brake MERCEDES-BENZ SPRINTER 2006 Service Manual

3.3.4 HANDLING NO TROUBLE CODE
PROBLEMS
After reading Section 3.0 (System Description
and Functional Operation), you should have a bet-
ter understanding of the theory and operation of the
on-board diagnostics and how this relates to the
diagnosis of a vehicle that may have a driveability-
related symptom or complaint. When there are no
trouble codes present, refer to the no trouble code
(*) tests.
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading the DTCs, erasing the
DTCs, lab scope usage and other DRBIIItfunc-
tions.
3.4.1 DRBIIITDOES NOT POWER UP
If the LEDs do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage at data link
connector cavity 16. A minimum of 11.0 volts is
required to adequately power the DRBIIIt. Check
for proper ground connection at data link connector
cavities 4 and 5.
If all connections are proper between the
DRBIIItand the vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
DRBIIItmay be the result of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate diagnostic manual.
3.4.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: HIGH-PRESSURE FUEL LINES
DELIVER DIESEL FUEL UNDER EXTREME
PRESSURE FROM THE INJECTION PUMP TO
THE FUEL INJECTORS. THIS MAY BE AS
HIGH AS 23,200 PSI (1600 BAR). USE
EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN CAUSING PERSONAL
INJURY OR DEATH. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A
SHEET OF CARDBOARD. WEAR SAFETY
GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING WHEN SERVICING FUEL
SYSTEM.
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREA WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection and remove any metal jewelry such as
watchbands or bracelets that might make electrical
contact.
When diagnosing powertrain system problems, it
is important to follow approved procedures where
applicable. These procedures can be found in the
8
GENERAL INFORMATION

Symptom:
P0500-WHEEL SPEED SENSOR PLAUS - CAN BUS MESSAGE FROM
ABS
When Monitored and Set Condition:
P0500-WHEEL SPEED SENSOR PLAUS - CAN BUS MESSAGE FROM ABS
When Monitored: With the ignition on.
Set Condition: The Boost Pressure Sensor Signal voltage exceeds 4.85 volts for at least 2
seconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
CHECK FOR RELATED CONTROLLER ANTILOCK BRAKES DTCS
CHECK FOR RELATED TRANSMISSION CONTROL MODULE DTCS
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: If the ECM displays multiple CAN Bus related DTC's, check the CAN
Bus circuits at the ECM harness connector for proper connection before
continuing with this test.
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 DRB, erase ECM DTCs.
Test drive the vehicle.
With the DRB, read the ECM DTC's.
Does the DRB display this DTC?All
Ye s!Go To 2
No!Go To 4
2 Turn the ignition on.
With the DRB, check for Controller Antilock Brakes DTCs.
NOTE: The ECM Receives vehicle speed messages via CAB Bus from the ABS
module. An interruption on the CAN Bus can cause this fault to set.
Are any related CAB DTCs present?All
Ye s!Refer to symptom list for problems related to CAB DTCs before
continuing.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
69
DRIVEABILITY - DIESEL

Symptom List:
P2203-TORQUE REDUCTION MESSAGE FROM ABS - CAN PLAUSI-
BILITY
P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGE
ERROR
P2203-TORQUE REDUCTION MESSAGE FROM ABS - MESSAGES
MISSING
P2203-TORQUE REDUCTION MESSAGE FROM ABS - NO COMMUN-
IOCATION
P2203-TORQUE REDUCTION MESSAGE FROM ABS - PLAUSIBIL-
ITY #1
P2203-TORQUE REDUCTION MESSAGE FROM ABS PLAUSIBILITY
#2
P2208-ABS BRAKE SIGNAL CAN MESSAGE IMPLAUSIBLE
P2208-ABS CAN BRAKE SIGNAL PLAUSIBILITY
P2209-ABS CAN MESSAGE MISSING OR INCORRECT
P2253-STEERING ANGLE SENSOR PLAUSIBILITY
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2203-TORQUE REDUCTION
MESSAGE FROM ABS - CAN PLAUSIBILITY.
POSSIBLE CAUSES
CAB DTCS
ENGINE CONTROL MODULE
VERIFY CAB COMMUNICATION
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIItattempt to communicate with the CAB.
NOTE: If there are other DTCs set with this DTC, refer to the Symptom List
and repair other stored ECM DTCs before diagnosing this DTC.
Is the CAB communicating with the DRB?All
Ye s!Go To 2
No!Refer to the appropriate symptom in the Body Diagnostic Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
180
DRIVEABILITY - DIESEL

Symptom List:
P2242-ABS BRAKE MESSAGE PLAUSIBILITY 1
P2242-ABS BRAKE MESSAGE PLAUSIBILITY 2
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2242-ABS BRAKE MESSAGE
PLAUSIBILITY 1.
POSSIBLE CAUSES
CAB DTCS
CHECKING BRAKE SWITCH INPUT
CONTROLLER ANTILOCK BRAKE MODULE
TCM DTCS
VERIFY CAB COMMUNICATION
VERIFY TCM COMMUNICATION
TEST ACTION APPLICABILITY
1NOTE: This DTC can be set if the vehicle operator depresses the brake pedal
and the accelerator at the same time (riding the brake pedal). Check with
vehicle operator for this type of driving behavior.
Turn the ignition on.
With the DRBIIItattempt to communicate with the CAB.
NOTE: If there are other DTCs set with this DTC, refer to the Symptom List
and repair other stored ECM DTCs before diagnosing this DTC.
Is the CAB communicating with the DRB?All
Ye s!Go To 2
No!Refer to the appropriate symptom in the Body Diagnostic Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition on.
With the DRBIIIt, read the CAB DTCs.
Are there any CAB DTCs?All
Ye s!Refer to symptom list for problems related to CAB.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition on.
With the DRBIIItattempt to communicate with the TCM.
Is the TCM communicating with the DRB?All
Ye s!Go To 4
No!Refer to the appropriate symptom in the Body Diagnostic Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
192
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
4 Turn the ignition on.
With the DRBIIIt, read the CAB DTCs.
Are there any CAB DTCs?All
Ye s!Refer to symptom list for problems related to TCM
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition on.
With the DRBIIItselect TCM then Sensors. Read the Brake Switch input while
pressing and releasing the brake pedal several times.
With the DRBIIItselect CAB then Sensors. Read the Brake Switch input while
pressing and releasing the brake pedal several times.
Is the Brake Switch input operating correctly for both modules?All
Ye s!Replace and program the CAB in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Refer to the Service Information wiring to diagnose brake switch
problem.
Perform BODY VERIFICATION TEST - VER 1.
193
DRIVEABILITY - DIESEL
P2242-ABS BRAKE MESSAGE PLAUSIBILITY 1 ÐContinued

Symptom List:
P2333-S/C VEHICLE SPEED PLAUSIBILITY
P2338-S/C EXCESSIVE ACCELERATION
P2338-S/C EXCESSIVE DECELERATION
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2333-S/C VEHICLE SPEED
PLAUSIBILITY.
POSSIBLE CAUSES
BRAKE SWITCH VERIFICATION
CAB DTCS
OPEN CAN BUS CIRCUITS
VERIFY CAB COMMUNICATION
WHEEL SPEED VERIFICATION
INTERMITTENT CONDITION
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.
With the DRBIIIt, erase ECM DTCs.
Test drive the vehicle and attempt to duplicate the problem.
With the DRB, read ECM DTC's.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 7
2 Turn the ignition on.
With the DRBIIItattempt to communicate with the CAB.
NOTE: If there are other DTCs set with this DTC, refer to the Symptom List
and repair other stored ECM DTCs before diagnosing this DTC.
Is the CAB communicating with the DRB?All
Ye s!Go To 3
No!Refer to the appropriate symptom in the Body Diagnostic Infor-
mation.
Perform ROAD TEST VERIFICATION - VER-2.
209
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
3 Turn the ignition on.
With the DRBIIIt, read the CAB DTCs.
Are there any CAB DTCs?All
Ye s!Refer to symptom list for problems related to CAB.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4 Turn the ignition off.
Disconnect the CAB Module harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of each CAN Bus circuit between the ECM harness connector
and the CAB harness connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Go To 5
No!Repair the open CAN Bus circuit(s) between the ECM and the
SKREEM.
Perform ROAD TEST VERIFICATION - VER-2.
5 With the DRBIIIt, perform the Wheel Speed Test of the ABS system.
Were any problems found?All
Ye s!Repair wheel speed signal problem as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 6
6 Check the Brake Switch for proper operation and adjustment.
Were any problems found?All
Ye s!Adjust or replace the Brake Switch as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
7WARNING: 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.
210
DRIVEABILITY - DIESEL
P2333-S/C VEHICLE SPEED PLAUSIBILITY ÐContinued

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
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
257
CONNECTOR PINOUTS

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
7Cooling
8AAudio/Video
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
VAINTRODUCTION 3