warning MERCEDES-BENZ SPRINTER 2006 Service Manual

POSSIBLE CAUSES
CHECKING THE FUEL DELIVERY SYSTEM
CORRECTION QUANTITY CHECK
CYLINDER SPEED CHECK
FUEL INJECTION PUMP CHECK
FUEL LEAK QUANTITY CHECK
FUEL LEAK QUANTITY CHECK
FUEL PRESSURE SOLENOID
FUEL PRESSURE SOLENOID CHECK
FUEL PRESSURE VARIATION CHECK
FUEL PUMP
FUEL QUANTITY SOLENOID
FUEL SYSTEM CONTAMINATION
FUEL SYSTEM LEAK
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Turn the ignition on.
With the DRBIIIt, read the ECM DTCs.
Are there any other DTCs present?All
Ye s!Refer to symptom list for problems related to the DTC other than
this DTC.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
2 Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Attempt to start the engine.
Does the engine start and idle?All
Ye s!Go To 3
No!Go To 17
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P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Inspect the entire fuel system for leakage.
Is there any evidence of leakage?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4NOTE: Mixing any other fuels such as gasoline or kerosine can cause this
DTC to set.
Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Refer to the Service Information and inspect the fuel system for contamination.
Is the fuel contaminated?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
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P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
13 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Test.
Did this test pass?All
Ye s!Go To 14
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
14 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Variation Test.
Did this test pass?All
Ye s!Go To 15
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
15 With the DRBIIIt, select System Test, then High Pressure Pump.
NOTE: During this test engine speed is set at 1,400 rpm and initial fuel
pressure at approximately 6,800 psi. During the test fuel pressure is
instantly set to above 20,000 psi. to test the performance of the Fuel
Injection Pump.
NOTE: After the test is completed, the DRB display fuel pressure in 30
counter steps. If the fuel pressure increases from approximately 6,800 psi to
above 20,000 psi in one counter step, the injection pump passes the test.
Did the fuel pressure increase to above 20,000 psi within one counter step on the
DRB?All
Ye s!Replace the Fuel Quantity Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace Fuel Injection Pump in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
16WARNING: 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 and at normal operating temperature, monitor the DRB IIIt
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.
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P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
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.
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P2025-INTAKE PRESSURE SENSOR PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
6 Turn the ignition off.
NOTE: Ensure all harness connectors are connected.
Turn the ignition on.
Measure the voltage of the Intake Pressure Sensor Signal circuit by back probing
ECM harness connector.
Is the voltage above 4.85 volts?All
Ye s!Replace the Intake Pressure Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
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.
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P2025-INTAKE PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH Ð
Continued

TEST ACTION APPLICABILITY
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.
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P2025-INTAKE PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW Ð
Continued

TEST ACTION APPLICABILITY
9WARNING: 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.
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P2026-O2 SENSOR CIRCUIT FAULT ÐContinued

TEST ACTION APPLICABILITY
3WARNING: 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.
139
DRIVEABILITY - DIESEL
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH Ð
Continued

TEST ACTION APPLICABILITY
16WARNING: 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 and 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.
Remove the CMP Sensor and the CKP Sensor, checking for loose mounting screws
and debris on the sensor magnets that can corrupt the sensor signal.
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.
145
DRIVEABILITY - DIESEL
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT Ð
Continued

TEST ACTION APPLICABILITY
2WARNING: 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.
3 Refer to the Service Information to ensure the Engine Drive Gears/Sprocket are
installed correctly and the camshaft and crankshaft gears are timed correctly.
Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and both of the CKP Sensor Signal circuits.
Is the resistance above 1000 ohms for both measurements?All
Ye s!Go To 4
No!Repair the CKP Sensor Signal circuit(s) for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the CKP Sensor Signal circuits.
Is the resistance above 1000 ohms?All
Ye s!Go To 5
No!Repair the CKP Sensor Signal circuits for a short together.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the CKP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of CKP Sensor Signal circuits.
Is the resistance below 10.0 ohms for both measurements?All
Ye s!Go To 6
No!Repair the CKP Sensor Signal circuit(s) for an open.
Perform ROAD TEST VERIFICATION - VER-2.
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P2045-CRANKSHAFT POSITION SENSOR CIRCUIT LOST SIGNAL Ð
Continued