service MERCEDES-BENZ SPRINTER 2006 Service Manual

Symptom List:
P1615-ECM VOLTAGE SUPPLY IS TOO HIGH
P1615-ECM VOLTAGE SUPPLY IS TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P1615-ECM VOLTAGE SUPPLY
IS TOO HIGH.
When Monitored and Set Condition:
P1615-ECM VOLTAGE SUPPLY IS TOO HIGH
When Monitored: With the ignition on.
Set Condition: The ECM detects voltage above 16 volts on the Battery Supply circuit(s).
P1615-ECM VOLTAGE SUPPLY IS TOO LOW
When Monitored: With the ignition on.
Set Condition: The ECM detects voltage below 8.0 volts on the ECM Battery Supply
circuit(s).
POSSIBLE CAUSES
CHECKING ECM POWER AND GROUNDS
ECM
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.
Turn the ignition on.
With the DRB, erase ECM DTCs.
NOTE: This DTC may be caused by a charging system problem. Refer to the
Service Information and verify proper charging system operation before
continuing.
Test drive the vehicle.
Turn the ignition on.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 3
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DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
2 Refer to the symptom list and perform the Checking the ECM Power and Ground
test.
Were any problem found with the ECM powers and grounds?All
Ye s!Repair as necessary.
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.
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.
101
DRIVEABILITY - DIESEL
P1615-ECM VOLTAGE SUPPLY IS TOO HIGH ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the SKREEM Module harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of each CAN Bus circuit between the ECM harness connector
and the SKREEM harness connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Replace and program the SKREEM Module in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the open CAN Bus circuit(s) between the ECM and the
SKREEM.
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.
103
DRIVEABILITY - DIESEL
P1630-IMMOBILIZER ÐContinued

Symptom List:
P1681-ACM CIRCUIT FAULT
P1681-ACM CIRCUIT SHORT TO VOLTAGE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P1681-ACM CIRCUIT FAULT.
POSSIBLE CAUSES
AIRBAG CONTROL MODULE
INTERMITTENT CONDITION
ACM SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE CONTROL MODULE
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.
With the DRB, check the Airbag Module for proper communication and DTCs. If
there are any ACM DTCs, repair them prior to continuing this test.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Start the engine.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 4
2 Turn the ignition off.
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 ACM Signal circuit.
Is the voltage below 1.0 volt?All
Ye s!Replace the Engine Control Module in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
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TEST ACTION APPLICABILITY
3 Turn the ignition off.
Refer to the Service Information and disconnect the ACM harness connector.
Disconnect the ECM harness connectors.
Remove the Engine Control Relay from the Fuse Block No.1
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 of the ACM Signal circuit.
Is the voltage below 1.0 volt?All
Ye s!Replace and program the Airbag Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the ACM Signal circuit for a short to voltage.
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.
105
DRIVEABILITY - DIESEL
P1681-ACM CIRCUIT FAULT ÐContinued

Symptom List:
P2009-WATER IN FUEL SENSOR - WATER IN FUEL
P2009-WATER IN FUEL SENSOR SIGNAL ERROR
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2009-WATER IN FUEL SENSOR
- WATER IN FUEL.
POSSIBLE CAUSES
12-VOLT SUPPLY CIRCUIT OPEN
CHECKING ECM POWER AND GROUNDS
CHECKING THE ENGINE CONTROL RELAY SYSTEM
ECM - WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - WATER IN FUEL SENSOR SIGNAL SHORT TO GROUND
SENSOR GROUND CIRCUIT OPEN
WATER IN FUEL SENSOR FAILURE
WATER IN FUEL SENSOR SIGNAL CIRCUIT OPEN
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO 12-VOLT SUPPLY
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTERMITTENT CONDITION
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: If you are here due to a P2009 indicating(Water In The Fuel Filter(
DTC, ensure that the fuel system is not contaminated with water or other
fluids before continuing.
NOTE: If the fuel system is contaminated, refer to the Service Information
to remove fuel, clean system and refill with known good fuel.
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 11
106
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect the Water In Fuel Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the 12-volt supply circuit and the Water In Fuel
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 Water In Fuel Sensor Signal circuit for a short to the
12-volt Supply circuit.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the 12-Volt Supply circuit between the ECM harness
connector and the Water In Fuel Sensor harness connector.
Is the resistance below 10.0 ohms?All
Ye s!Go To 7
No!Repair the 12-Volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Replace the Water In Fuel Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the Water In Fuel Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 9
No!Repair the Water In Fuel Sensor Signal circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
9 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance between ground and the Water In Fuel Sensor Signal circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 10
No!Repair the Water In Fuel Sensor Signal circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
108
DRIVEABILITY - DIESEL
P2009-WATER IN FUEL SENSOR - WATER IN FUEL ÐContinued

TEST ACTION APPLICABILITY
10 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance between Sensor Ground and the Water In Fuel 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 Water In Fuel Sensor Signal circuit for a short to the
Sensor Ground circuit.
Perform ROAD TEST VERIFICATION - VER-2.
11WARNING: 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.
109
DRIVEABILITY - DIESEL
P2009-WATER IN FUEL SENSOR - WATER IN FUEL ÐContinued

TEST ACTION APPLICABILITY
1NOTE: Inspect the turbocharger inlet tube between the MAF Sensor and the
turbocharger for damage, restriction or poor connection. Any of these
conditions can cause a MAF Plausibility 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 DRBIIIt, erase the ECM DTCs.
Test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Does the DRB III display a Mass Air Flow Sensor DTC?All
Ye s!Replace the MAF Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
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 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.
111
DRIVEABILITY - DIESEL
P2010-MASS AIR FLOW SENSOR NEGATIVE DEVIATION ÐContinued

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