heater MERCEDES-BENZ SPRINTER 2006 User Guide

reaching operating temperature. The heater's con-
trol unit controls and monitors combustion opera-
tion through various inputs and outputs that are
contained inside the heater assembly. The supple-
mental heater connects to the vehicle's heater hoses
and uses a separate fuel supply line and fuel pump
that connects to the vehicle's fuel tank. Unlike the
Heater Booster, the Cabin Heater Assembly has an
integral coolant pump which allows heater opera-
tion without the vehicle's engine running. In addi-
tion, a programmable timer module can also be
added to this system. Neither the Cabin Heater
Assembly nor the Heater Booster Assembly are
connected to the CAN Bus. Communication be-
tween the heater's control unit and the DRBIIIt
occurs through the Diagnostic Link Connector
(DLC) via a K-Line.
3.3.2.2 VENTING THE HEATER'S EXHAUST
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 INSTRUCTIONS CAN
RESULT IN PERSONAL INJURY OR DEATH.
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.
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 sys-
tem, affix the ventilation hose to the heater's ex-
haust 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 heater's
exhaust pipe.
When using a non-powered exhaust ventilation
system, affix the ventilation hose directly to the
heater's exhaust pipe.
3.3.2.3 SYSTEM DIAGNOSTICS
CAUTION: Always Perform The Heater
Pre-Test (In The Diagnostic Procedures) Prior
To Performing Any Other Test For The Test
Result To Be Valid.
Fault detection is through stored Diagnostic
Trouble Codes (DTCs). DTCs are displayed by the
DRBIIIt. The heater's control unit will store up to
five DTCs in its memory. If the 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. If the control unit detects a reoccurrence of a
stored fault, it will overwrite that fault's DTC with
the most recent occurrence.
DIAGNOSTIC TIPS
SENSOR VALUES
Operating Voltage
The normal range for the Operating Voltage is from
10 volts to 15 volts. The value indicates the voltage
at the heater 's Fused B+ terminal.
Heating Capacity
The normal range for the heating capacity is from
0% to 100%. The value indicates the momentary
output of the auxiliary heater in % of the maximum
output.
Coolant Temperature
The value indicates the current coolant tempera-
ture.
Flame Sensor Resistance
The normal range for the Flame Sensor is from 750
ohms to 2270 ohms. The value indicates the mo-
mentary resistance of the Flame Sensor.
INPUT/OUTPUT STATUS
Dosing Pump
A status of9ON9indicates that the Dosing Pump is
operational. A status of9OFF9indicates the Dosing
Pump is not operational.
Glow Pin
A status of9ON9indicates that the Glow Pin is
energized. A status of9OFF9indicates the Glow Pin
is not energized.
Combustion Fan
A status of9ON9indicates that the Combustion Fan
is operational. A status of9OFF9indicates the
Combustion Fan is not operational.
Circulation Pump
A status of9ON9indicates that the Circulation
Pump is operational. A status of9OFF9indicates the
Circulation Pump is not operational.
Front End Blower
A status of9ON9indicates that the Blower Motor is
operational. A status of9OFF9indicates the Blower
Motor is not operational.
8
GENERAL INFORMATION

Static Heater Signal
A status of9ON9indicates that the heater module
sees the9Stationary Heating Mode ON9signal after
switching on the heater with the heater timer or the
auxiliary heater switch. A status of9OFF9indicates
that the9Stationary Heating Mode ON9signal is
not present at the heater module.
Heater Booster Mode Signal
A status of9ON9indicates that the heater module
sees the9Heater Booster Mode ON9signal after
switching on the heater with the auxiliary heater
switch. A status of9OFF9indicates that the9Heater
Booster Mode ON9signal is not present at the
heater module.
3.4 INSTRUMENT CLUSTER
The Instrument Cluster has easy-to-read instru-
ments, is capable of CAN bus communication and
provides a diagnostic function. The Instrument
Cluster with analog speedometer, tachometer, fuel
and coolant temperature gauges comes in two ver-
sions.
²Speedometer with outer miles-per-hour (mph)
scale and inner kilometers-per-hour (km/h) scale.
Coolant temperature is indicated in Fahrenheit
(for US).
²Speedometer with outer kilometers-per-hour
(km/h) scale and inner miles-per-hours (mph)
scale. Coolant temperature is indicated in de-
grees Celsius (for Canada).
Below the speedometer, there is a LCD multi-
function indicator in clear view of the driver. Warn-
ing and indicator lights (based on colored light
emitting diodes) are located in the bottom of the
instrument cluster with the exception of the turn
signal indicator lights, ASR warning light and re-
serve fuel warning light. The warning lights for the
seat belt usage and parking brake/brake fluid level
are located in the line above the bottom line. The
indicator that illuminates up when the parking
brake is applied or the brake fluid level is low is
different for U.S. and Canada.
When the key is turned to the 2nd position in the
ignition, the function of the following indicator
lights is checked automatically: High Beam ON,
Preheating, airbag malfunction. In case of a broken
LED of the airbag malfunction light, the seat belt
usage warning light will flash for 6 seconds after
the function check is finished. The Instrument
Cluster is operated with the help of 4 buttons
located below the multifunction indicator. The back-
lighting for the instrument cluster uses yellow
LED's and can be adjusted electronically to daylight
and darkness.The instrument cluster includes a warning
buzzer, which sounds (in addition to a warning light
in some cases) when:
²The headlights are on with the ignition off and
the door opened.
²The driver 's seat belt is not fastened with the
ignition on.
²The key is in the ignition and the door is open.
²Critical ASSYST information is displayed in the
multifunction indicator.
3.5 POWER DOOR LOCKS/RKE
3.5.1 CENTRAL LOCKING
The Central Locking System locks all vehicle
doors if any door is locked from the inside or
mechanically locked with the key from the outside.
However, unlocking any door, in that manner, will
only unlock that particular door. The Master Door
Lock Switch on the dash enables the operator to
lock/unlock all doors. By pressing the top of the
rocker type switch once, all doors will lock. Pressing
the switch again will unlock all doors. Pressing the
lower part of the switch once will lock all doors
except the driver door. Pressing the lower part
again will unlock all doors except the driver door. If
the Central Locking System automatically unlocks
after the vehicle was attempted to be locked, at
least one door is not properly closed.
There are two LED indicators in the Master Door
Lock Switch. The left indicator is for the driver door
and the right indicator is for all passenger/cargo
doors. These will indicate if a door is ajar or if the
doors are locked. The door ajar switches are part of
the door lock motor and are mounted in the door
latch assembly.
Inside each door lock motor there is a command
switch. The command switch is operated by the
plunger and signals any change in the lock status,
locked or unlocked. Each command switch is wired
to the Central Timer Module (CTM) sometimes
referred to as the Central Locking Module. If all
doors are closed and are unlocked, and any door is
locked by the key or the interior handle, thereby
changing the command switch, all doors will be
locked. If one of the door lock motors does not reach
the end position after a locking command, it will be
detected by the CTM (command switch not in
9Locked9position) and the vehicle will be unlocked.
3.5.2 REMOTE KEYLESS ENTRY (RKE)
The SKREEM is a combination of the Remote
Keyless Entry Module and the SKIM (Sentry Key
Immobilizer Module). It is located behind the In-
strument Cluster and has an antenna that goes up
9
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
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.
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 on.
With the DRBIIIt, read Automatic Temperature Control DTCs.
Are any DTCs present?All
Ye s!Refer to Heating & A/C information for the related symptom(s).
Perform HEATER VERIFICATION TEST - VER 1.
No!Allow heater assembly to cool. Inspect the fuel line, air intake and
exhaust, and coolant hoses for restrictions, obstructions, loose
clamps, leakage, etc. Repair as necessary. Check the harness
connectors and grounds. Clean and repair as necessary.
Perform HEATER VERIFICATION TEST - VER 1.
71
CABIN HEATER
A. HEATER PRE-TEST ÐContinued

Symptom:
CIRC PUMP CONTROL OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
CIRCULATION PUMP RELAY HIGH SIDE CONTROL CIRCUIT OPEN
CIRCULATION PUMP RELAY
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.
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.
Remove the Circulation Pump Relay from the relay center.
Measure the resistance between ground and the Ground circuit (Circulation Pump
Relay connector terminal 85).
Is the resistance below 5.0 ohms?All
Ye s!Go To 2
No!Repair the Ground circuit for an open.
Perform HEATER VERIFICATION TEST - VER 1.
72
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 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

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 substitute Circulation Pump Relay from the relay center.
Measure the resistance between ground and the Circulation Pump Relay High Side
Control circuit.
Is the resistance below 10K ohms?All
Ye s!Repair the Circulation Pump Relay High Side Control circuit for
a short to ground. Reinstall the original Circulation Pump Relay.
Perform HEATER VERIFICATION TEST - VER 1.
No!Go To 3
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.
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 between the Circulation Pump Relay High Side Control
circuit and the Ground circuit (Circulation Pump Relay connector terminal 86 and
85).
Is the resistance below 10K ohms?All
Ye s!Repair the Circulation Pump Relay High Side Control circuit for
a short to the Ground circuit.
Perform HEATER VERIFICATION TEST - VER 1.
No!Replace the Cabin Heater Assembly in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
75
CABIN HEATER
CIRC PUMP CONTROL SHORTED ÐContinued