module C2 (Except OBD) BK Instrument Panel 22
Engine Control Module C2 (OBD) BK NS
Engine Control Module C3 (Except OBD) BK Instrument Panel 22
Engine Control Module C4 (Except OBD) BK Instrument Panel 22
Engine Control Module C5 (Except OBD) GY Instrument Panel 22
Engine Control Relay (Fuse Block No.1 NS
Engine Coolant Level Switch BK Engine Compartment 2, 8
Engine Coolant Temperature Sensor BK Engine Compartment 13
Engine Oil Sensor BK Engine Compartment 14
Evaporator Temperature Sensor WT Instrument Panel-Right 33
Fan Stage 1 Relay (Relay Block) BK Under Driver Seat N/S
Fog Lamp Relay (Relay Block) BK Under Driver Seat N/S
Fog Lamp Switch BK Instrument Panel 25
8W - 91 - 4 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

(39) Fill cooling system to proper level with the
appropriate coolant.
(40) Evacuate and recharge air conditioning.
(41) Check and refill all ancillary system fluid lev-
els.(42) Start engine and inspect for leaks (Refer to 14
- FUEL SYSTEM - WARNING).
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge Distri-
bution Pipe to Air Charge
Distribution Panel11 - 9 7
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover20 15 -
Bolt-Front Cover to Cylin-
der Head14 - 124
12m-Bolt-Cylinder Head
to Crankcase (3 stages,
torque, torque angle,
torque angle)60, 90É, 90É 44, 90É,90É -
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque an-
gle)55, 90É 40, 90É -
Bolt-End Cover to Crank-
case9-80
Bolt-Timing Case Cover
to Crankcase20 15 -
Plug-Coolant Drain to
Crankcase30 22 -
Oil Pan
6m-Bolt-Oil Pan to Crank-
case9-80
8m-Bolt-Oil Pan to Crank-
case20 15 -
Bolt-Oil Pan to End Cover 9 - 80
Bolt-Oil Pan to Timing
Case Cover9-80
Bolt-Oil Pan to Transmis-
sion Bell Housing40 30 -
Plug-Oil Pan to Oil Drain 47 35 -
Connecting Rod
VAENGINE 9 - 11

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat Ex-
changer to Timing Cover
Case15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube
to Cylinder Head14 - 123
Bolt-Oil Level Sensor to
Oil Pan14 - 123
Coolant Pre-Heater
Coolant Pre-Heater in En-
gine Block35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant
Pump8-35 6 - 26 -
Bolt-Coolant Pump to
Timing Case Cover 6m/
8m14/20 10 - 15 -
Bolt-Thremostat Housing
to Cylinder Head9-80
Coolant Drain Plug to
Crankcase30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage,
torque, torque angle)20/90É 15, 90É -
Bolt-Engine Mount to En-
gine Bracket55 40.5 -
Bolt-Front Engine Mount
to Front Axle Carrier35 26 -
Bolt-Rear Engine Cross
Member to Body40 30 -
Bolt-Rear Engine Mount
to Rear Engine Cross
Member35 26 -
Bolt/Nut- Rear Engine
Mount to Transmission40 26 -
Bolt-Shrowd to Engine
Bracket10 - 88.5
Nut-Front Engine Mount
to Engine Bracket65 48 -
Nut-Engine Mount to Ve-
hicle Frame35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
9 - 14 ENGINEVA