service MERCEDES-BENZ SPRINTER 2006 Service Manual

TEST ACTION APPLICABILITY
5 Turn the ignition off.
With the DRBIIIt, erase ECM DTCs.
Refer to the Service Information and perform the Glow Plug Test on each Glow plug.
Did each Glow Plug pass the test?All
Ye s!Replace the Glow Plug Module.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace the appropriate Glow Plug in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
6WARNING: 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 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.
84
DRIVEABILITY - DIESEL
P1482-GLOW PLUG MODULE - EXCESS CURRENT ÐContinued

Symptom List:
P1482-GLOW PLUG MODULE - INCORRECT TIMER
P1482-GLOW PLUG MODULE - INTERNAL FAULT
P2538-GLOW PLUG MODULE COMMUNICATION ERROR
P2538-GLOW PLUG MODULE EXCESSIVE CURRENT ERROR
P2538-GLOW PLUG MODULE TIMER ERROR
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P1482-GLOW PLUG MODULE -
INCORRECT TIMER.
POSSIBLE CAUSES
GLOW PLUG MODULE
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1NOTE: 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: This DTC indicates an internal Glow Plug Control Module problem
or an incorrect Glow Plug Module has been installed.
Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIIIt, read the ECM DTCs.
Did this DTC set again?All
Ye s!Replace and program the Glow Plug Control Module in accor-
dance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
85
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
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.
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 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.
86
DRIVEABILITY - DIESEL
P1482-GLOW PLUG MODULE - INCORRECT TIMER ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Install a substitute relay in place of the Engine Control Relay.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
Perform several ignition key cycles, pausing for at least 10 seconds between each
cycle.
Turn the ignition on.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 4
No!Replace the Engine Control Relay.
Perform ROAD TEST VERIFICATION - VER-2.
4 Refer to symptom Checking the ECM Power and Grounds.
Are the ECM Power and Ground circuits o.k.?All
Ye s!Replace the ECM in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
5WARNING: 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 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.
88
DRIVEABILITY - DIESEL
P1610-ENGINE CONTROL RELAY PLAUSIBILITY ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Turn the ignition off.
Install a substitute relay in place of the Engine Control Relay.
Perform several ignition key cycles, pausing for at least 10 seconds between each
cycle.
Turn the ignition on.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 4
No!Replace the Engine Control Relay.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Remove the Engine Control Relay.
Disconnect the ECM harness connectors.
Measure the resistance of the Engine Control Relay Control circuit while wiggling
the wiring harness and connectors between the ECM and the Fuse Block #1.
Was the resistance above 10.0 ohms at any time while wiggling the wiring harness
and connectors?All
Ye s!Repair the Engine Control Relay Control circuit for an intermit-
tent open.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
5WARNING: 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 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.
90
DRIVEABILITY - DIESEL
P1610-ENGINE CONTROL RELAY SHUTS OFF TOO EARLY ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Install a substitute relay in place of the Engine Control Relay.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
Perform several ignition key cycles, pausing for at least 10 seconds between each
cycle.
Turn the ignition on.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 4
No!Replace the Engine Control Relay.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Remove the Engine Control Relay.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the Engine Control Relay Control circuit
while wiggling the wiring harness and connectors.
Was the resistance below 1000.0 ohms at any time while wiggling the wiring harness
and connectors?All
Ye s!Repair the Engine Control Relay Control circuit for an intermit-
tent short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
5 Turn the ignition off.
Remove the Engine Control Relay.
Turn the ignition on.
Measure the voltage of the Engine Control Relay Output circuit.
Is the voltage below 0.5 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 Control Relay Output circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
92
DRIVEABILITY - DIESEL
P1610-ENGINE CONTROL RELAY SHUTS OFF TOO LATE ÐContinued

TEST ACTION APPLICABILITY
6WARNING: 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 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.
93
DRIVEABILITY - DIESEL
P1610-ENGINE CONTROL RELAY SHUTS OFF TOO LATE ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the APP and CMP Sensor harness connectors.
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 in Fuse Block No.1.
Turn the ignition on.
Measure the voltage at ECM harness connector cavities C1-38, C1-37, C2-13, C2-24
and C2-25.
Is the voltage above 1.0 volt for any of the measurements?All
Ye s!Repair the circuit(s) that measured above 1.0 volt for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
4WARNING: 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 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.
95
DRIVEABILITY - DIESEL
P1611-SENSOR SUPPLY 1 VOLTAGE IS TOO HIGH ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the CMP Sensor harness connector.
Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Turn the ignition off for 10 seconds. Turn the ignition on.
With the DRBIIIt, read ECM DTCs.
Does the DRB display this DTC?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace the Camshaft Position Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
8WARNING: 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 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.
98
DRIVEABILITY - DIESEL
P1611-SENSOR SUPPLY 1 VOLTAGE IS TOO LOW ÐContinued

Symptom:
P1612-IGNITION VOLTAGE - VOLTAGE ERROR
POSSIBLE CAUSES
CHECK THE ECM POWER AND GROUNDS
ENGINE CONTROL MODULE
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIIIt, read the ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 3
2 Refer to symptom Checking the ECM Power and Grounds.
Are the ECM Power and Ground circuits o.k.?All
Ye s!Replace the ECM in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
3WARNING: 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 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.
99
DRIVEABILITY - DIESEL