engine MERCEDES-BENZ SPRINTER 2006 User Guide

3.7 USING THE DRBIIIT
Refer to the DRBIIItuser guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.8 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill dis-
play one of only two error messages: user-requested
WARM Boot or User-Requested COLD Boot. If the
DRBIIItshould display any other error message,
record the entire display and call the STAR Center.
This is a sample of such an error message display:
ver: 2.14
date: 26 Jul93
file: key_iff.cc
date: Jul26 1993
line: 548
err: 0xi
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.9 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
connector cavity 16). A minimum of 11 volts is
required to adequately power the DRBIIIt. Check
for proper grounds at DLC 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 or a faulty cable or
vehicle wiring.
3.10 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: WHEN OPERATING, ENGINES
PRODUCE AN ODORLESS GAS CALLED
CARBON MONOXIDE. INHALING CARBON
MONOXIDE GAS CAN RESULT IN SLOWER
REACTION TIMES AND CAN LEAD TO
PERSONAL INJURY OR DEATH. 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 wheel 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 drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
rings, watchbands or bracelets that might make an
inadvertent electrical contact.
When diagnosing a body system problem, it is
important to follow approved procedures where
applicable. These procedures can be found in this
11
GENERAL INFORMATION

WARNING:REASSEMBLE ALL COMPONENTS
BEFORE ROAD TESTING A VEHICLE. DO NOT
TRY TO READ THE DRBIIITSCREEN OR
OTHER TEST EQUIPMENT DURING A TEST
DRIVE. DO NOT HANG THE DRBIIITOR OTHER
TEST EQUIPMENT FROM THE REARVIEW
MIRROR DURING A TEST DRIVE. HAVE AN
ASSISTANT AVAILABLE TO OPERATE THE
DRBIIITOR OTHER TEST EQUIPMENT.
FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN PERSONAL INJURY OR
DEATH.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box)
Jumper wires
Ohmmeter
Voltmeter
Test Light
8310 Airbag System Load Tool
8443 SRS Airbag System Load Tool
9001 R F Detector
6.0 GLOSSARY OF TERMS
ABSantilock brake system
ACMairbag control module
ACTactuator
AECMairbag electronic control module
(ACM)
ASDMairbag system diagnostic module
(ACM)
AT Cautomatic temperature control
CABcontroller antilock bake
CANcontroller area network
CHMcabin heater module
CPAconnector positive assurance
CTMcentral timer module
DABdriver airbag
DCHAdiesel cabin heater assist (cabin
heater)
DLCdata link connector
DTCdiagnostic trouble code
DRdriver
EBLelectric back lite (rear window de
fogger)
ECMengine control module
GCCGulf Coast Countries
HBMheater booster module
HVACheater ventilation, air conditioning
ICinstrument cluster
MICmechanical instrument cluster
RSMRain Sensor Module
SAshifter assembly
SKREEMsentry key remote entry module
SSMsecurity system module
TCMtransmission control module
13
GENERAL INFORMATION

Symptom:
A. HEATER PRE-TEST
POSSIBLE CAUSES
NO RESPONSE FROM CABIN HEATER MODULE OR HEATER BOOSTER MODULE
CABIN HEATER MODULE OR HEATER BOOSTER MODULE DTC(S) PRESENT
AUTOMATIC TEMPERATURE CONTROL DTC(S) PRESENT
HEATER SYSTEM COMPONENTS
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
Turn the ignition off and either allow the engine coolant to cool down to at least 50ÉC
(122ÉF) or cold soak the engine.
CAUTION: When using a powered exhaust ventilation system, do not attach
the exhaust ventilation hose directly to the heater's exhaust pipe. Too much
suction can prevent heater operation.
When using a powered exhaust ventilation system, affix the ventilation hose to the
heater's exhaust pipe or to the vehicle in such a manor that the end of the ventilation
hose remains approximately three inches away from the end of the exhaust pipe.
When using a non-powered exhaust ventilation system, affix the ventilation hose
directly to the heater's exhaust pipe.
Turn the ignition on.
With the DRBIIIt, attempt to communicate with the Cabin Heater Module or Heater
Booster Module and the Automatic Temperature Control Module.
Does the DRBIIItdisplay: NO RESPONSE?All
Ye s!Refer to the Communication Category for the related symptom.
Perform HEATER VERIFICATION TEST - VER 1.
No!Go To 2
69
CABIN HEATER

TEST ACTION APPLICABILITY
2WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
NOTE: The heater's control unit will store up to five DTCs in its memory.
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.
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.
Turn the ignition on.
Verify that the Cabin Heater or Heater Booster is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, record and erase the Cabin Heater or Heater Booster Module's
DTCs.
Start the engine. Allow the engine to idle.
With the DRBIIIt, monitor for Cabin Heater Module or Heater Booster Module DTCs
while performing the following step.
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.
Switch the Cabin Heater or Heater Booster on. If operable, allow the heater to run
through at least one cycle of operation (approximately 10 minutes), and then switch
the heater off.
Does the DRBIIItdisplay any DTCs?All
Ye s!If the Heater In Lockout Mode DTC is present, record and erase
DTCs before performing any diagnostic procedures. Return to the
symptom list and choose the symptom(s).
Perform HEATER VERIFICATION TEST - VER 1.
No!Go To 3
70
CABIN HEATER
A. HEATER PRE-TEST ÐContinued

TEST ACTION APPLICABILITY
2WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater harness connector.
Remove the Circulation Pump Relay from the relay center.
Measure the resistance of the Circulation Pump Relay High Side Control circuit
between the Cabin Heater harness connector and the relay center (Circulation Pump
Relay connector terminal 86).
Is the resistance below 5.0 ohms?All
Ye s!Go To 3
No!Repair the Circulation Pump Relay High Side Control circuit for
an open.
Perform HEATER VERIFICATION TEST - VER 1.
3WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
Turn the ignition off.
Reconnect the Cabin Heater harness connector.
Install a substitute relay in place of the Circulation Pump Relay.
Turn the ignition on.
Verify that the Cabin Heater is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, erase the Cabin Heater Module's DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater Module DTCs while performing the
following step.
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.
Switch the Cabin Heater on. If necessary, allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then turn the heater off.
Turn the engine off.
Does the DRBIIItdisplay: CIRC PUMP CONTROL OPEN?All
Ye s!Replace the Cabin Heater Assembly in accordance with the
Service Information. Reinstall the original Circulation Pump
Relay.
Perform HEATER VERIFICATION TEST - VER 1.
No!Replace the original Circulation Pump Relay in accordance with
the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
73
CABIN HEATER
CIRC PUMP CONTROL OPEN ÐContinued

Symptom:
CIRC PUMP CONTROL SHORTED
POSSIBLE CAUSES
CIRCULATION PUMP RELAY
CIRCULATION PUMP RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND
PUMP RELAY HIGH SIDE CONTROL CKT SHORTED TO PUMP RELAY GROUND CKT
CABIN HEATER CONTROL UNIT
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
Install a substitute relay in place of the Circulation Pump Relay.
Turn the ignition on.
Verify that the Cabin Heater is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, erase the Cabin Heater Module's DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater Module DTCs while performing the
following step.
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.
Switch the Cabin Heater on. If necessary, allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then switch the heater off.
Turn the engine off.
Does the DRBIIItdisplay: CIRC PUMP CONTROL SHORTED?All
Ye s!Go To 2
No!Replace the original Circulation Pump Relay in accordance with
the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
74
CABIN HEATER

Symptom:
DOSING PUMP SHORTED
POSSIBLE CAUSES
DOSING PUMP SHORTED TO GROUND
DOSING PUMP CONTROL CIRCUIT SHORTED TO GROUND CIRCUIT
DOSING PUMP CONTROL CIRCUIT SHORTED TO GROUND
CABIN HEATER OR HEATER BOOSTER CONTROL UNIT
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Dosing Pump harness connector.
Turn the ignition on.
Verify that the Cabin Heater or Heater Booster is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, erase the Cabin Heater or Heater Booster Module's DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater or Heater Booster Module DTCs while
performing the following step.
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.
Switch the Cabin Heater or Heater Booster on. If necessary, allow the heater to run
through at least one cycle of operation (approximately 10 minutes), and then switch
the heater off.
Turn the engine off.
Does the DRBIIItdisplay: DOSING PUMP HIGH OR OPEN?All
Ye s!Replace the Dosing Pump in accordance with the Service Infor-
mation.
Perform HEATER VERIFICATION TEST - VER 1.
No!Go To 2
81
CABIN HEATER

TEST ACTION APPLICABILITY
2WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater harness connector.
Remove the Fan Stage 1 Relay from the relay center.
Measure the resistance of the Fan Stage 1 Relay High Side Control circuit between
the Cabin Heater harness connector and the relay center (Fan Stage 1 Relay
connector terminal 86).
Is the resistance below 5.0 ohms?All
Ye s!Go To 3
No!Repair the Fan Stage 1 Relay High Side Control circuit for an
open.
Perform HEATER VERIFICATION TEST - VER 1.
3WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
Turn the ignition off.
Reconnect the Cabin Heater harness connector.
Install a substitute relay in place of the Fan Stage 1 Relay.
Turn the ignition on.
Verify that the Cabin Heater is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, erase the Cabin Heater Module's DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater Module DTCs while performing the
following step.
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.
Switch the Cabin Heater on. If necessary, allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then switch the heater off.
Turn the engine off.
Does the DRBIIItdisplay: FAN STAGE 1 RELAY CONTROL OPEN?All
Ye s!Replace the Cabin Heater Assembly in accordance with the
Service Information. Reinstall the original Fan Stage 1 Relay.
Perform HEATER VERIFICATION TEST - VER 1.
No!Replace the original Fan Stage 1 Relay in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
84
CABIN HEATER
FAN STAGE 1 RELAY CONTROL OPEN ÐContinued

Symptom:
FAN STAGE 1 RELAY CONTROL SHORTED
POSSIBLE CAUSES
FAN STAGE 1 RELAY
FAN STAGE 1 RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND
FAN STAGE 1 RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND CIRCUIT
CABIN HEATER CONTROL UNIT
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
Install a substitute relay in place of the Fan Stage 1 Relay.
Turn the ignition on.
Verify that the Cabin Heater is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIIIt, erase the Cabin Heater Module's DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater Module DTCs while performing the
following step.
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.
Switch the Cabin Heater on. If necessary, allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then switch the heater off.
Turn the engine off.
Does the DRBIIItdisplay: FAN STAGE 1 RELAY CONTROL SHORTED?All
Ye s!Go To 2
No!Replace the original Fan Stage 1 Relay in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
85
CABIN HEATER

Symptom List:
HEATER IN LOCKOUT MODE
HEATER OVERHEATED
SUCCESSIVE OVERHEATING
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be HEATER IN LOCKOUT MODE.
When Monitored and Set Condition:
HEATER IN LOCKOUT MODE
When Monitored: During heater activation and operation.
Set Condition: This DTC will set if multiple attempts to start the heater have failed or if
successive overheating occurs.
HEATER OVERHEATED
When Monitored: After heater activation, when the system is in a steady state of
operation.
Set Condition: This DTC will set if the Temperature Sensor's resistance or Overheating
Sensor's resistance is not within the expected parameters (coolant temperature in the
heater module exceeds 105ÉC [221ÉF]).
SUCCESSIVE OVERHEATING
When Monitored: After heater activation, when the system is in a steady state of
operation.
Set Condition: This DTC will set if successive overheating occurs.
POSSIBLE CAUSES
CABIN HEATER ASSEMBLY OR HEATER BOOSTER ASSEMBLY
HEATER'S COOLANT HOSES RESTRICTED/LEAKING/DAMAGED
ENGINE'S COOLING SYSTEM FAULT
CABIN HEATER OR HEATER BOOSTER CONTROL UNIT
HEATER OVERHEATED/SUCCESSIVE OVERHEATING CLEARED, ADDITIONAL DTC(S)
PRESENT
93
CABIN HEATER