battery MERCEDES-BENZ SPRINTER 2006 Service Manual

BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. Ensure that all accessories are turned off and the battery is fully charged.
3. NOTE: Refer to the service information for proper programming procedures if the
ABM; ACM; ATC; CTM; ECM; IC; SKREEM; SLA; or SSM was replaced.
4. If the SKREEM was replaced, program all RKE transmitters used with this vehicle.
5. NOTE: Perform the next 8 steps of this procedure if either diagnosing the
Automatic Temperature Control (ATC) system or if repairs were made to the ATC
system. All of the following criteria must be met in order to successfully run the ATC
Function Test.
6. With DRBIIIt, record and erase ATC DTCs.
7. Place the shift lever in Park.
8. Start the engine. Allow the engine to reach normal operating temperature.
9. Set the blower to high speed.
10. Press the Air Conditioning switch On.
11. With the DRBIIIt, verify that the ambient temperature is above 59ÉF (15ÉC), the refrigerant
pressure is between 29 and 348 PSI (2 and 24 bar), the evaporator temperature is above 36.5ÉF
(2.5ÉC), and the coolant temperature is above 158ÉF (70ÉC).
12. With the DRBIIItin ATC, select System Tests and select ATC Function Test. When the ATC
Function Test is complete, proceed to the next step of this procedure.
13. With the DRBIIIt, read active ATC DTCs. If any DTC is active or if the original condition
is still present, proceed to the conclusion question and answer Yes.
14. With the DRBIIIt, record and erase all DTCs from ALL modules. Start and run the engine
for 2 minutes. Operate all functions of the system that caused the original concern.
15. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIIIt, read
DTCs from ALL modules.
Are any DTC's present or is the original condition still present?All
Ye s!Repair is not complete, refer to the appropriate symptom.
No!Repair is complete.
245
VERIFICATION TESTS
Verification Tests ÐContinued

HEATER VERIFICATION TEST - VER 1 APPLICABILITY
1. WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES
NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE HEATER's
EXHAUST WHEN OPERATING THE HEATER. FAILURE TO FOLLOW THESE IN-
STRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
3. NOTE: The heater's control unit will store up to five DTCs in its memory.
4. NOTE: If the heater's control unit detects a new fault in the system, one that is not
already stored in its memory, it will clear the oldest of the five stored DTCs, and it
will store the new fault's DTC.
5. NOTE: If the heater's control unit detects a reoccurrence of a stored fault, it will
overwrite that fault's DTC with the most recent occurrence.
6. Verify that the vehicle's battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank. Add fuel, if
necessary.
8. Verify that all heater's coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of air
in accordance with the Service Information.
11. Turn the ignition on.
12. Verify that the Cabin Heater or Heater Booster is switched off.
13. Ensure that all accessories are turned off.
14. Set the blend control to the max heat position and the mode control to the floor position.
15. If a fuel system service requiring fuel to drain out of the heater's fuel line was performed,
prime the heater's Dosing Pump in accordance with the Service Information.
16. With the DRBIIIt, record and erase all DTCs from the Cabin Heater Module or Heater
Booster Module. Turn the ignition off, wait 5 seconds, then turn start the engine.
17. Allow the engine to idle.
18. NOTE: Do not disconnect the vehicle's battery or the heater's main power supply
while the heater is in operation or in run-down mode. Failure to follow these
instructions can result in excess emissions from the heater during heater operation.
19. Switch the Cabin Heater or Heater Booster on. Allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then turn the heater off.
20. With the DRBIIIt, read the Cabin Heater or Heater Booster Module's DTC.
21. Turn the engine off.
Are any DTC's present or is the original condition still present?All
Ye s!Repair is not complete, refer to the appropriate symptom.
No!Repair is complete.
246
VERIFICATION TESTS
Verification Tests ÐContinued

ver: 2.14
date: 26 Jul93
file: key_iff.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.9.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's 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 (data link
16-way connector cavity 16). A minimum of 11 volts
is required to adequately power the DRBIIIt. Also
check for a good ground at DLC.
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 or a faulty cable or
vehicle wiring.
3.9.2 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 latestinformation 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: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS 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 front
drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing an antilock brake or adjustable
pedals system problem, it is important to follow
approved procedures where applicable. These pro-
cedures can be found in the service manual. Follow-
ing these procedures is very important to safety of
individuals performing diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the antilock brake and trac-
tion control are intended to be serviced in assembly
only. Attempting to remove or repair certain sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
5
GENERAL INFORMATION

TEST ACTION APPLICABILITY
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 an
open.
Perform ABS VERIFICATION TEST - VER 1.
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 an open.
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 an open.
Perform ABS VERIFICATION TEST - VER 1.
11
BRAKES (CAB)
ANTI-LOCK BRAKE MODULE INTERNAL ÐContinued

TEST ACTION APPLICABILITY
6 Turn the ignition off.
Disconnect the appropriate brake switch harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output circuit at the harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Is the test light illuminated and bright?All
Ye s!Go To 7
No!Repair the Fused Ignition Switch Output circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
7 Turn the ignition off.
Disconnect the CAB harness connector.
Disconnect the appropriate brake switch harness connector.
Turn the ignition on.
Measure the voltage of the output circuit at the brake switch harness connector.
NOTE: Measurement is taken at the Brake Switch Output circuit or the
Brake Lamp Output circuit as determined by the previously performed
switch test.
Is there any voltage present?All
Ye s!Repair the affected circuit for a short to voltage.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 8
8 Turn the ignition off.
Disconnect the CAB harness connector.
Disconnect the appropriate brake switch harness connector.
Measure the resistance between ground and switch output circuit at the switch
connector.
NOTE: Measurement is taken at the Brake Switch Output circuit or the
Brake Lamp Output circuit as determined by the previously performed
switch test.
Is the resistance below 5.0 ohms?All
Ye s!Repair the affected circuit for a short to ground.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 9
9 Turn the ignition off.
Disconnect the CAB harness connector.
Disconnect the appropriate brake switch harness connector.
Measure the resistance of the output circuit between the switch harness connector
and the CAB harness connector.
NOTE: Measurement is taken at the Brake Switch Output circuit or the
Brake Lamp Output circuit as determined by the previously performed
switch test.
Is the resistance above 5.0 ohms?All
Ye s!Repair the affected circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 10
19
BRAKES (CAB)
BRAKE SWITCH CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
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 an
open.
Perform ABS VERIFICATION TEST - VER 1.
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 an open.
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 an open.
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.
22
BRAKES (CAB)
CAB CHECK SUM ÐContinued

TEST ACTION APPLICABILITY
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 an
open.
Perform ABS VERIFICATION TEST - VER 1.
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 an open.
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 an open.
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.
24
BRAKES (CAB)
CAB OPTION ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the CAB harness connector.
Turn the ignition on.
Measure the voltage of the CAN(+) circuit.
Measure the voltage of the CAN(-) circuit.
Is the voltage above 3.0 volts for either circuit?All
Ye s!Repair the CAN circuit(s) for a short to voltage.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
Disconnect the CAB harness connector.
Measure the resistance between ground and the CAN(+) circuit.
Measure the resistance between ground and the CAN(-) circuit.
Is the resistance below 5.0 ohms for either circuit?All
Ye s!Repair the CAN circuit(s) for a short to ground.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 6
6 Turn the ignition off.
Disconnect the CAB harness connector.
Measure the resistance between the CAN(+) circuit and the CAN(-) circuit.
Is the resistance below 5.0 ohms between the circuits?All
Ye s!Repair the shorted CAN circuit(s).
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 7
7 Turn the ignition off.
Disconnect the Engine Control Module harness connector.
Disconnect the CAB harness connector.
Measure the resistance of the CAN(+) circuit.
Measure the resistance of the CAN(-) circuit.
Is the resistance above 5.0 ohms for either circuit?All
Ye s!Repair the CAN circuit(s) for an open
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 8
8 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 9
No!Repair the Fused Optional Equipment Relay Output circuit for an
open.
Perform ABS VERIFICATION TEST - VER 1.
26
BRAKES (CAB)
CAN COMMUNICATION ERROR ÐContinued

TEST ACTION APPLICABILITY
9 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 10
No!Repair the Fused B(+) circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
10 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 an open.
Perform ABS VERIFICATION TEST - VER 1.
11 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.
27
BRAKES (CAB)
CAN COMMUNICATION ERROR ÐContinued

TEST ACTION APPLICABILITY
1NOTE: If a system undervoltage or overvoltage DTC is set along with this
DTC, diagnose the system voltage DTC first.
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.
Drive the vehicle over 15 km/h (10 mph) to test solenoid and pump circuits.
Stop the vehicle.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay any SOLENOID DTCs?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 an
open.
Perform ABS VERIFICATION TEST - VER 1.
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 an open.
Perform ABS VERIFICATION TEST - VER 1.
41
BRAKES (CAB)
LEFT FRONT INLET SOLENOID ÐContinued