MERCEDES-BENZ SPRINTER 2006 Service Manual

Symptom List:
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW
P2036-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH
P2036-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW
P2038-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH
P2038-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2034-O2 SENSOR CIRCUIT
CALIBRATION VALUE TOO HIGH.
POSSIBLE CAUSES
CHECKING CIRCUIT INTEGRITY
O2 SENSOR
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Using the Service Information wiring diagrams, inspect the wiring and connectors
between the ECM and the O2 sensor for damage, corrosion, poor terminal contact or
other problems.
Were any problems found?All
Ye s!Clean, repair or replace as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
2NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Turn the ignition off for 10 seconds.
Test drive the vehicle.
Monitor the DRB for ECM DTCs.
Did this DTC set again?All
Ye s!Replace the Oxygen Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
138
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
3WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
139
DRIVEABILITY - DIESEL
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH Ð
Continued

Symptom List:
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN OR SHORT
CIRCUIT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2043-CAMSHAFT POSITION
SENSOR CIRCUIT OPEN CIRCUIT.
POSSIBLE CAUSES
5-VOLT SUPPLY CIRCUIT OPEN
CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
CHECKING 5-VOLT SUPPLY CIRCUIT
DAMAGED CMP SENSOR OR CAMSHAFT
ECM
ECM
ECM - CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
SENSOR GROUND CIRCUIT OPEN
INTERMITTENT CONDITION
CMP SENSOR SIGNAL CIRCUIT OPEN
5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
CMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
CMASHAFT POSITION SENSOR
ECM SENSOR GROUND CIRCUIT OPEN
5-VOLT SUPPLY CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
CMP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
140
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
1NOTE: If DTC P1611, P2306 or P2332 is present with this DTC, diagnose
DTCs P1611, P2306 or P2332 before diagnosing this DTC.
NOTE: The Timing Belt/Chain must be correctly installed and operational
before diagnosis can be made. Refer to the Service Information to ensure
the timing belt is properly installed.
NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Attempt to start the engine cranking the engine for at least 7 seconds.
With the DRBIIIt, read the ECM DTCs.
Does the DRBIIItdisplay this DTC?All
Ye s!Go To 4
No!Go To 2
2 Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Does the DRBIIItdisplay this DTC?All
Ye s!Go To 3
No!Go To 16
3 Turn the ignition off.
Disconnect the Camshaft Position Sensor harness connector.
Turn the ignition on.
Measure the voltage of the CMP Sensor Signal circuit.
Select the appropriate voltage reading.All
Voltage is above 5.4 volts.
Go To 4
Voltage is between 4.7 and 5.4 volts.
Go To 5
Voltage is below 4.7 volts.
Go To 13
141
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Camshaft Position Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the Engine Control Relay.
Connect a jumper wire between cavity 30 and cavity 87 of the Engine Control Relay
connector.
Turn the ignition on.
Measure the voltage of the CMP Position Sensor Signal circuit.
Is the voltage below 1.0 volt?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Camshaft Position Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the Camshaft Position Sensor harness connector.
Turn the ignition on.
Measure the voltage of the CMP Sensor 5-Volt Supply circuit.
Select the appropriate voltage reading.All
Voltage is above 5.4 volts.
Repair the CMP 5-Volt Supply circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
Voltage is between 4.7 and 5.4 volts.
Go To 6
Voltage is below 4.7 volts.
Go To 10
6 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit between the CMP Sensor
harness connector and the ECM harness connector.
Is the resistance below 10.0 ohms?All
Ye s!Go To 7
No!Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition on.
Disconnect the ECT Sensor harness connector.
Disconnect the Camshaft Position Sensor harness connector.
Connect one end of a jumper wire to the ECT Sensor signal circuit in the ECT Sensor
harness connector.
Connect the other end of the jumper wire to the Sensor Ground circuit in the
Camshaft Position Sensor harness connector.
With the DRBIIItin Engine, Sensors, read the Engine Coolant Temp volts.
Is the voltage below 0.5 volt?All
Ye s!Go To 8
No!Replace and program the ECM in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
142
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

TEST ACTION APPLICABILITY
8 Turn the ignition off.
Remove the CMP Sensor.
Inspect the CMP Sensor for conditions such as loose mounting screws, damage, or
cracks.
Inspect the camshaft for conditions such as damage, debris or cracked teeth.
Is there any evidence of these conditions?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 9
9 Turn the ignition off.
With the DRBIIItlab scope lead, backprobe the CMP Signal circuit.
Set the DRBIIItlab scope settings as follows: Time = 0.2s/Div, 20 volts scale, Offset
= 0.00 volts, Probe = X10, Coupling = DC.
While observing the DRBIIItdisplay, crank the engine.
NOTE: The DRBIIItshould display a digital signal (square wave) similar to
that shown in Charts and Graphs.
Does the DRBIIItdisplay an uninterrupted digital signal (square wave)?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace the Camshaft Position Sensor in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
10 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the CMP Sensor harness connector.
Measure the resistance of the 5-Volt Supply circuit between the ECM harness
connector and the CMP Sensor harness connector.
Is the resistance below 10.0 ohms?All
Ye s!Go To 11
No!Repair the 5-Volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
11 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the CMP Sensor 5-Volt Supply circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 12
No!Repair the CMP Sensor 5-Volt Supply circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
143
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

TEST ACTION APPLICABILITY
12 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the CMP Sensor 5-Volt Supply circuit and the
Sensor Ground circuit at the CMP Sensor harness connector.
Is the resistance above 1000 ohms?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the CMP Sensor 5-Volt Supply and Sensor Ground circuits
for a short together.
Perform ROAD TEST VERIFICATION - VER-2.
13 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the CMP Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 14
No!Repair the CMP Sensor Signal circuit for an open
Perform ROAD TEST VERIFICATION - VER-2.
14 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the CMP Sensor Signal circuit.
Is the resistance below 1000 ohms?All
Ye s!Repair the CMP Sensor Signal circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 15
15 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the CMP Sensor Signal circuit and the Sensor
Ground circuit at the CMP Sensor harness connector.
Is the resistance below 1000 ohms?All
Ye s!Repair the CMP Sensor Signal and Sensor Ground circuits for a
short together.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
144
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

TEST ACTION APPLICABILITY
16WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running and at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Remove the CMP Sensor and the CKP Sensor, checking for loose mounting screws
and debris on the sensor magnets that can corrupt the sensor signal.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
145
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

Symptom List:
P2045-CRANKSHAFT POSITION SENSOR CIRCUIT LOST SIGNAL
P2045-CRANKSHAFT POSITION SENSOR CIRCUIT SIGNAL PLAU-
SIBILITY
P2322-CRANKSHAFT POSITION SENSOR PLAUSIBILITY
P2343-CKP PLAUSIBILITY
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2045-CRANKSHAFT POSITION
SENSOR CIRCUIT LOST SIGNAL.
POSSIBLE CAUSES
CKP MOUNTING AND FLYWHEEL
CRANKSHAFT POSITION SENSOR
ENGINE CONTROL MODULE
OPEN SHIELD CIRCUIT
INTERMITTENT CONDITION
CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT(S) SHORTED TO GROUND
CKP SENSOR CIRCUITS SHORTED TOGETHER
CKP SENSOR SIGNAL CIRCUITS OPEN
CKP SENSOR SIGNAL CIRCUIT(S) SHORTED TO VOLTAGE
TEST ACTION APPLICABILITY
1NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
Attempt to start the engine.
Did the engine start?All
Ye s!Go To 2
No!Go To 3
146
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
2WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
3 Refer to the Service Information to ensure the Engine Drive Gears/Sprocket are
installed correctly and the camshaft and crankshaft gears are timed correctly.
Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and both of the CKP Sensor Signal circuits.
Is the resistance above 1000 ohms for both measurements?All
Ye s!Go To 4
No!Repair the CKP Sensor Signal circuit(s) for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the CKP Sensor Signal circuits.
Is the resistance above 1000 ohms?All
Ye s!Go To 5
No!Repair the CKP Sensor Signal circuits for a short together.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of CKP Sensor Signal circuits.
Is the resistance below 10.0 ohms for both measurements?All
Ye s!Go To 6
No!Repair the CKP Sensor Signal circuit(s) for an open.
Perform ROAD TEST VERIFICATION - VER-2.
147
DRIVEABILITY - DIESEL
P2045-CRANKSHAFT POSITION SENSOR CIRCUIT LOST SIGNAL Ð
Continued