service MERCEDES-BENZ SPRINTER 2006 Service Manual

Symptom:
STEERING ANGLE SENSOR INTERNAL FAULT
POSSIBLE CAUSES
STEERING ANGLE SENSOR INTERMITTENT DTC
STEERING ANGLE SENSOR
TEST ACTION APPLICABILITY
1NOTE: If a system undervoltage or overvoltage DTC is set along with this
DTC, diagnose the system voltage DTC first.
NOTE: Electromagnetic (radio) interference can cause an intermittent
system malfunction by interrupting communication between the sensor
and the CAB.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
Move the Steering Wheel from stop to stop several times.
With the DRBIIIt, perform the road test procedure.
With the DRBIIIt, read DTCs.
NOTE: The Steering Angle Sensor is very sensitive to changes due to
alignment problems. The sensor must be recalculated using the DRBIIItif
alignment has been changed by more than 5 degrees.
Does this DTC reset?All
Ye s!Inspect the Steering Angle Sensor for proper installation. Inspect
the wiring and connectors. Repair as necessary. If no other
problems are found, replace the Steering Angle Sensor in accor-
dance with the Service Information.
No!Go To 2
2 The condition that set this DTC is not present at this time.
Monitor the DRBIIItwhile wiggle testing the related harness and connectors. Look
for any related parameters to change or for the DTC to reset.
Inspect the related harness and connectors.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Inspect the tires and wheels to make sure that they are the correct size. All tires must
be the same size.
Inspect the steering column and Steering Angle Sensor for correct mounting and
installation.
Inspect the front end and steering components for damage or misalignment.
Were any problems found?All
Ye s!Repair as necessary.
No!Test Complete.
74
BRAKES (CAB)

Symptom:
SYSTEM OVERVOLTAGE
POSSIBLE CAUSES
INTERMITTENT DTC
DAMAGED CAB/CAB HARNESS CONNECTOR
GROUND CIRCUIT OPEN
ANTI-LOCK BRAKE CONTROLLER
TEST ACTION APPLICABILITY
1NOTE: Repair any Powertrain charging system DTCs before continuing.
Turn the ignition on.
With the DRBIIIt, read DTCs.
With the DRBIIIt, erase DTCs.
Turn the ignition off.
Turn the ignition on.
Start the engine.
With the DRBIIIt, read DTCs.
Does this DTC reset?All
Ye s!Go To 2
No!Go To 4
2 Turn the ignition off.
Disconnect the CAB harness connector.
Inspect the CAB/CAB harness connector for damage.
Is there any broken, bent, pushed out, corroded or spread terminals?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to 12-volts, check the CAB harness connector
Ground circuits.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Replace the Controller Antilock Brake in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the Ground circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
75
BRAKES (CAB)

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to ground, check both Fused B(+) circuits at the
CAB harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Go To 5
No!Repair the Fused B(+) circuit for high resistance.
Perform ABS VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to 12-volts, check the CAB harness connector
Ground circuits.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Replace the Controller Antilock Brake in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the Ground circuit for high resistance.
Perform ABS VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
78
BRAKES (CAB)
SYSTEM UNDERVOLTAGE ÐContinued

Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the ignition off.
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from
ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system
that was malfunctioning.
5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read
DTC's from ALL modules.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. NOTE: If the CAB/HCU was replaced, ensure the CAB has been initialized
8. NOTE: If the SKREEM or ECM was replaced, refer to the service information for
proper programming procedures.
9. NOTE: For Sensor Circuit/Signal and Pump Motor faults, the CAB must sense all 4
wheels at 12 km/h (8 mph) before it will extinguish the ABS Indicator.
10. If there are no DTC's present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
11. CAUTION: Ensure braking capability is available before road testing.
12. Again, with the DRBIIItread DTC's. If any DTC's are present, return to Symptom list.
13. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can
no longer be duplicated, the repair is complete.
Are any DTC's present or is the original concern still present?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
79
VERIFICATION TESTS

BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. Ensure that all accessories are turned off and the battery is fully charged.
3. NOTE: Refer to the service information for proper programming procedures if the
ABM; ACM; ATC; CTM; ECM; IC; SKREEM; SLA; or SSM was replaced.
4. If the SKREEM was replaced, program all RKE transmitters used with this vehicle.
5. NOTE: Perform the next 8 steps of this procedure if either diagnosing the
Automatic Temperature Control (ATC) system or if repairs were made to the ATC
system. All of the following criteria must be met in order to successfully run the ATC
Function Test.
6. With DRBIIIt, record and erase ATC DTCs.
7. Place the shift lever in Park.
8. Start the engine. Allow the engine to reach normal operating temperature.
9. Set the blower to high speed.
10. Press the Air Conditioning switch On.
11. 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).
12. With the DRBIIItin ATC, select System Tests and select ATC Function Test. When the ATC
Function Test is complete, proceed to the next step of this procedure.
13. With the DRBIIIt, read active ATC DTCs. If any DTC is active or if the original condition
is still present, proceed to the conclusion question and answer Yes.
14. With the DRBIIIt, record and erase all DTCs from ALL modules. Start and run the engine
for 2 minutes. Operate all functions of the system that caused the original concern.
15. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIIIt, read
DTCs from ALL modules.
Are any DTC's present or is the original condition still present?All
Ye s!Repair is not complete, refer to the appropriate symptom.
No!Repair is complete.
80
VERIFICATION TESTS
Verification Tests ÐContinued

1.0 INTRODUCTION
The procedures contained in this manual include
all specifications, instructions and graphics needed
to diagnose engine control module (ECM) and sen-
try key remote entry module (SKREEM) problems;
they are no start, diagnostic trouble code (DTC) and
no trouble code problems for the ECM. The diagnos-
tics in this manual are based on the trouble condi-
tion or symptom being present at the time of diag-
nosis.
When repairs are required, refer to the appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; carryover sys-
tems may be enhanced. IT IS RECOMMENDED
THAT YOU REVIEW THE ENTIRE MANUAL TO
BECOME FAMILIAR WITH ALL NEW AND
CHANGED DIAGNOSTIC PROCEDURES.
This manual will cover all the necessary require-
ments to begin a logical diagnostic path for each
problem. If there is a diagnostic trouble code (DTC)
detected, go to the trouble code test. If there are no
DTCs present, go to a no trouble code (*), symptom
based test.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or recommendations, please fill
out the form at the back of the book and mail it back
to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers 2005
Sprinter vehicles equipped with the 2.7L common
rail diesel engine.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the engine control module (ECM)
and sentry key immobilizer system (SKREEM) is
done in six basic steps:
²verification of complaint
²verification of any related symptom
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
NOTE: All tests in this manual should be per-
formed with the engine at operating temperature,
unless otherwise specified within a particular test.
2.0 IDENTIFICATION OF
SYSTEM
The ECM is located to the left of the steering
column behind the steering column opening cover.
The sentry remote entry module (SKREEM) is
attached to the rear of the instrument cluster.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 2.7L direct injection diesel engine system is
equipped with the latest technical advances. The
on-board diagnostics incorporated in the engine
control module and SKREEM are intended to assist
the field technician in repairing vehicle problems by
the quickest means.
The engine system incorporates a common rail
fuel delivery design with exhaust emission feed-
back. This design utilizes electronically controlled
solenoid valve type fuel injectors. Each injector is
controlled individually by the ECM. Injector timing
and fuel quantity are controlled by the ECM based
on inputs from various sensors. The precision con-
trol of the injectors by the ECM helps to reduce the
engine noise, odor and smoke.
3.2 FUNCTIONAL OPERATION
3.2.1 ECM ON-BOARD DIAGNOSTICS
The ECM is programmed to monitor different
circuits of the diesel fuel injection system. This
monitoring is called on-board diagnostics.
Certain criteria must be met for a diagnostic
trouble code to be entered into the ECM memory.
The criteria may be a range of: engine rpm, engine
temperature, time or other input signals to the
ECM. If all of the criteria for monitoring a system or
circuit are met, and a problem is sensed, then a
DTC will be stored in the ECM memory.
It is possible that a DTC for a monitored circuit
may not be entered into the ECM memory, even
though a malfunction has occurred. This may hap-
pen when the monitoring criteria have not been
met.
The ECM compares input signal voltages from
each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored
in the ECM memory.
1
GENERAL INFORMATION

3.2.6 SKREEM OPERATION
When ignition power is supplied to the SKREEM,
the SKREEM performs an internal self-test. After
the self-test is complete, the SKREEM energizes
the antenna (this activates the transponder chip)
and sends a challenge to the transponder chip. The
transponder chip responds to the challenge by gen-
erating an encrypted response message.
After responding to the coded message, the tran-
sponder sends a transponder ID message to the
SKREEM. The SKREEM compares the transpon-
der ID message to the available valid key codes in
SKREEM memory (8 key maximum at any one
time). After validating the ignition key the
SKREEM sends a CAN Bus message request to the
ECM, then waits for the ECM response. If the ECM
does not respond, the SKREEM will send the re-
quest again. If the ECM does not respond again, the
SKREEM will stop sending the request and store a
trouble code in memory. If the ECM sends a correct
response to the SKREEM, the SKREEM sends a
valid/invalid key message to the ECM. The ECM
will allow or disallow engine operation based on this
message.
Secret Key - an electronically stored value (iden-
tification number) that is unique to each SKREEM.
The secret key is stored in the SKREEM, ECM and
all ignition key transponders.
Challenge - a random number that is generated by
the SKREEM at each ignition key cycle.
The secret key and challenge are the two vari-
ables used in the algorithm that produces the
encrypted response message. The transponder uses
the crypto algorithm to receive, decode and respond
to the message sent by the SKREEM. After re-
sponding to the coded message, the transponder
sends a transponder ID message to the SKREEM.
3.3 DIAGNOSTIC TROUBLE CODES
Each diagnostic trouble code (DTC) is diagnosed
by following a specific procedure. The diagnostic
test procedure contains step-by-step instruction for
determining the cause of the DTC as well as no
trouble code problems. It is not necessary to per-
form all of the tests in this book to diagnose an
individual code.
Always begin diagnosis by reading the DTCs
using the DRBIIIt. This will direct you to the
specific test(s) that must be performed.
3.3.1 HARD CODE
A DTC that comes back within one cycle of the
ignition key is a hard code. This means that the
problem is current every time the ECM/SKREEM
checks that circuit or function. Procedures in this
manual verify if the DTC is a hard code at thebeginning of each test. When the fault is not a hard
code, an intermittent test must be performed.
NOTE: If the DRBIIITdisplays faults for
multiple components (i.e. ECT, MAF, IAT
sensors) identify and check the shared
circuits for possible problems before
continuing (i.e. sensor grounds or 5-volt
supply circuits). Refer to the appropriate
schematic to identify shared circuits.
3.3.2 INTERMITTENT CODE
A DTC that is not current every time the ECM/
SKREEM checks the circuit or function is an inter-
mittent code. Most intermittent DTCs are caused
by wiring or connector problems. Problems that
come and go like this are the most difficult to
diagnose; they must be looked for under specific
conditions that cause them. The following checks
may assist you in identifying a possible intermit-
tent problem.
± Visually inspect the related wire harness con-
nectors. Look for broken, bent, pushed out or
corroded terminals.
± Visually inspect the related wire harness.
Look for chafed, pierced or partially broken
wire.
± Refer to hotlines or technical service bulletins
that may apply.
NOTE: Electromagnetic (radio) interference
can cause an intermittent system
malfunction. This interference can interrupt
communication between the ignition key
transponder and the SKREEM.
3.3.3 ECM DIAGNOSTIC TROUBLE CODES
IMPORTANT NOTE: Before replacing the
ECM for a failed driver, control circuit or
ground circuit, be sure to check the related
component/circuit integrity for failures not
detected due to a double fault in the circuit.
Most ECM driver/control circuit failures are
caused by internal failures to components
(i.e. relays and solenoids) and shorted
circuits (i.e. sensor pull-ups, drivers and
ground circuits). These faults are difficult to
detect when a double fault has occurred and
only one DTC has set.
If the DRBIIItdisplays faults for multiple com-
ponents (i.e. MAF, ECT, ENG OIL, etc.), identify
and check the shared circuits for possible problems
before continuing (i.e. sensor grounds or 5-volt
3
GENERAL INFORMATION

3.3.4 HANDLING NO TROUBLE CODE
PROBLEMS
After reading Section 3.0 (System Description
and Functional Operation), you should have a bet-
ter understanding of the theory and operation of the
on-board diagnostics and how this relates to the
diagnosis of a vehicle that may have a driveability-
related symptom or complaint. When there are no
trouble codes present, refer to the no trouble code
(*) tests.
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading the DTCs, erasing the
DTCs, lab scope usage and other DRBIIItfunc-
tions.
3.4.1 DRBIIITDOES NOT POWER UP
If the LEDs 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 at data link
connector cavity 16. A minimum of 11.0 volts is
required to adequately power the DRBIIIt. Check
for proper ground connection at data link connector
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 of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate diagnostic manual.
3.4.2 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: HIGH-PRESSURE FUEL LINES
DELIVER DIESEL FUEL UNDER 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. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE 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.
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREA WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels 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 the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection and remove any metal jewelry such as
watchbands or bracelets that might make electrical
contact.
When diagnosing powertrain system problems, it
is important to follow approved procedures where
applicable. These procedures can be found in the
8
GENERAL INFORMATION

service manual. Following these procedures is very
important to the safety of the individuals perform-
ing the diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced as an assembly only. At-
tempting to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIITMULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLE FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND SPECIFICATION LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
± Do not use the DRBIIItif it has been dam-
aged.
± Do not use the test leads if the insulation is
damaged or if metal is exposed.
± To avoid electrical shock, do not touch the test
leads, tip or the circuit being tested.
± Choose the proper range and function for the
measurement. Do not try voltage or current
measurements that may exceed the rated ca-
pacity.
± Do not exceed the limits shown in the table
below:
FUNCTION INPUT LIMIT
Volts 0±500 peak volts AC
0±500 volts DC
Ohms (Resistance)* 0±1.12 megaohms
Frequency Measure
Frequency Generated0±10 kHz
Temperature ±58 ± +1100ÉF
±50 ± +600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only on a non-powered
circuit.± Voltage between any terminal and ground
must not exceed 500v DC or 500v peak AC.
± Use caution when measuring voltage above
25v DC or 25v AC.
± The circuit being tested must be protected by a
10 amp fuse or circuit breaker.
± Use the low current shunt to measure circuits
up to 10 amps. Use the high current shunt to
measure circuits exceeding 10 amps.
± When testing for the presence of voltage or
current, make sure the meter is functioning
correctly. Take a reading of a known voltage or
current before accepting a zero reading.
± When measuring current, connect the meter in
series with the load.
± Disconnect the live test lead before disconnect-
ing the common test lead.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not hang the DRBIIIT
from the rear view mirror. Do not attempt to
read the DRBIIITwhile driving. Have an
assistant available to operate the DRBIIIT.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is off. Failure to do so could
damage the module. When testing voltage or circuit
integrity at any control module, use the terminal
side (not the wire end) of the harness connector. Do
not probe through the insulation; this will damage
it and eventually cause it to fail because of corro-
sion.
Be careful when performing electrical test so as to
prevent accidental shorting of terminals. Such a
mistake can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box) scan tool
vacuum gauge
ammeter
9
GENERAL INFORMATION

Symptom:
*NO RESPONSE FROM ENGINE CONTROL MODULE
POSSIBLE CAUSES
CHECK POWERS AND GROUNDS TO THE ENGINE CONTROL MODULE
K-ECM CIRCUIT SHORTED TO GROUND
K-ECM CIRCUIT SHORTED TO VOLTAGE
K-ECM CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Engine Control Module harness connectors.
Check each power and ground circuit to the module.
Were any problems found?All
Ye s!Refer to the wiring diagrams located in the service information to
help isolate an open or shorted condition. Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
2 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the DRBIIItfrom the DLC.
Measure the resistance between ground and the K-ECM circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the K-ECM circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
3 Turn the ignition off.
Disconnect the DRBIIItfrom the DLC.
Disconnect the ECM harness connectors.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the K-ECM circuit.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Repair the K-ECM circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
12
COMMUNICATION