MERCEDES-BENZ SPRINTER 2006 Service Manual

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2006 VA Sprinter Technical Publications
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SERVICE MANUAL2006
SPRINTER
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Copyright 2004 DaimlerChrysler Corporation
81-370-06070CD

CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN
ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies
innon-automotive applications should be repaired in accordance with instruc-
tions supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The
service procedures recommended and described in this publication were developed for pro-
fessional service personnel and are effective methods for performing vehicle repair. Following
these procedures will help assure efficient economical vehicle performance and service reli-
ability. Some of these service procedures require the use of special tools designed for specific
procedures. These special tools should be used when recommended throughout this publi-
cation.
Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless
removal may cause personal injury. Always wear safety goggles whenever work-
ing on vehicles or vehicle components.
It is important to note that this publication contains various CautionsandWarnings. These
should be carefully read in order to minimize the risk of personal injury, or the possibility that
improper service methods may damage the vehicle or render it unsafe. It is important to note
that these CautionsandWarnings cover only the situations and procedures Daimler-
Chrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation
could not possibly know, evaluate, and advise the
service trade of all conceivable ways that
service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler
Corporation has not undertaken any such broad service review. Accordingly, anyone who uses
a service procedure, or tool, that is not recommended in this publication must assure oneself
thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service
methods they select.
For other Service and Owner Manuals for Chrysler,
Plymouth, Dodge, Dodge Truck, and Jeep
Tvehicles, Call
(800) 890-4038 or FAX (440) 572-0815 to place an order. Or, visit our website at techauthority.daimlerchrysler.com.Tech Authority Online at our website offers you serviceinformation on a subscription basis.

UNITED STATES and CANADA
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-800-801-5420 FAX 1-800-578-7375
INTERNATIONAL
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-507-455-7320 FAX 1-800-578-7375

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX-STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1AIRBAG SYSTEM...................................................1
3.1.1DRIVER AIRBAG............................................2
3.1.2CLOCKSPRING.............................................3
3.1.3PASSENGER AIRBAG.......................................3
3.1.4SEAT BELT TENSIONERS....................................3
3.1.5SPECIAL TOOLS............................................3
3.1.6DIAGNOSTIC TROUBLE CODES..............................4
3.1.6.1ACTIVE CODES............................................4
3.1.6.2STORED CODES...........................................4
3.2COMMUNICATION..................................................4
3.2.1COMMUNICATION K-LINES..................................4
3.2.2CAN BUS..................................................5
3.3HEATING & A/C SYSTEM............................................5
3.3.1AUTOMATIC TEMPERATURE CONTROL (ATC)..................5
3.3.1.1SYSTEM CONTROLS........................................5
3.3.1.2SYSTEM DIAGNOSTICS.....................................5
3.3.2CABIN HEATER MODULE (CHM) & HEATER BOOSTER MODULE
(HBM).....................................................7
3.3.2.1SYSTEM DESCRIPTION.....................................7
3.3.2.2VENTING THE HEATER'S EXHAUST...........................8
3.3.2.3SYSTEM DIAGNOSTICS.....................................8
3.4INSTRUMENT CLUSTER.............................................9
3.5POWER DOOR LOCKS/RKE..........................................9
3.5.1CENTRAL LOCKING.........................................9
3.5.2REMOTE KEYLESS ENTRY (RKE).............................9
3.5.3AUTO DOOR LOCKS.......................................10
3.5.4ACCIDENT RESPONSE.....................................10
3.6VEHICLE THEFT SECURITY SYSTEM (VTSS)..........................10
3.7USING THE DRBIIIT................................................11
3.8DRBIIITERROR MESSAGES.........................................11
3.9DRBIIITDOES NOT POWER UP (BLANK SCREEN)......................11
3.10DISPLAY IS NOT VISIBLE...........................................11
4.0 DISCLAIMERS, SAFETY, WARNINGS......................................11
4.1DISCLAIMERS.....................................................11
4.2SAFETY..........................................................11
4.2.1TECHNICIAN SAFETY INFORMATION.........................11
4.2.2VEHICLE PREPARATION FOR TESTING.......................12
4.2.3SERVICING SUB-ASSEMBLIES..............................12
4.2.4DRBIIITSAFETY INFORMATION.............................12
4.3WARNINGS.......................................................12
4.3.1VEHICLE DAMAGE WARNINGS..............................12
4.3.2ROAD TESTING A COMPLAINT VEHICLE......................12
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TABLE OF CONTENTS - Continued
5.0 REQUIRED TOOLS AND EQUIPMENT.....................................13
6.0 GLOSSARY OF TERMS..................................................13
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................15
AIRBAG
AIRBAG WARNING INDICATOR - DRIVER HIGH.............................16
AIRBAG WARNING INDICATOR - DRIVER LOW..............................19
DRIVER SEAT BELT TENSIONER - INCORRECT FEEDBACK..................22
DRIVER SQUIB 1 - INCORRECT FEEDBACK................................22
INTERNAL 1...........................................................22
INTERNAL 2...........................................................22
INTERNAL 3...........................................................22
PASSENGER SEAT BELT TENSIONER - INCORRECT FEEDBACK..............22
PASSENGER SQUIB 1 - INCORRECT FEEDBACK............................22
STORED ENERGY FIRING 1..............................................22
STORED ENERGY FIRING 2..............................................22
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN............................24
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT..........................26
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................28
DRIVER SEAT BELT TENSIONER SHORT TO GROUND.......................31
DRIVER SQUIB 1 CIRCUIT OPEN.........................................33
DRIVER SQUIB 1 CIRCUIT SHORT........................................36
DRIVER SQUIB 1 SHORT TO BATTERY....................................39
DRIVER SQUIB 1 SHORT TO GROUND....................................42
LOSS OF IGNITION RUN - START.........................................45
PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN.......................47
PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT......................49
PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY..................51
PASSENGER SEAT BELT TENSIONER SHORT TO GROUND..................54
PASSENGER SQUIB 1 CIRCUIT OPEN.....................................56
PASSENGER SQUIB 1 CIRCUIT SHORT....................................59
PASSENGER SQUIB 1 SHORT TO BATTERY................................62
PASSENGER SQUIB 1 SHORT TO GROUND................................65
*AIRBAG WARNING INDICATOR FLASHING.................................68
CABIN HEATER
A. HEATER PRE-TEST...................................................69
CIRC PUMP CONTROL OPEN............................................72
CIRC PUMP CONTROL SHORTED.........................................74
COMBUST FAN SHORTED...............................................76
COMBUST FAN SPEED INCORRECT......................................76
COMBUSTION FAN OPEN................................................76
CONTROL UNIT FAULTY.................................................77
DOSING PUMP OPEN...................................................78
DOSING PUMP SHORTED...............................................81
FAN STAGE 1 RELAY CONTROL OPEN....................................83
FAN STAGE 1 RELAY CONTROL SHORTED.................................85
FLAME DETECT PRIOR TO COMBUST.....................................87
FLAME OUT...........................................................88
NO START.............................................................88
FLAME SENSOR OPEN..................................................91
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TABLE OF CONTENTS - Continued
FLAME SENSOR SHORTED..............................................91
GLOW PIN OPEN.......................................................91
GLOW PIN SHORTED...................................................91
HEATER IN LOCKOUT MODE.............................................93
HEATER OVERHEATED..................................................93
SUCCESSIVE OVERHEATING............................................93
OVER VOLTAGE........................................................96
OVERHEATING SENSOR OPEN...........................................97
OVERHEATING SENSOR SHORTED.......................................97
TEMP SENSOR OPEN...................................................98
TEMP SENSOR SHORTED...............................................98
UNDER VOLTAGE......................................................99
COMMUNICATION
*NO RESPONSE FROM AIRBAG CONTROL MODULE.......................102
*NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL..............104
*NO RESPONSE FROM CABIN HEATER MODULE..........................106
*NO RESPONSE FROM CENTRAL TIMER MODULE.........................108
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE...................110
*NO RESPONSE FROM ENGINE CONTROL MODULE.......................112
*NO RESPONSE FROM HEATER BOOSTER MODULE.......................114
*NO RESPONSE FROM INSTRUMENT CLUSTER...........................116
*NO RESPONSE FROM RADIO..........................................118
*NO RESPONSE FROM SECURITY SYSTEM MODULE......................120
*NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE.............122
*NO RESPONSE FROM SHIFTER ASSEMBLY..............................124
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE................126
HEATING & A/C
A/C COMPRESSOR CONTROL HIGH OR OPEN (ACTIVE)....................128
A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED)...................130
A/C COMPRESSOR CONTROL SHORTED LOW (STORED)...................130
AIR OUTLET TEMP SENSOR HIGH OR OPEN (STORED)....................130
AIR OUTLET TEMP SENSOR SHORTED LOW (STORED)....................130
AUX FAN RELAY CONTROL HIGH OR OPEN (STORED).....................130
AUX FAN RELAY CONTROL SHORTED LOW (STORED).....................130
BLOWER STAGE 1 HIGH OR OPEN (STORED).............................130
BLOWER STAGE 1 SHORTED LOW (STORED).............................130
CABIN HEATER CONTROL HIGH OR OPEN (STORED)......................130
CABIN HEATER CONTROL SHORTED LOW (STORED)......................130
CIRC PUMP CONTROL HIGH OR OPEN (STORED).........................130
CIRC PUMP CONTROL SHORTED LOW (STORED).........................130
EVAP TEMP SENSOR HIGH OR OPEN (STORED)..........................130
EVAP TEMP SENSOR SHORTED LOW (STORED)..........................130
NO COMMUNICATION BUS (STORED)....................................130
NO COMMUNICATION WITH ECM (STORED)..............................130
NO COMMUNICATION WITH IC (STORED).................................130
RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (STORED)...............130
RECIRC AIR SOLENOID CONTROL SHORTED LOW (STORED)...............130
REFRIG PRESS SENSOR HIGH OR OPEN (STORED).......................130
REFRIG PRESS SENSOR SHORTED LOW (STORED).......................130
WATER CYCLE VALVE CONTROL HIGH OR OPEN (STORED)................130
WATER CYCLE VALVE CONTROL SHORTED LOW (STORED)................130
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TABLE OF CONTENTS - Continued
A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE)....................132
AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE).....................134
AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE).....................136
ATC FUNCTION TEST COOL FAILURE....................................138
ATC FUNCTION TEST FAILURE..........................................138
ATC FUNCTION TEST HEAT FAILURE.....................................138
AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE)......................140
AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE)......................142
BLOWER STAGE 1 HIGH OR OPEN (ACTIVE)..............................144
BLOWER STAGE 1 SHORTED LOW (ACTIVE)..............................146
CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE).......................148
CABIN HEATER CONTROL SHORTED LOW (ACTIVE).......................150
CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE)..........................152
CIRC PUMP CONTROL SHORTED LOW (ACTIVE)..........................154
EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE)...........................156
EVAP TEMP SENSOR SHORTED LOW (ACTIVE)...........................158
NO COMMUNICATION BUS (ACTIVE).....................................160
NO COMMUNICATION WITH ECM (ACTIVE)...............................163
NO COMMUNICATION WITH IC (ACTIVE)..................................165
RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE)................167
RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE)................169
REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE)........................171
REFRIG PRESS SENSOR SHORTED LOW (ACTIVE)........................173
WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE).................175
WATER CYCLE VALVE CONTROL SHORTED LOW (ACTIVE).................177
INSTRUMENT CLUSTER
AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY......................179
AMBIENT TEMP SENSOR SHORT TO GROUND............................181
FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY.........................182
FUEL LEVEL SENSOR SHORT TO GROUND...............................184
INSTRUMENT CLUSTER INTERNAL FAILURE B1043........................185
INSTRUMENT CLUSTER INTERNAL FAILURE B1053........................186
INSTRUMENT CLUSTER OVERVOLTAGE..................................187
NO CAN COMMUNICATION WITH ABS....................................188
NO CAN COMMUNICATION WITH ECM...................................190
NO CAN COMMUNICATION WITH TCM....................................192
PREGLOW INDICATOR LAMP FAILURE...................................194
SRS INDICATOR LAMP FAILURE.........................................195
POWER DOOR LOCKS/RKE
DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND......196
PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND .198
REPLACE CONTROL MODULE..........................................200
RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM......................201
RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM..................203
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM.....................205
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM..................206
THE ACM HAS UNLOCKED THE DOORS..................................208
UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2......................209
*RKE INOPERATIVE....................................................210
*RKE POOR RANGE...................................................211
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TABLE OF CONTENTS - Continued
VEHICLE THEFT/SECURITY
DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND............212
DRIVER CYLINDER UNLOCK SWITCH CIRCUIT SHORT TO GROUND.........214
FRONT DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND................216
INTERNAL ERROR - SSM...............................................218
TOWING INCLINATION SENSOR BEYOND LIMITS..........................218
TOWING INCLINATION SENSOR VALUE IS INVALID.........................218
TOWING INCLINATION SENSOR VALUE IS MISSING........................218
INTRUSION SENSOR 1 CIRCUIT OPEN/SHORT TO GROUND................220
INTRUSION SENSOR 1 GROUND CIRCUIT OPEN..........................222
INTRUSION SENSOR 2 CIRCUIT OPEN/SHORT TO GROUND................223
INTRUSION SENSOR 2 GROUND CIRCUIT OPEN..........................225
INTRUSION SENSOR 3 CIRCUIT OPEN/SHORT TO GROUND................226
INTRUSION SENSOR 3 GROUND CIRCUIT OPEN..........................228
REAR OR SLIDING DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND......229
RKE INTERFACE CIRCUIT FAILURE - SSM................................231
SECURITY SYSTEM INTERFACE FAILURE - SSM...........................233
SIREN CIRCUIT OPEN/SHORTED TO GROUND............................235
SIREN INTERNAL FAILURE.............................................237
SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND....................238
WINDSHIELD WIPER & WASHER
CHECKING THE RAIN SENSOR/WIPER OPERATION........................239
VERIFICATION TESTS
VERIFICATION TESTS..................................................244
8.0 COMPONENT LOCATIONS..............................................249
8.1AIRBAG SYSTEM.................................................249
8.2AIRBAG CONTROL MODULE.......................................249
8.3DRIVER AIRBAG SQUIB...........................................249
8.4CLOCKSPRING..................................................250
8.5SEAT BELT TENSIONER...........................................250
8.6HEATING & A/C...................................................250
8.6.1AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM
COMPONENTS...........................................250
8.6.2CABIN HEATER & HEATER BOOSTER SYSTEM COMPONENTS .251
8.6.3AUTO TEMP CONTROL, CABIN HEATER, & HEATER BOOSTER
FUSES & RELAYS........................................251
8.6.4EVAP TEMP SENSOR & AIR OUTLET TEMP SENSOR..........251
8.7INSTRUMENT CLUSTER...........................................252
8.7.1AMBIENT TEMPERATURE SENSOR.........................252
8.8POWER DOOR LOCKS/RKE........................................252
8.8.1CENTRAL TIMER MODULE.................................252
8.8.2SENTRY KEY REMOTE ENTRY MODULE.....................253
8.8.3DOOR LOCK MOTOR/AJAR SWITCH........................253
8.8.4CONTACT PLATES........................................253
8.8.5DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS...........254
v