brake MERCEDES-BENZ SPRINTER 2006 Owners Manual

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
76
BRAKES (CAB)
SYSTEM OVERVOLTAGE ÐContinued

Symptom:
SYSTEM UNDERVOLTAGE
POSSIBLE CAUSES
INTERMITTENT DTC
DAMAGED CAB/CAB HARNESS CONNECTOR
FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT HIGH RESISTANCE
FUSED B(+) CIRCUIT HIGH RESISTANCE
GROUND CIRCUIT HIGH RESISTANCE
ANTI-LOCK BRAKE CONTROLLER
TEST ACTION APPLICABILITY
1NOTE: An undercharged battery may cause this DTC to set. Repair any
Powertrain charging system DTCs before continuing.
Turn the ignition on.
With the DRBIIIt, read DTCs.
With the DRBIIIt, erase DTCs.
Turn the ignition off.
Turn the ignition on.
Start the engine.
With the DRBIIIt, read DTCs.
Does this DTC reset?All
Ye s!Go To 2
No!Go To 6
2 Turn the ignition off.
Disconnect the CAB harness connector.
Inspect the CAB/CAB harness connector for damage.
Is there any broken, bent, pushed out, corroded or spread terminals?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition off.
Disconnect the CAB harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Optional Equipment
Relay Output circuit at the CAB harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Go To 4
No!Repair the Fused Optional Equipment Relay Output circuit for
high resistance.
Perform ABS VERIFICATION TEST - VER 1.
77
BRAKES (CAB)

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to ground, check both Fused B(+) circuits at the
CAB harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Go To 5
No!Repair the Fused B(+) circuit for high resistance.
Perform ABS VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to 12-volts, check the CAB harness connector
Ground circuits.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Replace the Controller Antilock Brake in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the Ground circuit for high resistance.
Perform ABS VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
78
BRAKES (CAB)
SYSTEM UNDERVOLTAGE ÐContinued

9.0 CONNECTOR PINOUTS
BRAKE FLUID LEVEL SWITCHCAV CIRCUIT FUNCTION
1 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
2 16BR GROUND
BRAKE LAMP SWITCH C1 (EXCEPT ESP)CAV CIRCUIT FUNCTION
1 20WT BRAKE SWITCH OUTPUT
2 16RD/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 20BK/BL/RD BRAKE LAMP SWITCH
4- -
BRAKE LAMP SWITCH C2 (EXCEPT ESP) - BLACKCAV CIRCUIT FUNCTION
1 16BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 16BK/RD BRAKE LAMP SWITCH OUTPUT
3- -
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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
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CONNECTOR PINOUTS

INSTRUMENT CLUSTER C2 - WHITECAV CIRCUIT FUNCTION
1- -
2- -
3 20RD/YL FUSED B(+)
4 20BR/WT BRAKE WEAR SENSOR SIGNAL
5- -
6 18BR GROUND
7 20GY/DG/RD LAMP DRIVER
8 20BL/WT FUSED HIGH BEAM SWITCH OUTPUT
9 20BL/RD/WT VEHICLE SPEED SENSOR OUTPUT
10 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
12 - -
13 20BK/WT LEFT TURN SIGNAL
14 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
15 20BL GENERATOR FIELD DRIVER
16 20YL AIRBAG WARNING INDICATOR DRIVER
17 - -
18 20BL/VT D(+) RELAY NO. 1 CONTROL
18 20BL/VT D(+) RELAY NO. 1 CONTROL
STEERING ANGLE SENSORCAV CIRCUIT FUNCTION
1 20DG/WT CAN C BUS (-)
2- -
3 20DG CAN C BUS (+)
4- -
5 20BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
6 20BR GROUND
TCS SWITCH (ASR) - BLACKCAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2- -
3 18BK/BL TCS SWITCH (ASR) SENSE
4- -
5- -
6- -
7 16BK/BL/DG FUSED IGNITION SWITCH OUTPUT
8- -
9- -
10 16BR GROUND
WHEEL SPEED SENSOR-LEFT FRONTCAV CIRCUIT FUNCTION
1 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
2 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
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CONNECTOR PINOUTS

10.0 SCHEMATIC DIAGRAMS
10.1 BOSCH 5.7 ANTILOCK BRAKE SYSTEM ± ABS
S
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SCHEMATIC DIAGRAMS

TABLE OF CONTENTS - Continued
P2500-FUEL PRESSURE SOLENOID CIRCUIT OPEN CIRCUIT................173
P2501-FUEL PRESSURE SOLENOID CIRCUIT SHORTED TO GROUND OR B+ . .173
P2197-FUEL QUANTITY SOLENOID OPEN CIRCUIT.........................177
P2198-FUEL QUANTITY SOLENOID SHORT TO VOLTAGE...................177
P2199-FUEL QUANTITY SOLENOID SHORT TO GROUND....................177
P2502-FUEL QUANTITY SOLENOID SHORT TO GROUND....................177
P2203-TORQUE REDUCTION MESSAGE FROM ABS - CAN PLAUSIBILITY.....180
P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGE ERROR......180
P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGES MISSING . . .180
P2203-TORQUE REDUCTION MESSAGE FROM ABS - NO COMMUNIOCATION .180
P2203-TORQUE REDUCTION MESSAGE FROM ABS - PLAUSIBILITY #1.......180
P2203-TORQUE REDUCTION MESSAGE FROM ABS PLAUSIBILITY #2.........180
P2208-ABS BRAKE SIGNAL CAN MESSAGE IMPLAUSIBLE..................180
P2208-ABS CAN BRAKE SIGNAL PLAUSIBILITY............................180
P2209-ABS CAN MESSAGE MISSING OR INCORRECT......................180
P2253-STEERING ANGLE SENSOR PLAUSIBILITY..........................180
P2204-TORQUE REDUCTION MESSAGE FROM TCM - CAN PLAUSIBILITY.....182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - ENGINE STOP.........182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - MESSAGE ERROR.....182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - MESSAGES MISSING . . .182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - PLAUSIBILITY..........182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - TCM DTC #1...........182
P2204-TORQUE REDUCTION MESSAGE FROM TCM - TCM DTC #2...........182
P2210-ESM CAN MESSAGE MISSING OR INCORRECT......................184
P2234-ABS DTC EXTERNAL QUANTITY CONTROL FAULT PRESENT..........184
P2252-LATERAL ACCELERATOR SENSOR PLAUSIBILTY.....................184
P2211-ETC CAN MESSAGE MISSING OR INCORRECT......................186
P2258-TCM MESSAGE ERROR..........................................186
P2258-TCM NO CAN MESSAGE..........................................186
P2217-TCM DTC INTERNAL FAULT PRESENT..............................188
P2218-TCM DTC 1-2 AND 4-5 SHIFT SOLENOID FAULT PRESENT............188
P2219-TCM DTC 2-3 SHIFT SOLENOID FAULT PRESENT....................188
P2220-TCM DTC 3-4 SHIFT SOLENOID FAULT PRESENT....................188
P2221-TCM DTC TORQUE CONVERTER CLUTCH SOLENOID FAULT PRESENT .188
P2222-TCM DTC MODULATING PRESSURE SOLENOID FAULT PRESENT......188
P2223-TCM DTC SHIFT PRESSURE SOLENOID FAULT PRESENT.............188
P2224-TCM DTC VALVE VOLTAGE SUPPLY FAULT PRESENT................188
P2225-TCM DTC SPEED SENSOR VOLTAGE FAULT PRESENT...............188
P2226-TCM DTC EWM CAN MESSAGE FAULT PRESENT....................188
P2227-TCM DTC RIGHT REAR WHEEL SPEED IMPLAUSIBLE FAULT PRESENT .188
P2228-TCM DTC TRANSMISSION RATIO ERROR FAULT PRESENT...........188
P2229-TCM DTC CAN MSG IMPLAUSIBLE FAULT PRESENT.................188
P2230-TCM DTC TCC EXCESSIVE POWER CONSUMPTION FAULT PRESENT . .188
P2231-TCM DTC NOT UNEQUIVOCAL FAULT PRESENT.....................188
P2232-TCM DTC NEGATIVE GEAR COMPARISON FAULT PRESENT...........188
P2240-ABS STEERING ANGLE SENSOR CAN MESSAGE IMPLAUSIBLE 1......190
P2240-ABS STEERING ANGLE SENSOR CAN MESSAGE IMPLAUSIBLE 2......190
P2242-ABS BRAKE MESSAGE PLAUSIBILITY 1.............................192
P2242-ABS BRAKE MESSAGE PLAUSIBILITY 2.............................192
P2244-INSTRUMENT CLUSTER MESSAGE PLAUSIBILITY...................194
P2259-TORQUE REDUCTION MESSAGE FROM HVAC- PARITY ERROR........196
P2259-TORQUE REDUCTION MESSAGE FROM HVAC- SWITCH SIGNAL
ERROR..............................................................196
viii

TABLE OF CONTENTS - Continued
*CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS...................233
*CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS....................234
*CHECKING THE POWER AND GROUNDS................................235
*ENGINE CRANKS BUT WILL NOT START.................................239
*ENGINE WILL NOT CRANK.............................................242
VERIFICATION TESTS
VERIFICATION TESTS..................................................246
8.0 COMPONENT LOCATIONS..............................................249
8.1CONTROL MODULES.............................................249
8.2CONTROLS AND SOLENOIDS......................................249
8.3DATA LINK CONNECTOR..........................................250
8.4SENSORS.......................................................251
8.5SWITCHES......................................................253
9.0 CONNECTOR PINOUTS................................................255
ACCELERATOR PEDAL POSITION SENSOR (OBD).........................255
AIRBAG CONTROL MODULE - YELLOW...................................255
BOOST PRESSURE SENSOR (OBD)......................................255
BOOST PRESSURE SERVOMOTOR (OBD)................................256
CAMSHAFT POSITION SENSOR - BLACK.................................256
CONTROLLER ANTILOCK BRAKE........................................257
CRANKCASE HEATER - BLACK..........................................257
CRANKSHAFT POSITION SENSOR - BLACK...............................258
DATA LINK CONNECTOR - BLACK........................................258
EGR VALVE - BLACK...................................................258
ENGINE CONTROL MODULE C1 (OBD)...................................259
ENGINE CONTROL MODULE C2 (OBD)...................................260
ENGINE COOLANT TEMPERATURE SENSOR - BLACK......................260
ENGINE OIL SENSOR - BLACK..........................................261
FUEL INJECTOR NO. 1 - BLACK.........................................261
FUEL INJECTOR NO. 2 - BLACK.........................................261
FUEL INJECTOR NO. 3 - BLACK.........................................261
FUEL INJECTOR NO. 4 - BLACK.........................................262
FUEL INJECTOR NO. 5 - BLACK.........................................262
FUEL PRESSURE SENSOR - BLACK.....................................262
FUEL PRESSURE SOLENOID............................................262
FUEL PUMP (OBD).....................................................262
FUEL PUMP RELAY (OBD)..............................................263
FUEL QUANTITY CONTROL VALVE (OBD).................................263
FUEL TEMPERATURE SENSOR..........................................263
ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)...........................265
FUSES (FUSE BLOCK NO. 1)............................................265
FUSES (FUSE BLOCK NO. 2)............................................267
FUSES (FUSE/RELAY BLOCK)...........................................269
STARTER MOTOR RELAY (FUSE/RELAY BLOCK)...........................269
GLOW PLUG CONTROL MODULE C1 - BLACK.............................270
GLOW PLUG CONTROL MODULE C2 - BLACK.............................270
INTAKE AIR PRESSURE SENSOR (OBD)..................................270
INTAKE AIR TEMPERATURE SENSOR - BLACK............................270
x

supply circuits). Refer to the appropriate wiring
diagrams to identify shared circuits.
abs brake message plausibility 1
abs brake message plausibility 2
abs brake signal can message implausible
abs can brake signal plausibility
abs can message missing or incorrect
abs dtc external quantity control fault present
abs steering angle sensor can message implausible
1
abs steering angle sensor can message implausible
2
acc pedal position sensor 1 ckt plausibility
acc pedal position sensor 1 ckt signal voltage too
high
acc pedal position sensor 1 ckt signal voltage too low
acc pedal position sensor 2 circuit plausibility
acc pedal position sensor 2 ckt signal voltage too
high
acc pedal position sensor 2 ckt signal voltage too low
acm circuit fault
acm circuit short to voltage
ambient air temperature signal voltage too high
ambient air temperature signal voltage too low
app sensor plausibility
atmospheric pressure sensor plausibility with boost
pressure sensor
atmospheric pressure sensor signal voltage too high
atmospheric pressure sensor signal voltage too low
automatic transmission coded as manual transmis-
sion
boost pressure servo motor circuit excessive current
boost pressure servo motor circuit open circuit
boost pressure servo motor circuit short circuit
boost pressure servo motor circuit short to ground
boost pressure servo motor excessive current
boost pressure servo motor open circuit
boost pressure servo motor short to ground
boost pressure servo motor short to ground
boost pressure servo motor short to voltage
boost pressure too high
boost pressure too low
camshaft position sensor circuit open circuit
camshaft position sensor circuit open or short cir-
cuit
can bus circuit interuption
can data bus -bus circuit fault
can message error
*checking the fuel pressure sensor circuits
*checking the fuel pressure solenoid circuits
*checking the fuel quantity solenoid circuits
*checking the power and grounds
ckp plausibility
cmp/ckp synchronization error
crankcase vent heater excessive current
crankcase vent heater open circuit
crankcase vent heater shorted to ground
crankcase vent heater shorted to voltagecrankshaft position sensor circuit lost signal
crankshaft position sensor circuit signal plausibil-
ity
crankshaft position sensor plausibility
cylinder #1 injector open circuit
cylinder #2 injector open circuit
cylinder #3 injector open circuit
cylinder #4 injector open circuit
cylinder #5 injector open circuit
cylinder 1-injector circuit excessive current
cylinder 1-injector circuit open or shorted to ground
cylinder 1-injector circuit shorted to voltage
cylinder 1-injector circuit shorted to ground
cylinder 2-injector circuit excessive current
cylinder 2-injector circuit open or shorted to ground
cylinder 2-injector circuit shorted to ground
cylinder 2-injector circuit shorted to voltage
cylinder 3-injector circuit excessive current
cylinder 3-injector circuit open or shorted to ground
cylinder 3-injector circuit shorted to ground
cylinder 3-injector circuit shorted to voltage
cylinder 4-injector circuit excessive current
cylinder 4-injector circuit open or shorted to ground
cylinder 4-injector circuit shorted to ground
cylinder 4-injector circuit shorted to voltage
cylinder 5-injector circuit excessive current
cylinder 5-injector circuit open or shorted to ground
cylinder 5-injector circuit shorted to ground
cylinder 5-injector circuit shorted to voltage
ecm a/d converter high
ecm a/d converter low
ecm a/d converter plausibility
ecm checksum error #1
ecm checksum error #2
ecm incorrect value
ecm injection quantity error
ecm injector monitoring 1
ecm injector monitoring 2
ecm injector monitoring 3
ecm injector monitoring 4
ecm injector output stage #1
ecm injector output stage #1 short circuit
ecm injector output stage #2
ecm injector output stage #2 short circuit
ecm injector undervoltage
ecm internal error
ecm internal error
ecm internal error
ecm internal error
ecm internal error 1
ecm internal error 1
ecm internal error 1
ecm internal error 1
ecm internal error 1
ecm internal error 2
ecm internal error 2
ecm internal error 2
ecm internal error 3
4
GENERAL INFORMATION