service MERCEDES-BENZ SPRINTER 2006 Service Manual

TEST ACTION APPLICABILITY
4 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Reconnect the Automatic Temperature Control (ATC) C1 harness connector.
Turn the ignition on.
While back probing, measure the voltage between the 5 Volt Supply circuit and
ground.
While back probing, measure the voltage between the Refrigerant Pressure Sensor
Feedback circuit and ground.
Is the voltage above 5.3 volts on either circuit?All
Ye s!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Refrigerant Pressure Sensor harness connector.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance of the 5 Volt Supply circuit between the Automatic Temper-
ature Control (ATC) C1 harness connector and the Refrigerant Pressure Sensor
harness connector.
Is the resistance below 5.0 ohms?All
Ye s!Go To 6
No!Repair the 5 Volt Supply circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
6 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Refrigerant Pressure Sensor harness connector.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance of the Refrigerant Pressure Sensor Feedback circuit between
the Automatic Temperature Control (ATC) C1 harness connector and the Refrigerant
Pressure Sensor harness connector.
Is the resistance below 5.0 ohms?All
Ye s!Go To 7
No!Repair the Refrigerant Pressure Sensor Feedback circuit for an
open.
Perform BODY VERIFICATION TEST - VER 1.
7 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Refrigerant Pressure Sensor harness connector.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance of the Sensor Ground circuit between the Automatic
Temperature Control (ATC) C1 harness connector and the Refrigerant Pressure
Sensor harness connector.
Is the resistance below 5.0 ohms?All
Ye s!Replace the Refrigerant Pressure Sensor in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Repair the Sensor Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
172
HEATING & A/C
REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE) ÐContinued

Symptom:
REFRIG PRESS SENSOR SHORTED LOW (ACTIVE)
POSSIBLE CAUSES
REFRIGERANT PRESSURE SENSOR
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND CIRCUIT
5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT
REFRIGERANT PRESSURE SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND
REFRIGERANT PRESSURE SENSOR FEEDBACK CIRCUIT SHORTED TO GROUND CIRCUIT
REFRIGERANT PRESSURE SENSOR FEEDBACK CIRCUIT SHORTED TO SENSOR GROUND
CIRCUIT
AUTOMATIC TEMPERATURE CONTROL (ATC)
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Refrigerant Pressure Sensor harness connector.
NOTE: All of the following criteria must be met in order to successfully run
the ATC Function Test.
Place the shift lever in Park.
Turn the ignition on.
With the DRBIIIt, record and erase ATC DTC's.
Start the engine. Allow the engine to reach normal operating temperature.
Set the blower to high speed.
Press the Air Conditioning switch On.
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).
With the DRBIIItin Automatic Temperature Control (ATC), select System Tests and
select ATC Function Test. When the ATC Function Test is complete, proceed as
follows:
With the DRBIIIt, read the active ATC DTCs.
Does the DRBIIItdisplay: REFRIG PRESS SENSOR SHORTED LOW?All
Ye s!Go To 2
No!Replace the Refrigerant Pressure Sensor in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between ground and the 5 Volt Supply circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the 5 Volt Supply circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
173
HEATING & A/C

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the 5 Volt Supply circuit and the Ground circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the 5 Volt Supply circuit for a short to the Ground circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off.
Disconnect the Refrigerant Pressure Sensor harness connector.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the 5 Volt Supply circuit and the Sensor Ground
circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the 5 Volt Supply circuit for a short to the Sensor Ground
circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between ground and the Refrigerant Pressure Sensor
Feedback circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the Refrigerant Pressure Sensor Feedback circuit for a
short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 6
6 Turn the ignition off.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the Refrigerant Pressure Sensor Feedback circuit
and the Ground circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the Refrigerant Pressure Sensor Feedback circuit for a
short to the Ground circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 7
7 Turn the ignition off.
Disconnect the Refrigerant Pressure Sensor harness connector.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the Refrigerant Pressure Sensor Feedback circuit
and the Sensor Ground circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the Refrigerant Pressure Sensor Feedback circuit for a
short to the Sensor Ground circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
174
HEATING & A/C
REFRIG PRESS SENSOR SHORTED LOW (ACTIVE) ÐContinued

Symptom:
WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE)
POSSIBLE CAUSES
WATER CYCLE VALVE
WATER CYCLE VALVE CONTROL CIRCUIT SHORTED TO VOLTAGE
AUTOMATIC TEMPERATURE CONTROL (ATC)
WATER CYCLE VALVE CONTROL CIRCUIT OPEN
GROUND CIRCUIT OPEN
AUTOMATIC TEMPERATURE CONTROL (ATC)
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Press the Residual Engine Heat Utilization (REST) switch off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Water Cycle Valve harness connector.
Connect a 12-volt test light between the Water Cycle Valve Control circuit and the
Ground circuit in the Water Cycle Valve harness connector. The test light should
operate as follows:
With the Residual Engine Heat Utilization (REST) switch off, the test light should
not illuminate.
Press the Residual Engine Heat Utilization (REST) switch on.
With the Blend control set to Full Cold, the test light should illuminate brightly and
continuously.
With the Blend control set to one position below the half Cold/Hot setting, the test
light should illuminate brightly and blink at a slow continuous rate.
With the Blend control set to the half Cold/Hot setting or above, the test light should
be off.
Does the test light operate as specified?All
Ye s!Replace the Water Cycle Valve in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
No, Light Illuminates With REST Off.
Go To 2
No, Light Will Not Illuminate
Go To 3
No, Light Won't Correspond To Blend
Go To 3
175
HEATING & A/C

TEST ACTION APPLICABILITY
2 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Turn the ignition on.
Measure the voltage of the Water Cycle Valve Control circuit.
Is the voltage above 0.2 volts?All
Ye s!Repair the Water Cycle Valve Control circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Disconnect the Water Cycle Valve harness connector.
Measure the resistance of the Water Cycle Valve Control circuit between the
Automatic Temperature Control (ATC) C1 harness connector and the Water Cycle
Valve harness connector.
Is the resistance below 5.0 ohms?All
Ye s!Go To 4
No!Repair the Water Cycle Valve Control circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
4 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Water Cycle Valve harness connector.
Measure the resistance between ground and the Ground circuit.
Is the resistance below 5.0 ohms?All
Ye s!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Repair the Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
176
HEATING & A/C
WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE) ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Reconnect the Automatic Temperature Control (ATC) C1 harness connector.
Press the Residual Engine Heat Utilization (REST) switch off.
Disconnect the Water Cycle Valve harness connector.
Connect a 12-volt test light between the Water Cycle Valve Control circuit and the
Ground circuit in the Water Cycle Valve harness connector. The test light should
operate as follows:
With the Residual Engine Heat Utilization (REST) switch off, the test light should
not illuminate.
Press the Residual Engine Heat Utilization (REST) switch on.
With the Blend control set to Full Cold, the test light should illuminate brightly and
continuously.
With the Blend control set to one position below the half Cold/Hot setting, the test
light should illuminate brightly and blink at a slow continuous rate.
With the Blend control set to the half Cold/Hot setting or above, the test light should
be off.
Does the test light operate as specified?All
Ye s!Replace the Water Cycle Valve in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
178
HEATING & A/C
WATER CYCLE VALVE CONTROL SHORTED LOW (ACTIVE) ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Instrument Cluster C1 harness connector.
Disconnect the Ambient Temperature Sensor harness connector.
Measure the resistance of the Ambient Temperature Sensor Signal (+) circuit
between the Instrument Cluster C1 harness connector and the Ambient Temperature
Sensor harness connector.
Is the resistance above 10 ohms?All
Ye s!Repair the Ambient Temperature Sensor Signal (+) circuit for an
open.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Instrument Cluster in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
180
INSTRUMENT CLUSTER
AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY ÐContinued

Symptom:
AMBIENT TEMP SENSOR SHORT TO GROUND
POSSIBLE CAUSES
AMBIENT TEMPERATURE SENSOR
AMBIENT TEMPERATURE SENSOR SIGNAL (+) CIRCUIT SHORT TO GROUND
AMBIENT TEMPERATURE SENSOR SIGNAL (+) CIRCUIT SHORT TO SENSOR RETURN CIR-
CUIT
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Ambient Temperature Sensor harness connector.
Turn the ignition on. With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay Ambient Temperature Sensor Open/Short to Battery?All
Ye s!Replace the Ambient Temperature Sensor.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 2
2 Turn the ignition off.
Disconnect the Instrument Cluster C1 harness connector.
Disconnect the Ambient Temperature Sensor harness connector.
Measure the resistance between ground and the Ambient Temperature Sensor Signal
(+) circuit.
Is the resistance below 1000 ohms?All
Ye s!Repair the Ambient Temperature Sensor Signal (+) circuit for a
short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition off.
Disconnect the Ambient Temperature Sensor harness connector.
Disconnect the Instrument Cluster C1 harness connector.
Measure the resistance between the Ambient Temperature Sensor Signal (+) circuit
and Ambient Temperature Sensor Signal Return circuit.
Is the resistance below 1000 ohms?All
Ye s!Repair the Ambient Temperature Sensor Signal (+) circuit for a
short to the Sensor Return circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Instrument Cluster in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
181
INSTRUMENT CLUSTER

Symptom:
FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY
POSSIBLE CAUSES
FUEL LEVEL SENSOR
FUEL LEVEL SENSOR SIGNAL (+) CIRCUIT SHORT TO VOLTAGE
FUEL LEVEL SENSOR SIGNAL RETURN CIRCUIT OPEN
FUEL LEVEL SENSOR SIGNAL (+) CIRCUIT OPEN
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the Instrument Cluster C1 harness connector.
Turn the ignition on.
Measure the voltage between Fuel Level Sensor Signal (+) circuit and ground.
Is the voltage above 0.2 volts?All
Ye s!Repair the Fuel Level Sensor Signal (+) circuit for a short to
voltage.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 2
2 Turn the ignition off.
Reconnect the Instrument Cluster C1 harness connector.
Disconnect the Fuel Pump Module harness connector.
Connect a jumper wire between the Fuel Level Sensor Signal (+) and the Fuel Level
Sensor Signal Return circuit.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay Fuel Level Sensor Open/Short to Battery?All
Ye s!Go To 3
No!Replace the Fuel Level Sensor in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the Instrument Cluster C1 harness connector.
Measure the resistance of the Fuel Level Sensor Signal Return circuit between the
Fuel Pump Module harness connector and the Instrument Cluster harness connector.
Is the resistance above 10 ohms?All
Ye s!Repair the Fuel Level Sensor Signal Return circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 4
182
INSTRUMENT CLUSTER

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the Instrument Cluster C1 harness connector.
Measure the resistance of the Fuel Level Sensor Signal (+) circuit between the Fuel
Pump Module harness connector and the Instrument Cluster harness connector.
Is the resistance above 10 ohms?All
Ye s!Repair the Fuel Level Sensor Signal (+) circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Instrument Cluster in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
183
INSTRUMENT CLUSTER
FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY ÐContinued