engine MERCEDES-BENZ SPRINTER 2006 Service Manual

NO START VERIFICATION - VER-1 APPLICABILITY
1. NOTE: IMPORTANT! If the Engine Control Module or Sentry Key Immobilizer
Module has been replaced, ensure the programming procedure for the module has
been performed in accordance with the Service Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
ROAD TEST VERIFICATION - VER-2 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4. If not, proceed to step 5.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) has not been changed, perform steps 7 and 8, otherwise,
continue with step 9.
7. With the DRB IIIt, erase all diagnostic trouble codes (DTCs), then disconnect the DRB IIIt.
8. Turn the ignition off for at least 10 seconds.
9. If equipped with a Transfer Case Position Switch, perform step 10, otherwise, continue with
step 11.
10. With the ignition switch on, place the Transfer Case Shift Lever in each gear position,
stopping for 15 seconds in each position.
11. Ensure no DTCs remain by performing steps 12 through 15.
12. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
13. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
14. Upon completion of the road test, turn the engine off and check for DTCs with the DRB IIIt.
15. If the repaired DTC has set again, the repair is not complete. Check for any pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the
repair was successful and is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
247
VERIFICATION TESTS
Verification Tests ÐContinued

BOOST PRESSURE SERVOMOTOR (OBD)CAV CIRCUIT FUNCTION
1 16YL/BK FUSED ENGINE CONTROL RELAY OUTPUT
2 16YL/WT GROUND
3- -
4 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL
5- -
CAMSHAFT POSITION SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 18RD/BL (EXCEPT OBD) CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
3 20RD/BL (OBD) CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
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CONNECTOR PINOUTS

CONTROLLER ANTILOCK BRAKECAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
3- -
4- -
5 14BR GROUND
6 14RD FUSED B(+)
7- -
8 20BK/DG SENSOR SIGNAL
9 20YL/WT SENSOR SIGNAL
10 20YL/RD SENSOR SIGNAL
11 18BL/BK K-ABS/SHIFTER ASSEMBLY
12 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
13 - -
14 20WT LEFT REAR WHEEL SPEED SENSOR (+)
15 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)
16 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
17 - -
18 - -
19 - -
20 20WT BRAKE SWITCH OUTPUT
21 20BR GROUND
22 - -
23 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
24 20DG/WT CAN C BUS (+)
25 20BR SENSOR GROUND
26 20WT/GY BRAKE PRESSURE SENSOR SIGNAL
27 18BK/BL TCS SWITCH (ASR) SENSE
28 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
29 20BR LEFT REAR WHEEL SPEED SENSOR (-)
30 20BR RIGHT REAR WHEEL SPEED SENSOR (-)
31 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
32 18BK/RD BRAKE LAMP SWITCH OUTPUT
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 20RD/BL POWER INPUT
40 20DG CAN C BUS (-)
41 20DG/YL SENSOR SIGNAL
42 20WT/RD 5 VOLT SUPPLY
CRANKCASE HEATER - BLACKCAV CIRCUIT FUNCTION
1 18BR (EXCEPT OBD) GROUND
1 18BK/RD (OBD) CRANKCASE HEATER SIGNAL
2 16BK/RD (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 18BK/BR (OBD) CRANKCASE HEATER GROUND
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CONNECTOR PINOUTS

CRANKSHAFT POSITION SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20DG (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
1 20DG/WT (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG/WT (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
DATA LINK CONNECTOR - BLACKCAV CIRCUIT FUNCTION
1 20WT/DG K-SKREEM
2- -
3 20DG/YL ENGINE RPM
4 20BR GROUND
5 20BR GROUND
6- -
7 20BL/YL K-ECM
8 20BK/BL/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 20BL/BK K-ABS/SHIFTER ASSEMBLY
10 - -
11 20BL K-TCM/RADIO
12 20GY/DG/RD K-CTM/SSM
13 20BK/RD K-ACM
14 - -
15 20WT/GY K-IC/ATC/HBM/CHM
16 20RD/YL FUSED B(+)
EGR VALVE - BLACKCAV CIRCUIT FUNCTION
1 20RD/YL (EXCEPT OBD) EGR VALVE CONTROL
1 20DG/WT (OBD) EGR VALVE CONTROL
2 16BK/GY (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 16BK/DG (OBD) FUSED ENGINE CONTROL RELAY OUTPUT
3 18BR/BK (EXCEPT OBD) SENSOR GROUND
3 20BR/DG (OBD) SENSOR GROUND
4- -
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C1 (OBD)CAV CIRCUIT FUNCTION
1 16BL FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
2 16BL/WT FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL
3 16DG FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
4 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
8 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
10 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
11 20GY/BL ENGINE OIL SENSOR SIGNAL
12 20BR/RD INTAKE PRESSURE SENSOR GROUND
13 20VT/DG INTAKE PRESSURE SENSOR SIGNAL
14 20BR/DG CAMSHAFT POSITION SENSOR GROUND
15 20DG/BK O2 1/1 PUMP CELL SIGNAL
20 18BK/YL WATER IN FUEL SENSOR SIGNAL
21 18BK/RD CRANKCASE HEATER SIGNAL
25 16BK FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
26 16BK/WT FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL
28 18RD/BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY
31 20YL/BL MASS AIR FLOW SENSOR GROUND
32 18DG/BK FUEL TEMPERATURE SENSOR GROUND
35 20BR/BK SENSOR GROUND
36 20VT/RD INTAKE PRESSURE SENSOR 5 VOLT SUPPLY
37 20RD/BL CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
38 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
39 20GY O2 1/1 SENSOR CELL SIGNAL
40 20GY/WT O2 1/1 VIRTUAL GROUND
49 16BK/VT FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
50 16BK/DG FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
51 16BK/YL FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
52 20BK/WT FUEL PRESSURE SOLENOID CONTROL
55 18BR WATER IN FUEL SENSOR GROUND
56 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
57 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
59 20DG/VT FUEL PRESSURE SENSOR SIGNAL
61 20BR/VT MASS AIR FLOW SENSOR 5 VOLT SUPPLY
62 20DG/YL O2 1/1 PUMP CELL CONTROL
72 20GY/BL O2 1/1 HEATER CONTROL
73 16BK/RD FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
74 16BK/BL FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
76 18BR/YL FUEL QUANTITY SOLENOID CONTROL
79 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
84 20BR/GY FUEL PRESSURE SENSOR GROUND
85 20YL/DG MASS AIR FLOW SENSOR SIGNAL
86 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
87 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
88 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
90 20DG/WT EGR VALVE CONTROL
91 18BK/BR CRANKCASE HEATER GROUND
93 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C2 (OBD)CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
2 14BR GROUND
3 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
6 14BR GROUND
7 18RD S/C SWITCH 12 VOLT SUPPLY
8 18BR/WT HIGH IDLE ON SIGNAL
10 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
11 18WT/DG BOOST PRESSURE SENSOR SIGNAL
12 18BR/WT SENSOR GROUND
13 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
14 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
17 18BR/DG KICKDOWN SWITCH SIGNAL
18 20DG/YL ENGINE RPM
19 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
25 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
26 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
28 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
31 20BL/YL K-ECM
32 20DG ENHANCED ACCIDENT REPORT DRIVER
36 18VT IGNITION SWITCH OUTPUT (START)
37 18DG ACCEL/SET SIGNAL
38 18BK VERIFICATION SIGNAL
42 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
43 18BK/RD GLOW PLUG MODULE CONTROL
44 18YL/BL ENGINE CONTROL RELAY CONTROL
50 18YL DECEL/SET SIGNAL
51 18GY OFF SIGNAL
52 18BL RESUME SIGNAL
53 20DG/WT CAN C BUS (+)
54 20DG CAN C BUS (-)
55 18BR/RD FUEL PUMP RELAY CONTROL
58 18VT/DG STARTER MOTOR RELAY CONTROL
ENGINE COOLANT TEMPERATURE SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
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CONNECTOR PINOUTS

ENGINE OIL SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20GY/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
FUEL INJECTOR NO. 1 - BLACKCAV CIRCUIT FUNCTION
1 14BK/BL (EXCEPT OBD) FUEL INJECTOR NO. 1 CONTROL
1 16BK/RD (OBD) FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16BL (OBD) FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
FUEL INJECTOR NO. 2 - BLACKCAV CIRCUIT FUNCTION
1 14BK/VT (EXCEPT OBD) FUEL INJECTOR NO. 2 CONTROL
1 16BK/BL (OBD) FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
2 14BL (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 2
2 16BK (OBD) FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
FUEL INJECTOR NO. 3 - BLACKCAV CIRCUIT FUNCTION
1 14BK/RD (EXCEPT OBD) FUEL INJECTOR NO. 3 CONTROL
1 16BK/DG (OBD) FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16DG (OBD) FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
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CONNECTOR PINOUTS

FUEL PUMP RELAY (OBD)CAV CIRCUIT FUNCTION
30 14RD/BK FUSED B(+)
85 18BR/RD FUEL PUMP RELAY CONTROL
86 18BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
87 14BK FUEL PUMP RELAY OUTPUT
87A - -
FUEL QUANTITY CONTROL VALVE (OBD)CAV CIRCUIT FUNCTION
1 20BK/WT FUEL QUANTITY SOLENOID CONTROL
2 18RD/BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY
FUEL TEMPERATURE SENSORCAV CIRCUIT FUNCTION
1 18DG/BK FUEL TEMPERATURE SENSOR GROUND
2 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
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CONNECTOR PINOUTS

ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 INTERNAL ENGINE CONTROL RELAY CONTROL
86 INTERNAL FUSED B(+)
87 INTERNAL ENGINE CONTROL RELAY OUTPUT
87A --
FUSES (FUSE BLOCK NO. 1)FUSE
NO.AMPS FUSED CIRCUIT FUNCTION
1- - -
2 10A 16WT FUSED HIGH BEAM SWITCH OUTPUT
3 10A 16WT FUSED HIGH BEAM SWITCH OUTPUT
4 10A 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 10A 16BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 20A INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 15A 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20A 16RD/YL FUSED B(+)
9 15A INTERNAL FUSED B(+)
10 10A 16GY/DG/RD HEADLAMP SWITCH OUTPUT
11 10A 16GY/BK FUSED LEFT LAMP RELAY OUTPUT
12 10A 18YL HEADLAMP SWITCH OUTPUT
13 10A 18YL HEADLAMP SWITCH OUTPUT
14 15A 16BK/YL/WT FOG LAMP RELAY SIGNAL
15 10A 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
16 15A 12BK/BL ENGINE CONTROL RELAY OUTPUT
17 15A 16BK/RD ENGINE CONTROL RELAY OUTPUT
18 15A 14BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
19 15A 14RD/BK (OBD) FUSED B(+)
20 15A 16RD/BL FUSED B(+)
21 30A 12RD FUSED B(+)
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CONNECTOR PINOUTS

KICK DOWN SWITCH - BLACKCAV CIRCUIT FUNCTION
1 18BR/DG KICKDOWN SWITCH SIGNAL
2 18BR (EXCEPT OBD) SENSOR GROUND
2 18BR (OBD) GROUND
MASS AIR FLOW SENSOR - BLACKCAV CIRCUIT FUNCTION
1 16YL/RD (OBD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 20YL/RD (EXCEPT OBD) MASS AIR FLOW SENSOR 12 VOLT SUPPLY
2 20BR/VT (OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
3 20BR/YL (EXCEPT OBD) MASS AIR FLOW SENSOR GROUND
3 20YL/BL (OBD) MASS AIR FLOW SENSOR GROUND
4 20BR/BK (EXCEPT OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
4 20YL/DG (OBD) MASS AIR FLOW SENSOR SIGNAL
5 20YL/DG (EXCEPT OBD) MASS AIR FLOW SENSOR SIGNAL
OXYGEN SENSOR (OBD)CAV CIRCUIT FUNCTION
1 20DG/BK O2 1/1 PUMP CELL SIGNAL
2 20GY/WT O2 1/1 VIRTUAL GROUND
3 20GY/BL O2 1/1 HEATER CONTROL
4 20RD/DG FUSED ENGINE CONTROL RELAY OUTPUT
5 20DG/YL O2 1/1 PUMP CELL CONTROL
6 20GY O2 1/1 SENSOR CELL SIGNAL
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CONNECTOR PINOUTS