MERCEDES-BENZ SPRINTER 2006 Service Manual

Symptom List:
ATC FUNCTION TEST COOL FAILURE
ATC FUNCTION TEST FAILURE
ATC FUNCTION TEST HEAT FAILURE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be ATC FUNCTION TEST COOL
FAILURE.
When Monitored and Set Condition:
ATC FUNCTION TEST COOL FAILURE
When Monitored: With the engine running.
Set Condition: This DTC will set if specific operating criteria are not met when
attempting to run the ATC Function Test.
ATC FUNCTION TEST FAILURE
When Monitored: With the engine running.
Set Condition: This DTC will set if specific operating criteria are not met when
attempting to run the ATC Function Test.
ATC FUNCTION TEST HEAT FAILURE
When Monitored: With the engine running.
Set Condition: This DTC will set if specific operating criteria are not met when
attempting to run the ATC Function Test.
POSSIBLE CAUSES
ATC FUNCTION TEST OPERATING CRITERIA NOT MET
AUTOMATIC TEMPERATURE CONTROL (ATC) DTC(S) PRESENT
ENGINE CONTROL MODULE DTC(S) PRESENT
CRITERIA TO RUN ATC FUNCTION TEST NOT MET AND NO DTCS PRESENT
138
HEATING & A/C

TEST ACTION APPLICABILITY
1 Verify that all of the following criteria was met when attempting to run the ATC
Function Test.
The vehicle was stationary.
The engine was running.
The air conditioning switch was On.
The ambient temperature was above 59ÉF (15ÉC).
The refrigerant pressure was between 29 and 348 PSI (2 and 24 bar).
The evaporator temperature was above 36.5ÉF (2.5ÉC).
The coolant temperature was above 158ÉF (70ÉC).
Was all criteria met when attempting to run the ATC Function Test?All
Ye s!Go To 2
No!Attempt to activate the ATC Function Test when all of the specific
operating criteria are met. If the criteria cannot be met, proceed
to Test 2 of this procedure.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition on.
With the DRBIIIt, read Automatic Temperature Control DTCs.
Does the DRBIIItdisplay any DTCs?All
Ye s!Return to the Heating & A/C symptom list and choose the
symptom(s).
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition on.
With the DRBIIIt, read Engine Control Module DTCs.
Does the DRBIIItdisplay any DTCs?All
Ye s!Refer to Powertrain Diagnostic information for the related symp-
tom(s).
Perform BODY VERIFICATION TEST - VER 1.
No!Refer to Service Information to diagnose the system(s) that failed
to meet the ATC Function Test operating criteria.
Perform BODY VERIFICATION TEST - VER 1.
139
HEATING & A/C
ATC FUNCTION TEST COOL FAILURE ÐContinued

Symptom:
AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE)
POSSIBLE CAUSES
A/C AUXILIARY FAN RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO VOLTAGE
GROUND CIRCUIT OPEN
A/C AUXILIARY FAN RELAY HIGH SIDE CONTROL CIRCUIT OPEN
A/C AUXILIARY FAN RELAY
AUTOMATIC TEMPERATURE CONTROL (ATC)
TEST ACTION APPLICABILITY
1 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Remove the A/C Auxiliary Fan Relay from the relay center.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the voltage of the A/C Auxiliary Fan Relay High Side Control circuit.
Is the voltage above 0.2 volts?All
Ye s!Repair the A/C Auxiliary Fan Relay High Side Control circuit for
a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 2
2 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Remove the A/C Auxiliary Fan Relay from the relay center.
Measure the resistance between ground and the Ground circuit in the relay center
(A/C Auxiliary Fan Relay connector terminal 85).
Is the resistance below 5.0 ohms?All
Ye s!Go To 3
No!Repair the Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
3 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Remove the A/C Auxiliary Fan Relay from the relay center.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance of the A/C Auxiliary Fan Relay High Side Control circuit
between the Automatic Temperature Control (ATC) C1 harness connector and the
relay center (A/C Auxiliary Fan Relay connector terminal 86).
Is the resistance below 5.0 ohms?All
Ye s!Go To 4
No!Repair the A/C Auxiliary Fan Relay High Side Control circuit for
an open.
Perform BODY VERIFICATION TEST - VER 1.
140
HEATING & A/C

TEST ACTION APPLICABILITY
4 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Reconnect the Automatic Temperature Control (ATC) C1 harness connector.
Install a substitute relay in place of the A/C Auxiliary Fan Relay.
Turn the ignition on.
With the DRBIIIt, erase Automatic Temperature Control DTCs.
Turn the ignition off, wait 5 seconds, then turn the ignition on.
With the DRBIIIt, read Automatic Temperature Control DTCs.
Does the DRBIIItdisplay: AUX FAN RELAY CONTROL HIGH OR OPEN?All
Ye s!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information. Reinstall the original A/C Auxiliary
Fan Relay.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the original A/C Auxiliary Fan Relay in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
141
HEATING & A/C
AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE) ÐContinued

Symptom:
AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE)
POSSIBLE CAUSES
A/C AUXILIARY FAN RELAY
A/C AUXILIARY FAN RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND
A/C AUXILIARY FAN RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND CIRCUIT
AUTOMATIC TEMPERATURE CONTROL (ATC)
A/C AUXILIARY FAN RELAY HIGH SIDE CONTROL CKT SHORTED TO SENSOR GROUND CKT
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Install a substitute relay in place of the A/C Auxiliary Fan Relay.
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: AUX FAN RELAY CONTROL SHORTED LOW?All
Ye s!Go To 2
No!Replace the original A/C Auxiliary Fan Relay in accordance with
the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Remove the substitute A/C Auxiliary Fan Relay from the relay center.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between ground and the A/C Auxiliary Fan Relay High Side
Control circuit.
Is the resistance below 10K ohms?All
Ye s!Repair the A/C Auxiliary Fan Relay High Side Control circuit for
a short to ground. Reinstall the original A/C Auxiliary Fan Relay.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
142
HEATING & A/C

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Remove the A/C Auxiliary Fan Relay from the relay center.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the A/C Auxiliary Fan Relay High Side Control
circuit and the Ground circuit in the Automatic Temperature Control (ATC) C1
harness connector.
Is the resistance below 10K ohms?All
Ye s!Repair the A/C Auxiliary Fan Relay High Side Control circuit for
a short to the Ground circuit.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off.
Remove the A/C Auxiliary Fan Relay from the relay center.
Disconnect the Automatic Temperature Control (ATC) C1 harness connector.
Measure the resistance between the A/C Auxiliary Fan Relay High Side Control
circuit and the Sensor Ground circuit in the Automatic Temperature Control (ATC)
C1 harness connector.
Is the resistance below 10K ohms?All
Ye s!Repair the A/C Auxiliary Fan Relay High Side Control 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.
143
HEATING & A/C
AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE) ÐContinued

Symptom:
BLOWER STAGE 1 HIGH OR OPEN (ACTIVE)
POSSIBLE CAUSES
BLOWER MOTOR
BLOWER MOTOR DRIVER CIRCUIT(S) SHORTED TO VOLTAGE
BLOWER MOTOR DRIVER CIRCUIT(S) OPEN
BLOWER MOTOR RESISTOR BLOCK
AUTOMATIC TEMPERATURE CONTROL (ATC)
TEST ACTION APPLICABILITY
1 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Blower Motor harness connector.
Connect a fused jumper wire between Battery (+) and Blower Motor cavity 1.
Connect a jumper wire between ground and Blower Motor cavity 2.
Does the Blower Motor run at full speed?All
Ye s!Go To 2
No!Replace the Blower Motor in accordance with the Service Infor-
mation.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Blower Motor Resistor Block harness connector.
Disconnect the Blower Motor harness connector.
Disconnect the Automatic Temperature Control (ATC) C2 harness connector.
Turn the ignition on.
Measure the voltage of each of the Blower Motor Driver circuits (Low, M1, M2, High).
Is the voltage above 0.2 volts on any of the circuits?All
Ye s!Repair each circuit with voltage above 0.2 volts for a short to
voltage.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Automatic Temperature Control (ATC) C2 harness connector.
Disconnect the Blower Motor Resistor Block harness connector.
Disconnect the Blower Motor harness connector.
Measure the resistance of the Blower Motor Driver circuits (Low, M1, M2, High)
between the Automatic Temperature Control (ATC) C2 harness connector and the
Blower Motor Resistor Block harness connector.
Measure the resistance of the Blower Motor High Driver circuit between the
Automatic Temperature Control (ATC) C2 harness connector and the Blower Motor
harness connector.
Is the resistance below 5.0 ohms on each of the circuits?All
Ye s!Go To 4
No!Repair each circuit with a resistance above 5.0 ohms for an open.
Perform BODY VERIFICATION TEST - VER 1.
144
HEATING & A/C

TEST ACTION APPLICABILITY
4 Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Blower Motor Resistor Block harness connector.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 1.
The approximate resistance should be 1.4 ohms.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 3.
The approximate resistance should be 0.8 ohms.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 4.
The approximate resistance should be 1.6 ohms.
Is the resistance as specified for each circuit?All
Ye s!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Blower Motor Resistor Block in accordance with the
Service Information.
Perform BODY VERIFICATION TEST - VER 1.
145
HEATING & A/C
BLOWER STAGE 1 HIGH OR OPEN (ACTIVE) ÐContinued

Symptom:
BLOWER STAGE 1 SHORTED LOW (ACTIVE)
POSSIBLE CAUSES
BLOWER MOTOR FUSE
BLOWER MOTOR
BLOWER MOTOR DRIVER CIRCUIT(S) SHORTED TO GROUND
FUSED B+ CIRCUIT SHORTED TO GROUND
BLOWER MOTOR RESISTOR BLOCK
AUTOMATIC TEMPERATURE CONTROL (ATC)
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Remove and inspect the Blower Motor Fuse, and replace it if necessary.
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: BLOWER STAGE ONE SHORTED LOW?All
Ye s!Go To 2
No!Refer to the wiring diagrams located in the service information to
help isolate a possible intermittent short to ground condition.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Disconnect the Blower Motor harness connector.
Connect a fused jumper wire between Battery (+) and Blower Motor cavity 1.
Connect a jumper wire between ground and Blower Motor cavity 2.
Does the Blower Motor run at full speed?All
Ye s!Go To 3
No!Replace the Blower Motor in accordance with the Service Infor-
mation. Remove and inspect the Blower Motor Fuse, and replace
it if necessary.
Perform BODY VERIFICATION TEST - VER 1.
146
HEATING & A/C

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Blower Motor Resistor harness connector.
Disconnect the Blower Motor harness connector.
Disconnect the Automatic Temperature Control (ATC) C2 harness connector.
Measure the resistance between ground and each of the Blower Motor Driver circuits
(Low, M1, M2, High).
Is the resistance below 10k ohms on any of the circuits?All
Ye s!Repair each circuit with a resistance below 10k ohms for a short
to ground. Remove and inspect the Blower Motor Fuse, and
replace it if necessary.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off.
Remove the Blower Motor Fuse.
Disconnect the Automatic Temperature Control (ATC) C2 harness connector.
Measure the resistance between ground and the Fused B+ circuit.
Is the resistance below 10k ohms?All
Ye s!Repair the Fused B+ circuit for a short to Ground. Remove and
inspect the Blower Motor Fuse, and replace it if necessary.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
Disconnect the Blower Motor Resistor Block harness connector.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 1.
The approximate resistance should be 1.4 ohms.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 3.
The approximate resistance should be 0.8 ohms.
Measure the resistance between Blower Motor Resistor Block cavity 2 and cavity 4.
The approximate resistance should be 1.6 ohms.
Is the resistance as specified for each circuit?All
Ye s!Replace the Automatic Temperature Control (ATC) in accordance
with the Service Information. Remove and inspect the Blower
Motor Fuse, and replace it if necessary.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Blower Motor Resistor Block in accordance with the
Service Information. Remove and inspect the Blower Motor Fuse,
and replace it if necessary.
Perform BODY VERIFICATION TEST - VER 1.
147
HEATING & A/C
BLOWER STAGE 1 SHORTED LOW (ACTIVE) ÐContinued