check engine MERCEDES-BENZ SPRINTER 2006 Owner's Manual

²Four Wheel Speed Sensors/Tone Wheel assem-
blies
²ABS warning indicator
²TCS (ASR) event indicator
²TCS (ASR) warning indicator
²Steering Angle Sensor
²Lateral Acceleration/Yaw Rate Sensor
²Brake Pressure Sensor
²ESP event indicator
²Brake Fluid Level switch
²Brake Switch (BS)
²Brake Lamp Switch (BLS)
²TCS Switch (TCSS)
²K - ABS
²CAN C Bus
²Fuses, grounds, and wiring
3.7.1 ABS AND TCS (ASR) INDICATORS
This system is equipped with an ABS warning
indicator, TCS (ASR) warning indicator, and TCS
(ASR) event indicator to alert the driver of a
malfunction/event it has detected. The CAB can
request the illumination of the ABS warning indi-
cator, TCS (ASR) warning indicator, and TCS (ASR)
event indicator via CAN C BUS. The CAB controls
the ABS warning indicator by:
²Light steady during an initial test at the begin-
ning of an ignition cycle to function as a bulb
check
²Light steady when a system malfunction exists
(DTC)
²Light steady - If you have not met the speed
required to reset/retest the ABS components
The Instrument Cluster (IC) controls the indica-
tors. The Instrument Cluster transmits a message
over the CAN C Bus relating to diagnostics and
current lamp status for the ABS and TCS (ASR)
indicators. The CAB can control the operation of
TCS warning and TCS event indicators by:
²Both light steady with engine off and both go out
with engine running
²TCS warning indicator lights steady when a TCS
malfunction exists
²TCS event indicator will flash when TCS is in an
active event
3.7.2 CONTROLLER ANTILOCK BRAKE
(CAB)
The CAB is mounted directly to the Hydraulic
Control Unit (HCU) that includes a microprocessor
and twelve solenoids that control valves that con-trol brake pressure during antilock braking or trac-
tion control events. The CAB also has circuits that
monitor the following:
²Double brake switch outputs are monitored to
determine whether or not to prepare for possible
ABS braking
²Wheel Speed Sensors are monitored to determine
when a wheel is tending to lock up. The CAB will
operate the valves in the HCU to control braking
pressure during ABS braking
²Detect ABS system related problems and take
diagnostic action
²Able to execute self-tests and output control com-
mands
When equipped with Electronic Stability (ESP),
the CAB also monitors the following:
²The ESP looks at the Steering Angle Sensor value
and monitors the speed of the inner and outer
wheels to ensure that the values are plausible.
The Steering Angle Sensor also monitors the
speed that the steering wheel is turned.
²The Lateral Acceleration/Yaw Rate Sensor is con-
tained in one unit. The sensor measures side to
side (lateral) motion and rotational motion (how
fast the vehicle is turning).
²The ESP uses data from the Brake Pressure
Sensor to analyze how hard and fast that the
driver wants to brake.
3.7.3 HYDRAULIC CONTROL UNIT (HCU)
The HCU on the Bosch 5.7 has an integral valve
body for controlling the front and rear brakes.
Within the HCU are inlet, outlet, and shuttle
valves, to release brake pressure as required to
avoid wheel lockup, keeping the wheels rolling, and
maintain optimum deceleration with stability. The
Pump Motor is attached to the HCU which works
with the ABS and TCS and is controlled by the
CAB. The primary function is to provide extra
amount of fluid when needed.
3.7.4 SWITCHES/SENSORS
BRAKE SWITCH (BS):This switch prepares the
CAB for a possible antilock event. The CAB uses an
output state voltage from the BS when the brake
pedal is either released/depressed. The Fused Igni-
tion Switch Output circuit supplies 12 volts to the
BS. A released brake pedal will close the BS circuit
and the BS Output circuit supplies 12 volts to the
CAB. When the driver depresses the brake pedal,
the BS Output circuit voltage drops to 0 volts and
the CAB senses the brake pedal state. This tells the
CAB what position the brake pedal is currently in to
make an ABS event possible. When using the
DRBIIItin Inputs/Outputs, the BS and BLS will
3
GENERAL INFORMATION

ver: 2.14
date: 26 Jul93
file: key_iff.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.9.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's 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 (data link
16-way connector cavity 16). A minimum of 11 volts
is required to adequately power the DRBIIIt. Also
check for a good ground at DLC.
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 or a faulty cable or
vehicle wiring.
3.9.2 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 latestinformation 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: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS 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 front
drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing an antilock brake or adjustable
pedals system problem, it is important to follow
approved procedures where applicable. These pro-
cedures can be found in the service manual. Follow-
ing these procedures is very important to safety of
individuals performing 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 antilock brake and trac-
tion control are intended to be serviced in assembly
only. Attempting to remove or repair certain 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.
5
GENERAL INFORMATION

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the CAB harness connector.
Turn the ignition on.
Measure the voltage of the CAN(+) circuit.
Measure the voltage of the CAN(-) circuit.
Is the voltage above 3.0 volts for either circuit?All
Ye s!Repair the CAN circuit(s) for a short to voltage.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
Disconnect the CAB harness connector.
Measure the resistance between ground and the CAN(+) circuit.
Measure the resistance between ground and the CAN(-) circuit.
Is the resistance below 5.0 ohms for either circuit?All
Ye s!Repair the CAN circuit(s) for a short to ground.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 6
6 Turn the ignition off.
Disconnect the CAB harness connector.
Measure the resistance between the CAN(+) circuit and the CAN(-) circuit.
Is the resistance below 5.0 ohms between the circuits?All
Ye s!Repair the shorted CAN circuit(s).
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 7
7 Turn the ignition off.
Disconnect the Engine Control Module harness connector.
Disconnect the CAB harness connector.
Measure the resistance of the CAN(+) circuit.
Measure the resistance of the CAN(-) circuit.
Is the resistance above 5.0 ohms for either circuit?All
Ye s!Repair the CAN circuit(s) for an open
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 8
8 Turn the ignition off.
Disconnect the CAB harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Optional Equipment
Relay Output circuit 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 9
No!Repair the Fused Optional Equipment Relay Output circuit for an
open.
Perform ABS VERIFICATION TEST - VER 1.
26
BRAKES (CAB)
CAN COMMUNICATION ERROR ÐContinued

TEST ACTION APPLICABILITY
1NOTE: If a system undervoltage or overvoltage DTC is set along with this
DTC, diagnose the system voltage DTC first.
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.
Drive the vehicle over 15 km/h (10 mph) to test solenoid and pump circuits.
Stop the vehicle.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay any SOLENOID DTCs?All
Ye s!Go To 2
No!Go To 6
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.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Optional Equipment
Relay Output circuit 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 4
No!Repair the Fused Optional Equipment Relay Output circuit for an
open.
Perform ABS VERIFICATION TEST - VER 1.
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 an open.
Perform ABS VERIFICATION TEST - VER 1.
41
BRAKES (CAB)
LEFT FRONT INLET SOLENOID ÐContinued

Symptom:
NO COMMUNICATION WITH ECM
When Monitored and Set Condition:
NO COMMUNICATION WITH ECM
When Monitored: Ignition On - Continuously
Set Condition: When the CAB fails to receive all messages from the ECM.
POSSIBLE CAUSES
NO COMMUNICATION WITH BUS
ENGINE CONTROL MODULE DTC(S) PRESENT
ENGINE CONTROL MODULE'S POWER/GROUND CIRCUIT(S) SHORTED OR OPEN
CAN C BUS (+)/CAN C BUS (-) CIRCUIT(S) OPEN TO ENGINE CONTROL MODULE
CAN C BUS (+)/CAN C BUS (-) CIRCUIT(S) OPEN TO CAB
ANTI-LOCK BRAKE CONTROLLER
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read CAB DTCs.
Does the DRBIIItdisplay: NO COMMUNICATION WITH BUS?All
Ye s!Refer to the symptom list for the appropriate diagnostic proce-
dure.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 2
2 Turn the ignition on.
With the DRBIIIt, read ECM DTCs.
Does the DRBIIItdisplay any DTCs?All
Ye s!Refer to Powertrain Diagnostic information for the related symp-
tom(s).
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition on.
With the DRBIIIt, check the TCM, IC, and ATC module for the same or similar No
Communication with Engine Control Module DTC.
Does the DRBIIItdisplay same or similar DTC in TCM, IC, & ATC module?All
Ye s!Go To 4
No!Go To 6
52
BRAKES (CAB)

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the ECM harness connectors.
Check all of the ECM's power circuits for a short or open condition.
Check all of the ECM's ground circuits for an open condition.
Were any problems found?All
Ye s!Repair the power/ground circuit(s) as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Measure the resistance between the CAN C Bus (+) circuit and the CAN C Bus (-)
circuit in the ECM harness connector.
Is the resistance 57 to 63 ohms?All
Ye s!Replace the Engine Control Module in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the CAN C Bus (+)/CAN C Bus (-) circuit(s) for an open.
Perform ABS VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Disconnect the CAB harness connector.
Measure the resistance between the CAN C Bus (+) circuit and the CAN C Bus (-)
circuit in the CAB harness connector.
Is the resistance 57 to 63 ohms?All
Ye s!Replace the Controller Antilock Brake in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the CAN C Bus (+)/CAN C Bus (-) circuit(s) for an open.
Perform ABS VERIFICATION TEST - VER 1.
53
BRAKES (CAB)
NO COMMUNICATION WITH ECM ÐContinued

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)

Symptom:
SYSTEM UNDERVOLTAGE
POSSIBLE CAUSES
INTERMITTENT DTC
DAMAGED CAB/CAB HARNESS CONNECTOR
FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT HIGH RESISTANCE
FUSED B(+) CIRCUIT HIGH RESISTANCE
GROUND CIRCUIT HIGH RESISTANCE
ANTI-LOCK BRAKE CONTROLLER
TEST ACTION APPLICABILITY
1NOTE: An undercharged battery may cause this DTC to set. 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 6
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.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Optional Equipment
Relay Output circuit 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 4
No!Repair the Fused Optional Equipment Relay Output circuit for
high resistance.
Perform ABS VERIFICATION TEST - VER 1.
77
BRAKES (CAB)

TABLE OF CONTENTS - Continued
*CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS...................233
*CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS....................234
*CHECKING THE POWER AND GROUNDS................................235
*ENGINE CRANKS BUT WILL NOT START.................................239
*ENGINE WILL NOT CRANK.............................................242
VERIFICATION TESTS
VERIFICATION TESTS..................................................246
8.0 COMPONENT LOCATIONS..............................................249
8.1CONTROL MODULES.............................................249
8.2CONTROLS AND SOLENOIDS......................................249
8.3DATA LINK CONNECTOR..........................................250
8.4SENSORS.......................................................251
8.5SWITCHES......................................................253
9.0 CONNECTOR PINOUTS................................................255
ACCELERATOR PEDAL POSITION SENSOR (OBD).........................255
AIRBAG CONTROL MODULE - YELLOW...................................255
BOOST PRESSURE SENSOR (OBD)......................................255
BOOST PRESSURE SERVOMOTOR (OBD)................................256
CAMSHAFT POSITION SENSOR - BLACK.................................256
CONTROLLER ANTILOCK BRAKE........................................257
CRANKCASE HEATER - BLACK..........................................257
CRANKSHAFT POSITION SENSOR - BLACK...............................258
DATA LINK CONNECTOR - BLACK........................................258
EGR VALVE - BLACK...................................................258
ENGINE CONTROL MODULE C1 (OBD)...................................259
ENGINE CONTROL MODULE C2 (OBD)...................................260
ENGINE COOLANT TEMPERATURE SENSOR - BLACK......................260
ENGINE OIL SENSOR - BLACK..........................................261
FUEL INJECTOR NO. 1 - BLACK.........................................261
FUEL INJECTOR NO. 2 - BLACK.........................................261
FUEL INJECTOR NO. 3 - BLACK.........................................261
FUEL INJECTOR NO. 4 - BLACK.........................................262
FUEL INJECTOR NO. 5 - BLACK.........................................262
FUEL PRESSURE SENSOR - BLACK.....................................262
FUEL PRESSURE SOLENOID............................................262
FUEL PUMP (OBD).....................................................262
FUEL PUMP RELAY (OBD)..............................................263
FUEL QUANTITY CONTROL VALVE (OBD).................................263
FUEL TEMPERATURE SENSOR..........................................263
ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)...........................265
FUSES (FUSE BLOCK NO. 1)............................................265
FUSES (FUSE BLOCK NO. 2)............................................267
FUSES (FUSE/RELAY BLOCK)...........................................269
STARTER MOTOR RELAY (FUSE/RELAY BLOCK)...........................269
GLOW PLUG CONTROL MODULE C1 - BLACK.............................270
GLOW PLUG CONTROL MODULE C2 - BLACK.............................270
INTAKE AIR PRESSURE SENSOR (OBD)..................................270
INTAKE AIR TEMPERATURE SENSOR - BLACK............................270
x

3.2.2 ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For
example, the ECM must calculate a different fuel
quantity and fuel timing for engine idle condition
than it would for a wide open throttle condition.
There are several different modes of operation that
determine how the ECM responds to the various
input signals.
Ignition Switch On (Engine Off)
When the ignition is turned on the ECM activates
the glow plug relay for a time period that is deter-
mined by engine coolant temperature, intake air
temperature and battery voltage.
Engine Start-Up Mode
The ECM uses the intake air temperature sensor,
engine temperature sensor and the crankshaft po-
sition sensor (engine speed) inputs to determine
fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based
on all of the sensor inputs to the ECM. The ECM
uses these sensor inputs to adjust fuel quantity and
fuel injector timing. EGR valve control is performed
using feedback from the oxygen sensor. An oxygen
sensor is located in the exhaust manifold to sample
oxygen content exiting the engine cylinders. The
ECM uses the O2 sensor, along with other sensor
inputs, to govern the amount of exhaust gas recir-
culation to reduce HC (HydroCarbons) and CO
(Carbon Monoxide). Engine coolant is routed
through the base of the EGR valve to provide
additional cooling of the exhaust gas, which further
helps the reductions of emissions. The EGR valve
has a self-cleaning function. When the engine is
shut off, the EGR valve rotates twice to reduce
carbon deposits at the valve seat.
Overheat Production Mode
If the engine temperature is above 105ÉC (221ÉF)
and vehicle speed is above 40 km/h (25 MPH) the
ECM will limit fuel quantity for engine protection.
Limp-In Mode
The ECM utilizes different degrees of engine
limp-in. The ECM is able to limit engine rpm,
engine power output (turbo boost reduction), acti-
vate engine cooling fan or all of these functions
based on the type of fault that is detected. Critical
engine performance faults such as accelerator pedal
position sensor fault will result in a fixed idle speed
of approximately 680 rpm regardless of actual pedalposition. Other less critical faults will result in
power reduction throughout the full range of driv-
ing conditions.
Overspeed Detection Mode
If the ECM detects engine RPM that exceeds
5200 RPM, the ECM will set a DTC in memory,
limit engine RPM to no more than 2500 RPM, and
illuminate the MIL until the DTC is cleared.
After-Run Mode
The ECM transfers RAM information to ROM
and performs an Input/Output state check.
3.2.3 MONITORED CIRCUITS
The ECM is able to monitor and identify most
driveability related trouble conditions. Some cir-
cuits are directly monitored through ECM feedback
circuitry. In addition, the ECM monitors the voltage
state of some circuits and compares those states
with expected values. Other systems are monitored
indirectly when the ECM conducts a rationality test
to identify problems.
Although most subsystems of the engine control
module are either directly or indirectly monitored,
there may be occasions when diagnostic trouble
codes are not immediately identified. For a trouble
code to set, a specific set of conditions must occur
and unless these conditions occur, a DTC will not
set.
3.2.4 SKREEM OVERVIEW
The sentry key remote entry module system
(SKREEM) is designed to prevent unauthorized
vehicle operation. The system consists of a sentry
key remote entry module (SKREEM), ignition
key(s) equipped with a transponder chip and the
ECM. When the ignition switch is turned on, the
SKREEM interrogates the ignition key. If the igni-
tion key is Valid or Invalid, the SKREEM sends a
message to the ECM indicating ignition key status.
Upon receiving this message the ECM will termi-
nate engine operation or allow the engine to con-
tinue to operate.
3.2.5 SKREEM ON-BOARD DIAGNOSTICS
The SKREEM has been programmed to transmit
and monitor many different coded messages as well
as CAN Bus messages. This monitoring is called
On-Board Diagnostics. Certain criteria must be met
for a DTC to be entered into SKREEM memory. The
criteria may be a range of; input voltage, CAN Bus
message or coded messages to the SKREEM. If all
the criteria for monitoring a circuit or function are
met and a fault is detected, a DTC will be stored in
the SKREEM memory and the START ERROR indi-
cator will be turned on in the instrument cluster.
2
GENERAL INFORMATION