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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz Sprinter (from 1995 to 2000, the year of issue)

general info. full specifications. diagnostics. hints. tips. tricks
Mercedes-Benz Sprinter
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Mercedes-Benz
Sprinter
General Information
Engine
Greasing system
Cooling
injection systems and exhaust
Coupling
Manual transmission
Front Axle
Rear axle and driveshaft
Front and rear suspension
Steering
Brakes
Electrical system
Tires and wheels
Automatic Transmission
Map service
Applications
Diagrams
Schemes 1-5
Schemes 6-10
Schemes 11-15
Schemes 16-20
 


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Schemes 1-5



Figure 1. The fuel injection system of the diesel engine with exhaust gas recirculation
(engine 601 series 901, 902, 903 and 904)
A6
ECU EGR (AGR)
5L, 9L
B72
Sensor Engine speed
15L
F12
Fuse (10 A), computer recycling


OG (output <15>)
6H
J31
Conclusion <15>, protected by a fuse
7J
J265
Conclusion <15>
3H
K34
The relay automatically turn reduced


transmission (system Kickdown) automatic


Transmission
4A
N6
ECU air conditioning compressor
3L
P15
Device combination
17A
S70
Switch exhaust gas recirculation (AGR)
13L
W3
Connecting to <mass> in the left headlight
11H
W5
Connecting to <mass> in the block under the seat
4H, 9H
W7
Connecting to <mass> in the engine compartment
17G
W15
Connecting to <mass> on the engine
13H
X33
Pin TD
17K
X78
Pin wiring harness Engine


and body
9H
X81
Pin wiring harness frame and body
16G
Y12
EGR solenoid valve


Exhaust gas (EGR 2)
11L

Scheme 2. (part 2, 3) control system diesel engine with a distribution type injection pump (engine modes. 02,980 Series 901, 902, 903 and 904)
A12
The central mounting block
1L


26L


48L
A12F5
Fuse 15 A
26K
A12F7
Fuse 15 A
48K
A12F8
Fuse 20 A
49K
A20
Engine ECU (MSA)
4A


12A


21A


28A


36A


44A
B16
Coolant temperature
8L
B18
4-pin brake light switch


(vehicles with cruise control)
29L
B19
2-pin brake light switch
24L
B47
Pressure sensor (pressurization) of the air intake


collector
23L
B49
Sensor the start of injection of fuel
10L
B73
Sensor crankshaft angle
11L
F15
Fuse (15 A) Engine ECU
6E
G2
Accumulator battery
2L, 51L
G14
Intake air temperature sensor
19L
J5
Conclusion <50>
30E
J6
Conclusion <30>, protected by a fuse
48H
J8
Conclusion stoplight
2G


24G


29G
J12
Sensor output for connection to <mass>
8E


11G


15E


19E


22E
J13
Conclusion ECU pump (EVE)
5G


17E
J14
Conclusion ECU pump (EVE)
17E
J18
Conclusion <15>, protected by a fuse
1E
J22
Conclusion <15>, protected by a fuse
47H
J49
Output speed sensor crankshaft
44E
J59
The injectors
6G


14E


28G


35G
J105
Conclusion <15>
36G
J149
Output speed sensor crankshaft
42E
J210
Conclusion <30>
4G
J277
Conclusion <15>
31E
K5
Relay ECU Power engine
4L
P4
Tachograph
42L
P11
14-pin diagnostic connector
45L
P15
Device combination
37L


43L
P15h73
The control lamp of EDC
37L
R40
Accelerator pedal position sensor
21L
R40s1
Switch idling
21K
S53
Egnition lock
53L
S105
Switch on the clutch pedal
41L
S123
The switch of the cruise control system
32L
W4
Connecting to <mass> on the partition


engine compartment
2H


22H


40H


45G
W7
Connecting to <mass> in the engine compartment
2E
X78
Harness connector frame and engine
7H


12H
X79
Harness connector frame and body
38G
X81
Harness connector frame and body
42G
Y44
EGR valve
6L
Y45
The electronically controlled fuel pump
13L


17L
Y45.1
Solenoid connector couplings


fuel injection timing
13H
Y45.3
Computer connector pump
15H
Y45b1
The fuel temperature sensor
18L
Y45l1
Travel sensor rail injection pump
16L
Y45l2
Travel sensor rail injection pump
15L
Y45y1
Regulator fuel supply quantity
17L
Y45y2
Solenoid valve timing device


injection
14K
Y45y3
Solenoid valve fuel cut
13L
Y46
The solenoid valve changes the pressure


injection
35L
Y47
Solenoid valve the fuel injection timing
34L

Figure 3. (part 2, 3, 4) Control system of diesel engine fuel injection pump of the distribution type (cars of release since October 1997)
A12
The central mounting block
1L


26L


55L
A12F5
Fuse 15 A
26K
A12F7
Fuse 15 A
54K
A12F8
Fuse 20 A
55K
A20
Engine ECU (MSA)
4A


12A


21A


28A


36A


44A


51A
B16
Coolant temperature
8L
B18
4-pin brake light switch


(vehicles with cruise control)
29L
B19
2-pin brake light switch
24l
B47
Pressure sensor (pressurization) of the air intake


collector
23L
B49
Sensor the start of injection of fuel
10L
B73
Sensor crankshaft angle
11L
B101
Mass Air Flow Meter
44L
D3
The output stage preheating
54A


58A
F15
Fuse (15 A) Engine ECU
6E
G2
Accumulator battery
2L


59L
G14
Intake air temperature sensor
19L
J5
Conclusion <50>
45E
J6
Conclusion <30>, protected by a fuse
54H
J8
Conclusion stoplight
2G


24G


29G
J12
Output Sensor for connection with <mass>
8E


15E


19E
J13
Conclusion ECU pump (EVE)
5G


17E
J14
Conclusion ECU pump (EVE)
17E
J18
Conclusion <15>, protected by a fuse
1E
J22
Conclusion <15>, protected by a fuse
53H
J49
Output speed sensor crankshaft
50E
J59
The injectors
6G


14E


28G


37G


41G
J105
Conclusion <15>
39G
J149
Output speed sensor crankshaft
49E
J210
Conclusion <30>
4G
J272
The output of the accelerator pedal position sensor,


pressure (pressurization) of the air intake


manifold and the intake air temperature
21E


44G
J277
Conclusion <15>
30E
J316
Output switch idling
21G


43G
K5
Relay ECU Power engine
4L
P4
Tachograph
48L
P11
14-pin diagnostic connector
51L
P15
Device combination
39L


49L
P15h73
The control lamp of EDC
39L
R13
Glow
55E
R14
Glow
55E
R15
Glow
55E
R16
Glow
54E
R17
Glow
54E
R40
Accelerator pedal position sensor
21L
R40s1
Switch idling
22K
S53
Egnition lock
58L
S105
Switch on the clutch pedal
47L
S123
Cruise control switches
31L
W4
Connecting to <mass> on the partition


engine compartment
2H


22H


47H


51G
W7
Connecting to <mass> in the engine compartment
2E


9D


57E
X78
Harness connector frame and engine
7H


12H
X79
Harness connector frame and body
40G
X81
Harness connector frame and body
49G
Y45
The electronically controlled fuel pump
13L


17L
Y45.1
Solenoid connector couplings


fuel injection timing
13H
Y45.3
Computer connector pump
15H
Y45b1
The fuel temperature sensor
18L
Y45l1
Travel sensor rail injection pump
16L
Y45l2
Travel sensor rail injection pump
15L
Y45y1
Regulator fuel supply quantity
17L
Y45y2
Solenoid valve timing device


injection
14K
Y45y3
Solenoid valve fuel cut
13L
Y46
The solenoid valve changes the pressure


injection
38L
Y47
Solenoid valve the fuel injection timing
37L
Y80
Boost pressure control valve
42L
Y83
Pressure controller in the system recirculation
6L

Figure 4. (part 2, 3) control system diesel engine with 602,980 distributor-type injection pump
(cars of release since July 1998)
A12
The central mounting block
1L


26L


55L
A12F5
Fuse 15 A
26K
A12F7
Fuse 15 A
54K
A12F8
Fuse 20 A
55K
A20
Engine ECU (MSA)
4A


12A


21A


28A


36A


44A


52A
B16
Coolant temperature
8L
B18
4-pin brake light switch


(vehicles with cruise control)
29L
B19
2-pole switch brake
24L
B47
Pressure sensor (pressurization) of the air intake


collector
23L
B49
Sensor the start of injection of fuel
10L
B73
Sensor crankshaft angle
11L
D3
The output stage preheating
55A


58A
F15
Fuse (15A), the engine ECU
6E
G2
Accumulator battery
2L


60L
G14
Intake air temperature sensor
19L
J5
Conclusion <50>
46E
J6
Conclusion <30>, protected by a fuse
55H
J8
Output brake
2G


24G


29G
J12
Sensor output for connection to <mass>
8E


15E


19E
J13
Conclusion ECU pump (EVE)
5G


17E


44G
J14
Conclusion ECU pump (EVE)
17E
J18
Conclusion <15>, protected by a fuse
1E
J22
Conclusion <15>, protected by a fuse
54H
J49
Output speed sensor crankshaft
51E
phaJ59
The injectors
6G


14E


28G


37G


45G
J105
Conclusion <15>
39G
J149
Output speed sensor crankshaft
49E
J210
Conclusion <30>
4G
J271
Conclusion <87>
42G
J272
The output of the accelerator pedal position sensor,


pressure (supercharging air) in the intake manifold


and intake air temperature
21E
J277
Conclusion <15>
30E
K5
Relay ECU Power engine
4L
K45
Relay preheating
43L
P4
Tachograph
49L
P11
14-pin diagnostic connector
52L
P15
Device combination
40L


50L
P15h13
The control lamp of a prior


heating and immobilizer
41L
P15h73
The control lamp of EDC
39L
R13
Glow
56E
R14
Glow
55E
R15
Glow
55E
R16
Glow
55E
R17
Glow
54E
R40
Accelerator pedal position sensor
21L
R40s1
Switch idling
22K
S53
Egnition lock
58L
S105
Switch on the clutch pedal
47L
S123
Cruise Control Switch
31L
W4
Connecting to <weight> on the partition of a motor


cover
2H


22H


47H


51G
W7
Connecting to <mass> in the engine compartment
2E


9D


57E
X78
Harness connector frame and engine
7H


12H
X79
Harness connector frame and body
40G
X81
Harness connector frame and body
49G
Y44
EGR valve
6L
Y45
The electronically controlled fuel pump
13L


17L
Y45.1
Solenoid connector couplings


fuel injection timing
13H
Y45.3
Computer connector pump
15H
Y45b1
The fuel temperature sensor
18L
Y45l1
Travel sensor rail injection pump
16L
Y45l2
Travel sensor rail injection pump
15L
Y45y1
Regulator fuel supply quantity
17L
Y45y2
Solenoid valve timing device


injection
14L
Y45y3
Solenoid valve outage


fuel
13L
Y46
The solenoid valve changes the pressure


injection
38L
Y47
Solenoid valve the fuel injection timing
37L
Y80
Boost pressure control valve
45L

Figure 5. Rear Defrost
E60
Right rear window heater
4L
E61
Left rear window heater
8L
F63
Fuse (30 A), rear window defogger
1H
J16
Conclusion <30>
1L
J19
Conclusion <61>
11E
J22
Conclusion <15>, protected by a fuse
10E
J46
Conclusion <58>
11G
J60
Conclusion <15>, protected by a fuse
1E
K3
Relay rear window defogger
4A


11A
S81
Rear window defroster switch
11L
W1
Connecting to <mass> roof
4F


6F
W5
Connecting to <mass> in the block under the seat
2E
W6
Connecting to <mass> taillights
9E
W8
Connecting to <mass> on the body
12E
X29
3-pin wiring harness connector to the left


back of the car
7H
X32
2-pin wiring harness heater


the right rear of the car
2H
X34
3-pin wiring harness connector to the right


back of the car
5H
X46
Harness connector frame and body


(optional equipment)
4E
X80
Harness connector frame and body
10H




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Schemes 6-10

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