oil MERCEDES-BENZ SPRINTER 2006 User Guide

ohmmeter
voltmeter
jumper wires and probes
oscilloscope
6.0 GLOSSARY OF TERMS
A/Cair conditioning
APPaccelerator pedal position (sensor)
BCMbody control module
BPboost pressure (sensor)
CKPcrankshaft position (sensor)
CMPcamshaft position (sensor)
CTMcentral timer module
DLCdata link connector
ECMengine control module
ECTengine coolant temperature (sensor)
EGRexhaust gas recirculation (solenoid/
valve)
EOSengine oil sensor
IATintake air temperature (sensor)
IPintake pressure sensorMAFmass air flow (sensor)
MILmalfunction indicator lamp
msmillisecond(s)
O2oxygen sensor
PDCpower distribution center
S/Cspeed control
SKREEMsentry key remote entry module
SRCsignal range check
WIFwater in fuel (sensor)
10
GENERAL INFORMATION

Symptom List:
P0105-INTAKE PRESSURE SENSOR CAN MESSAGE ERROR
P0105-INTAKE PRESSURE SENSOR PLAUSIBILITY
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0105-INTAKE PRESSURE
SENSOR CAN MESSAGE ERROR.
POSSIBLE CAUSES
AIR FILTER
AIR RESTRICTION
INTERMITTENT CONDITION
CAN BUS COMMUNICATION DTCS
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR SIGNAL CIRCUIT
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR GROUND CIRCUIT
CAN BUS CIRCUITS OPEN TO THE SHIFTER MODULE
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: If DTC P1611, P2306 or P2332 is present with this DTC, diagnose
DTCs P1611, P2306 or P2332 before diagnosing this DTC.
NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Turn the ignition off, wait 30 seconds.
Test drive the vehicle.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 9
2 Turn the ignition off.
Remove and inspect the Air Filter for soiling or excessive dirt and debris which may
cause air flow restriction.
Were any of these problems found?All
Ye s!Replace the Air Filter element.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
25
DRIVEABILITY - DIESEL

Symptom:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT PLAUSIBILITY
WITH ENGINE OIL SENSOR
When Monitored and Set Condition:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT PLAUSIBILITY WITH EN-
GINE OIL SENSOR
When Monitored: With the engine running.
Set Condition: The ECT Sensor signal indicates a different engine temperature than the
EOS Sensor.
POSSIBLE CAUSES
CURRENT DTC
ECT SENSOR
ECT SENSOR - COLD
ECT SENSOR - HOT
ENGINE OIL SENSOR SENSOR
HGH RESISTANCE IN ECT SENSOR CIRCUITS
ENGINE COLD TOO LONG
TEST ACTION APPLICABILITY
1 Verify that the coolant level is correct.
Start the engine.
NOTE: The thermostat must be operating correctly for this test to be valid.
With the DRBIIIt, erase ECM DTCs.
With the DRBIIIt, set the engine RPM to 1500 and allow the engine to warm up for
10-15 minutes.
With the DRBIIIt, monitor the Engine Coolant Temperature value during the warm
up cycle. Make sure the transition of temperature change is smooth.
Did the engine temperature reach a minimum of 80É C (176É F)?All
Ye s!Go To 2
No!Refer to the Service Information for cooling system performance
diagnosis. The most probable cause is a Thermostat problem.
Also, refer to any related TSBs.
Perform ROAD TEST VERIFICATION - VER-2.
2 Turn the ignition on.
With the DRBIIIt, read the ECM DTCs.
Did this DTC return after performing the previous test?All
Ye s!Go To 3
No!Check for possible connecor or wiring problems at the ECT sensor
that may cause an intermittent problem. Repair as necessary.
Test Complete.
Perform ROAD TEST VERIFICATION - VER-2.
42
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
3NOTE: The engine temperature must be below 50ÉC (120ÉF) for this test.
NOTE: The thermostat must be operating correctly for this test to be valid.
With the DRBIIItin Sensors, read and note the engine coolant temperature.
Using a temperature probe, measure the engine block temperature near the ECT
Sensor.
Are the readings within 7ÉC (13ÉF) of each other?All
Ye s!Go To 4
No!Go To 5
4NOTE: The thermostat must be operating correctly for this test to be valid.
Start the engine and bring the engine to operating temperature (thermostat open).
Turn the engine off and wait 10 minutes to allow the engine temperature to stabilize.
Using a temperature probe, measure the engine block temperature near the ECT
Sensor.
With the DRBIIIt, select Engine, then Sensors and read the engine coolant
temperature.
Are the readings within 7ÉC (13ÉF) of each other?All
Ye s!Replace the Engine Oil Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
5 Disconnect the ECT harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the ECT Sensor Signal circuit between the ECM harness
connector and the ECT harness connector.
Measure the resistance of the Sensor Ground circuit between the ECM harness
connector and the ECT harness connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Replace the Engine Coolant Temperature Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the ECT Sensor circuit(s) that measured above 10.0 ohms
for high resistance.
Perform ROAD TEST VERIFICATION - VER-2.
43
DRIVEABILITY - DIESEL
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT PLAUSIBILITY
WITH ENGINE OIL SENSOR Ð
Continued

Symptom List:
P2014-ENGINE OIL SENSOR OIL TEMPERATURE PLAUSIBILITY
P2014-ENGINE OIL SENSOR SIGNAL PLAUSIBILITY
P2014-ENGINE OIL SENSOR SIGNAL VOLTAGE IS TOO HIGH
P2014-ENGINE OIL SENSOR SIGNAL VOLTAGE IS TOO LOW
P2040-ENGINE OIL SENSOR CIRCUIT INVALID LEVEL
P2040-ENGINE OIL SENSOR CIRCUIT LEVEL OUT OF RANGE
P2040-ENGINE OIL SENSOR CIRCUIT LEVEL OUT OF RANGE
P2041-ENGINE OIL SENSOR POOR OIL QUALITY
P2041-ENGINE OIL SENSOR QUALITY MEASUREMENT ERROR
P2041-ENGINE OIL SENSOR QUALITY PLAUSIBILITY
P2042-ENGINE OIL SENSOR WATER CONTAMINATION
P2061-ENGINE OIL SENSOR OPEN CIRCUIT
P2062-ENGINE OIL SENSOR SIGNAL ERROR
P2062-ENGINE OIL SENSOR SYNCHRONIZATION ERROR
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2014-ENGINE OIL SENSOR OIL
TEMPERATURE PLAUSIBILITY.
POSSIBLE CAUSES
5-VOLT SUPPLY CIRCUIT OPEN
ECM - ENGINE OIL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - ENGINE OIL SENSOR SIGNAL SHORT TO GROUND
ENGINE OIL SENSOR FAILURE
ENGINE OIL SENSOR SIGNAL CIRCUIT OPEN
ENGINE OIL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ENGINE OIL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
ENGINE OIL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
SENSOR GROUND CIRCUIT OPEN
ENGINE OIL CONTAMINATION
INTERMITTENT CONDITION
11 3
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
1NOTE: If DTC P1611, P2306 or P2332 is present with this DTC, diagnose
DTCs P1611, P2306 or P2332 before diagnosing this DTC.
NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
NOTE: The engine oil must be at the proper level for this test to be valid.
Refer to the Service Information and ensure the engine oil level is at the
specified level.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Start the engine several times, letting the engine run for at least 30 seconds at a
time.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 10
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.
Refer to any Technical Service Bulletins (TSB) that may apply.
Turn the ignition off.
NOTE: This DTC implies that the engine may be contaminated by water,
engine coolant or other material due to a mechanical or service failures
such as failed gaskets, seals, cracks or incorrectly installed components.
Inspect the engine for conditions referred to in the above note.
Were any of the above conditions present?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
3 Turn the ignition off.
Disconnect the Engine Oil Sensor harness connector.
Turn the ignition on.
Measure the voltage of the Engine Oil Sensor Signal circuit.
Select the appropriate voltage reading.All
Voltage is above 5.4 volts.
Go To 4
Voltage is between 4.7 and 5.4 volts.
Go To 5
Voltage is below 4.7 volts.
Go To 7
11 4
DRIVEABILITY - DIESEL
P2014-ENGINE OIL SENSOR OIL TEMPERATURE PLAUSIBILITY Ð
Continued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Engine Oil Sensor harness connector.
Disconnect the ECM harness connectors.
Remove the Engine Control Relay.
Connect a jumper wire between cavity 30 and cavity 87 of the Engine Control Relay
connector.
Turn the ignition on.
Measure the voltage of the Engine Oil Sensor Signal circuit.
Is the voltage below 1.0 volt?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Engine Oil Sensor Signal circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Engine Oil Sensor harness connector.
Measure the resistance of the 5-Volt Supply circuit between the ECM harness
connector and the Engine Oil Sensor harness connector.
Is the resistance below 10.0 ohms?All
Ye s!Go To 6
No!Repair the 5-Volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Engine Oil Sensor harness connector.
Measure the resistance of the Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Replace the Engine Oil Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Engine Oil Sensor harness connector.
Measure the resistance of the Engine Oil Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 8
No!Repair the Engine Oil Sensor Signal circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Engine Oil Sensor harness connector.
Measure the resistance between ground and the Engine Oil Sensor Signal circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 9
No!Repair the Engine Oil Sensor Signal circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
11 5
DRIVEABILITY - DIESEL
P2014-ENGINE OIL SENSOR OIL TEMPERATURE PLAUSIBILITY Ð
Continued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Engine Oil Sensor harness connector.
Measure the resistance between Sensor Ground and the Engine Oil Sensor Signal
circuit.
Is the resistance above 1000 ohms?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Engine Oil Sensor Signal circuit for a short to the
Sensor Ground circuit.
Perform ROAD TEST VERIFICATION - VER-2.
10WARNING: 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.
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.
11 6
DRIVEABILITY - DIESEL
P2014-ENGINE OIL SENSOR OIL TEMPERATURE PLAUSIBILITY Ð
Continued

TEST ACTION APPLICABILITY
8 Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel pressure to
deviate from specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, failed fuel lift pump, failed fuel sending unit, contami-
nated fuel, faulty injector.
Were there any problems with the Fuel Delivery System?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 9
9 Refer to each of the following symptoms in the Driveability category.
CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS
CHECKING THE FUEL PRESSURE SENSOR CIRCUITS
Were any problems found?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 10
10NOTE: An injector that sticks open can cause this DTC. A sticking injector
will cause the engine to misfire and emit excessive black smoke from the
exhaust system.
Refer to the Service Information and perform the Fuel Injector Leak Quantity Test.
Were any problems found?All
Ye s!Using the Service Information, remove and inspect the Fuel
Injectors for signs of damage or debris that may cause the injector
to stick. Sticking injectors may cause the combustion chamber to
become black and oil soaked. Replace Injector(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 11
11 With the DRBIIIt, select System Test, Smooth Eng Run Check, then Correction
Quantity Check.
Perform this test at Idle, 2000 rpm and 3000 rpm.
NOTE: Readings per cylinder should be below   0.00450 mm
3/stroke for each
cylinder at each engine speed.
Did any of the cylinders exceed   0.00450 mm
3/stroke during this test?All
Ye s!Replace Fuel Injector of the cylinder(s) that had readings above  
0.00450 mm
3/stroke.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 12
12 With the DRBIIIt, select System Test, Smooth Eng Run Check, then Cylinder Speed
Check.
NOTE: Readings for all cylinders should be close to each other. Look for one
or two cylinders to differ high or low from the other cylinders.
Did any of the cylinders differ significantly from the majority of the other cylinders?All
Ye s!Replace Fuel Injector of the cylinder(s) that had readings signif-
icantly above or below the other fuel injectors.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 13
121
DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
17 Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel pressure to
deviate from specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, air in fuel system, failed fuel sending unit, contaminated
fuel, faulty injector.
Were there any problems with the Fuel Delivery System?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 18
18 Refer to each of the following symptoms in the Driveability category.
CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS
CHECKING THE FUEL PRESSURE SENSOR CIRCUITS
Were any problems found?All
Ye s!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 19
19NOTE: An injector that sticks open can cause this DTC. A sticking injector
will cause the engine to misfire and emit excessive black smoke from the
exhaust system.
Refer to the Service Information and perform the Fuel Injector Leak Quantity during
engine cranking test.
Were any problems found?All
Ye s!Using the Service Information, remove and inspect the Fuel
Injectors for signs of damage or debris that may cause the injector
to stick. Sticking injectors may cause the combustion chamber to
become black and oil soaked. Replace Injector(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 20
20 Turn the ignition off.
Replace the Fuel Pressure Solenoid in accordance with the Service Information.
Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Attempt to start and test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Did this DTC set again?All
Ye s!Go To 21
No!Test Complete.
123
DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued