MERCEDES-BENZ SPRINTER 2006 Service Manual

INSTALLATION
The starter relay is located in the Fuse/Relay
Block. The Fuse/Relay Block is located under, and to
the left side of the drivers seat. See Fuse/Relay Block
cover for relay identification and location, or refer to
(Fig. 12).
(1) Install relay into Fuse/Relay Block.
(2) Install cover to side of Fuse/Relay Block (snaps
on).
Fig. 13 FUSE / RELAY BLOCK COVER
1 - LEFT SIDE OF DRIVERS SEAT
2 - FUSE / RELAY BLOCK
3 - RELEASE TABS (2)
4 - COVER (ACCESS PANEL)
8F - 36 STARTING SYSTEMVA

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS........................... 1
HEATED MIRRORS......................... 9HEATED SEATS........................... 10
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM.....2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH......5
REMOVAL.............................6
INSTALLATION..........................6
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR........7
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear window defogger system, also known as
the electric backlight (EBL), consists of a backglass
with two vertical bus bars linked by a series of grid
lines fired onto the inside surface of the rear window.
The EBL system is turned On or Off by a control
switch (Fig. 1) located in the instrument panel near
the right side of the steering wheel, which sends a
request signal to the rear window defogger module
that operates the left and right rear window defogger
relays located in the fuse/relay block under the driv-
ers seat.
Circuit protection is provided by a 30 amp fuse
also located in the fuse/relay block.
OPERATION
When the rear window defogger switch is pressed
to the On position, current is directed through the
switch to the rear window defogger module. The rear
window defogger module then grounds the control
side of the left and right rear window defogger (EBL)
Fig. 1 Rear Window Defogger Switch
1 - REAR WINDOW DEFOGGER SWITCH
2 - INSTRUMENT PANEL
VAHEATED SYSTEMS 8G - 1

relays which allows battery current to flow to the
rear window defogger grid lines. The heated grid
lines heat the rear glass to help clear the rear win-
dow surfaces of fog or frost.
The electric backlight (EBL) system is controlled
by the EBL timing circuity, which is integral to the
rear window defogger module. A yellow indicator in
the switch will illuminate to indicate when the EBL
system is turned on.
NOTE: The EBL system turns off automatically after
approximately 10 minutes of initial operation. Each
following activation cycle of the EBL system will
last approximately five minutes.
The EBL system will be automatically turned off
after a programmed time interval of about ten min-
utes. After the initial time interval has expired, if the
rear window defogger switch is pressed to the On
position again during the same ignition cycle, the
EBL system will automatically turn off after about
five minutes.
The EBL system will automatically shut off if the
ignition switch is turned to the Off position, or it can
be turned off manually by pressing the defogger
switch a second time.
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
EBL system, refer to 8W - WIRING DIAGRAM
INFORMATION.
Operation of the electrical backlight (EBL) system
can be confirmed by the following:
(1) Turn the ignition switch to the On position. Set
the rear window defogger switch in the On position.
The rear window defogger operation can be checked
by feeling the rear window glass. A distinct difference
in temperature between the grid lines and the adja-
cent clear glass should be detected within three to
four minutes of operation.
(2) If a temperature difference is not detected, use
a 12-volt DC voltmeter and contact the rear glass
heating grid terminal B with the negative lead, and
terminal A with the positive lead (Fig. 2). The volt-
meter should read battery voltage. If the voltmeter
does not read battery voltage, check the following:²Confirm that the ignition switch is in the On
position.
²Make sure that the rear glass heating grid feed
wires and ground wires are connected to the window
terminals. Confirm that the ground wires have conti-
nuity to ground.
²Check that fuse 7 (15 amp) in fuse block #1 and
fuse 10 (30 amp) in the fuse/relay block are OK. The
fuses must be tight in there receptacles and all elec-
trical connections must be secure.
(3) When the above steps have been completed and
the rear glass heating grid is still inoperative, one or
more of the following is faulty.
²Rear window defogger switch in the instrument
panel.
²Rear window defogger (EBL) relays in the fuse/
relay block.
²Rear window defogger (EBL) relay control circu-
ity in the rear window defogger module.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or the power feed or ground wire
not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
the defogger switch indicator does not illuminate,
check for voltage at the defogger indicator from the
rear window defogger module when the defogger
switch is activated. If power is present, replace the
rear window defogger switch.
(5) If broken defogger grid lines are suspected, use
a 12-volt DC voltmeter and contact terminal B with
the negative lead and each rear glass heating grid
line at it's mid-point with the positive lead. The volt-
meter should read approximately 6 volts at each grid
line mid-point C. If the voltmeter does not read
approximately 6 volts, repair the open grid line(s)
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER GRID - STANDARD PROCE-
DURE).
8G - 2 HEATED GLASSVA

REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The left and right rear window defogger (EBL)
relays are International Standards Organization
(ISO)-type relays (Fig. 3). Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal functions and patterns.
The EBL relays are electromechanical devices that
switch battery current through fuse 10 (30 amp)
located in the fuse/relay block under the driver seat
to the rear window defogger grids and when
equipped, switches battery current to the outside
mirror heating grids. The EBL relays are energized
when the relay coils are provided battery current by
the rear window defogger module.
The EBL relays are located in the fuse/relay block
under the driver seat. Refer to the fuse and relay
map located on the inner surface of the fuse/relay
block cover for the left and right rear window defog-
ger (EBL) relay locations.The black, molded plastic case is the most visible
component of the two rear window defogger (EBL)
relays. Five male spade-type terminals extend from
the bottom of the base to connect each relay to the
vehicle electrical system, and the ISO designation for
each terminal is molded into the base adjacent to
each terminal.
OPERATION
The left and right rear window defogger (EBL)
relays are electromechanical switches that uses a low
current input from the rear window defogger module
to control the high current output to the rear window
defogger grids. The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. The resistor or diode is con-
nected in parallel with the relay coil in the relay, and
helps to dissipate voltage spikes and electromagnetic
interference that can be generated as the electromag-
netic field of the relay coil collapses.
The EBL relay terminals are connected to the vehi-
cle electrical system through receptacles in the fuse/
relay block. The inputs and outputs of the EBL
relays include:
²The common feed terminal (30) receives a bat-
tery current input from fuse 10 (30 amp) in the fuse/
relay block through a fused B(+) circuit at all times.
Fig. 2 Grid Line Test
1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C)
5 - HEATED WINDOW GRID
6 - GROUND WIRE
7 - GROUND (B)
Fig. 3 Rear Window Defogger (EBL) Relays
1 - REAR WINDOW DEFOGGER (EBL) RELAY (2)
2 - TERMINAL PATTERN
VAHEATED GLASS 8G - 3

²The coil ground terminal (86) is hardwired to
ground point G202.
²The coil battery terminal (85) receives a battery
current input from the rear window defogger module
when the rear window defogger switch is energized.
²The normally open terminal (87) provides a bat-
tery current output to the rear window defogger grid
lines through the relay output circuit only when the
rear window defogger relay coil is energized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the rear window
defogger relay coil is de-energized.
The left and right EBL relays cannot be repaired
and, if faulty or damaged, they must be replaced.
Refer to the appropriate wiring information for diag-
nosis and testing of the EBL relays and for complete
rear window defogger system wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the fuse/relay block
(Fig. 4).
NOTE: Refer to the fuse and relay map located on
the inner surface of the fuse/relay block cover for
the left and right rear window defogger (EBL) relay
locations.
(3) Remove the EBL relays from the fuse/relay
block as required.
INSTALLATION
NOTE: Refer to the fuse and relay map located on
the inner surface of the fuse/relay block cover for
the left and right rear window defogger (EBL) relay
locations.
(1) Position the rear window defogger (EBL) relays
as required into their proper receptacles in the fuse/
relay block.
(2) Align the EBL relay terminals with the termi-
nal cavities in the fuse/relay block receptacles.
(3) Push down firmly on the EBL relays until the
terminals are fully seated in the terminal cavities in
the fuse/relay block receptacles.
(4) Install the cover onto the fuse/relay block.
(5) Reconnect the negative battery cable.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The rear window defogger switch is mounted in the
instrument panel to the right of the steering wheel
(Fig. 5). The rear window defogger switch contains a
yellow indicator lamp that illuminates when the rear
window defogger (EBL) system is activated.
The rear window defogger switch and the defogger
switch indicator cannot be repaired and, if faulty or
damaged, the rear window defogger switch must be
replaced.
OPERATION
A yellow indicator lamp will illuminate when the
rear window defogger switch is activated. The switch
Fig. 4 Rear Window Defogger (EBL) Relays
1 - DRIVERS SEAT
2 - FUSE/RELAY BLOCKFig. 5 Rear Window Defogger Switch
1 - REAR WINDOW DEFOGGER SWITCH
2 - INSTRUMENT PANEL
8G - 4 HEATED GLASSVA

energizes the timing circuit of the rear window defog-
ger module which then activates the rear window
defogger (EBL) relays. The EBL relays controls the
current flow to the rear window defogger grids. The
EBL system will operate for approximately five min-
utes or until the rear window defogger switch or igni-
tion switch is turned off. Refer to 8 - ELECTRICAL/
HEATED GLASS - DIAGNOSIS AND TESTING for
diagnosis and testing of the rear window defogger
switch.
The rear window defogger switch cannot be
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. 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 air-
bag system. Failure to take the proper precautions
could result in an accidental airbag deployment and
possible personal injury.
NOTE: The rear window defogger switch may be
tested in the vehicle or out of the vehicle, on a
bench.
NOTE: For circuit descriptions and diagrams of the
rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.
(1) Remove the rear window defogger switch from
the instrument panel, but leave the switch connected
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER SWITCH - REMOVAL).
(2) Turn the ignition switch ON.
(3) Using a voltmeter, check for battery voltage at
Pin 3 of the rear window defogger switch (Fig. 6).
(a) If OK, go to Step 4.
(b) If NOT OK, check fuse 7 (15 amp) in fuse
block #1. If fuse is OK, check the wiring circuits.
Refer to 8W - WIRING DIAGRAM INFORMA-
TION.
(4) Check Pin 7, with defogger switch in the On
position there should be battery voltage and, no volt-
age with the switch in the Off position.
(a) If OK, go to Step 5.(b) If NOT OK, no voltage in the On position or
voltage in the Off position, replace the rear window
defogger switch.
(5) Press the defogger switch to the On position.
The indicator lamp should come on and remain on
for approximately 5 minutes.
(a) If OK, install the rear window defogger
switch (Refer to 8 - ELECTRICAL/HEATED
GLASS/REAR WINDOW DEFOGGER SWITCH -
INSTALLATION).
(b) If NOT OK, go to Step 6.
(6) Check Pin 9, with defogger switch in the On
position there should be battery voltage.
(a) If OK, go to Step 7.
(b) If NOT OK, check the wiring circuits. Refer
to 8W - WIRING DIAGRAM INFORMATION.
(7) Check Pin 10 for a good ground.
(a) If OK, replace the rear window defogger
switch.
(b) If NOT OK, check the wiring circuits. Refer
to 8W - WIRING DIAGRAM INFORMATION.
Fig. 6 Rear Window Defogger Switch Connector
VAHEATED GLASS 8G - 5

DEFOGGER SWITCH CONNECTOR PIN
CALL-OUT
PIN FUNCTION
1 FUSED B+ (DRL RELAY)
3 IGNITION SWITCH OUTPUT (START-
RUN)
5 PANEL LAMPS DRIVER
7 DEFOGGER SWITCH OUTPUT
9 PANEL LAMPS DRIVER
10 GROUND
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 negative battery
cable.
(2) Remove the cluster bezel from the instrument
panel (Fig. 7) (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).(3) From the back of the cluster bezel, squeeze the
two latches on the rear window defogger switch body
and push the switch out through the face of the bezel
(Fig. 8).
(4) Remove the rear window defogger switch from
the cluster bezel.
INSTALLATION
(1) Position the rear window defogger switch to the
proper mounting hole on the face of the cluster bezel.
(2) Using hand pressure, push the rear window
defogger switch firmly and evenly into the switch
Fig. 7 Cluster Bezel Remove/Install
1 - SCREWS (2)
2 - CLUSTER BEZEL
3 - REAR WINDOW DEFOGGER SWITCH
4 - DEFOGGER SWITCH CONNECTOR
5 - WIRE HARNESS CONNECTOR
6 - WIRE HARNESS CONNECTOR
Fig. 8 Headlamp Leveling Switch Remove/Install
1 - SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL
8G - 6 HEATED GLASSVA

mounting hole of the cluster bezel until both of the
latches on the switch body are fully engaged.
(3) Install the cluster bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(4) Reconnect the negative battery cable.
REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINE REPAIR
WARNING: The repair kit contains epoxy resin and
amine type hardener which may cause skin or eye
irritation and can be harmful if swallowed. Use with
adequate ventilation. Do not use near fire or open
flame the contents contain flammable solvents.
Keep out of reach of children.
²DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
²IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
²IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
The repair of the grid lines is possible using the
MopartGrid Line Repair Package or an equivalent.
(1) Mask the repair area so the conductive epoxy
can be extended onto the grid line(s) or the bus bar
(Fig. 9).
(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the conductive epoxy thoroughly. Fold in half and cut
the center corner to dispense the epoxy.
(4) Apply the conductive epoxy through the slit in
the masking tape. Overlap both ends of the break(s)
by 19 mm (3/4 inch).
(5) Carefully remove the masking tape from the
grid line(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204É C (400É
F).
(6) Allow the epoxy to cure 24 hours at room tem-
perature or use a heat gun with a 260É to 371É C
(500É to 700É F) range for 15 minutes. Hold the heat
gun approximately 254 mm (10 inches) from the
repaired area.(7) After the conductive epoxy is properly cured,
verify operation of the rear window defogger.
REAR WINDOW DEFOGGER GRID TERMINAL REPAIR
CAUTION: Do not use a flame type solder gun or an
electric solder gun rated greater than 500 watts or
damage to the glass may occur.
If the rear window defogger grid terminal(s) is
damaged or separated from the rear window, the new
grid terminal(s) must be securely fastened to the rear
window defogger bus bar by soldering.
(1) If the grid terminal(s) is broken and a portion
of the terminal is still attached to the heating grid,
remove the portion of the clip remaining in the wire
harness connector(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204É C (400É
F).
(2) If the grid terminal(s) is broken and a portion
of the terminal is still attached to the rear window
defogger bus bar, apply heat with a solder gun to the
portion of the terminal on the glass until the solder
starts to flow. Remove the terminal and carefully
smooth the solder on the bus bar.
NOTE: Wait five minutes for the glass to cool after
applying heat with a solder gun before proceeding.
NOTE: Use care when cleaning the mating surfaces.
Excessive abrasion may wear away the copper grid
surface causing grid continuity to be lost.
(3) Clean the mating surfaces on the grid bus bar
and the new terminal(s) with ª000º Extra Fine Steel
Wool or an equivalent.Fig. 9 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
VAHEATED GLASS 8G - 7

NOTE: The terminal attaching clip(s) must face out-
board. Failure to reorient the terminal(s) may result
in an additional failure.
(4) Properly orient the new terminal(s) with the
attaching clip facing outboard in the original loca-
tion(s) on the grid bus bar and hold the terminal(s)
with a metal pick or other suitable pointed tool.
CAUTION: Do not allow the glass surface to exceed
204É C (400É F), glass may fracture.
NOTE: New rear window defogger terminals are pre-
soldered and fluxed. Do not reuse a terminal if it
has been previously heated.
Place the solder gun onto the new terminal(s) and
heat the terminal until the solder flows. Remove the
solder gun and continue to hold the terminal in the
correct position for an additional five seconds.
(5) Allow the solder to cool for ten minutes.
NOTE: To ensure proper installation, do not attach
the wire harness connector(s) to the terminal(s)
until the solder is completely cooled.
(6) After the solder has cooled, reconnect the wire
harness connector(s) and verify operation of the rear
window defogger.
8G - 8 HEATED GLASSVA

HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................9OPERATION............................9
HEATED MIRRORS
DESCRIPTION
The available heated outside rear view mirror sys-
tem is operational anytime the ignition switch is in
the Run position (Fig. 1). When energized, each of
these heater grids produce heat to help clear the out-
side mirrors of ice, snow, or fog.
OPERATION
The electric heater grid located behind the glass of
each of the outside rear view mirrors is energized
when the ignition switch is turned to the Run posi-
tion. The heater grids heat the glass surface of the
outside rear view mirrors.
If the outside mirror heating grids are inoperative,
refer to 8W - WIRING DIAGRAM INFORMATION.
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
mirror glass must be replaced (Refer to 23 - BODY/
EXTERIOR/MIRROR-SIDE VIEW - GLASS -
REMOVAL).
Fig. 1 SIDE VIEW MIRROR - GLASS
1 - MIRROR GLASS
2 - ELECTRICAL CONNECTORS
3 - GUIDES
VAHEATED MIRRORS 8G - 9