ignition MERCEDES-BENZ SPRINTER 2006 Service Manual

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.
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DRIVEABILITY - DIESEL
P2010-MASS AIR FLOW SENSOR NEGATIVE DEVIATION ÐContinued

Symptom List:
P2013-AMBIENT AIR TEMPERATURE SIGNAL VOLTAGE TOO
HIGH
P2013-AMBIENT AIR TEMPERATURE SIGNAL VOLTAGE TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2013-AMBIENT AIR TEMPER-
ATURE SIGNAL VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P2013-AMBIENT AIR TEMPERATURE SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The Ambient Air Temperature Sensor signal is above 4.82 volts.
P2013-AMBIENT AIR TEMPERATURE SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The Ambient Air Temperature Sensor signal is below 0.068 volt.
TEST ACTION APPLICABILITY
1NOTE: The Ambient Air Temperature Sensor is hardwired to the Instrument
Cluster
NOTE: Refer to the Instrument Cluster Diagnostic Information for the
related symptom(s).
Test Complete.All
Ye s!Test Complete.
11 2
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.
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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

POSSIBLE CAUSES
CHECKING THE FUEL DELIVERY SYSTEM
CORRECTION QUANTITY CHECK
CYLINDER SPEED CHECK
FUEL INJECTION PUMP CHECK
FUEL LEAK QUANTITY CHECK
FUEL LEAK QUANTITY CHECK
FUEL PRESSURE SOLENOID
FUEL PRESSURE SOLENOID CHECK
FUEL PRESSURE VARIATION CHECK
FUEL PUMP
FUEL QUANTITY SOLENOID
FUEL SYSTEM CONTAMINATION
FUEL SYSTEM LEAK
INTERMITTENT CONDITION
TEST ACTION APPLICABILITY
1WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Turn the ignition on.
With the DRBIIIt, read the ECM DTCs.
Are there any other DTCs present?All
Ye s!Refer to symptom list for problems related to the DTC other than
this DTC.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
2 Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Attempt to start the engine.
Does the engine start and idle?All
Ye s!Go To 3
No!Go To 17
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P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Inspect the entire fuel system for leakage.
Is there any evidence of leakage?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4NOTE: Mixing any other fuels such as gasoline or kerosine can cause this
DTC to set.
Turn the ignition off.
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UN-
DER 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.
WARNING: FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE 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.
Refer to the Service Information and inspect the fuel system for contamination.
Is the fuel contaminated?All
Ye s!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
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P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

TEST ACTION APPLICABILITY
5NOTE: 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 IIItat 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: Refer to the Service Information and perform the Air Bleed Proce-
dure before continuing diagnosis.
Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Start and idle the engine while monitoring for ECM DTC's.
If the DTC does not reset at idle condition, test drive the vehicle under various load
and speed conditions to attempt to duplicate the fault.
NOTE: Driving the vehicle up and down steep hills or rapid cornering with
a low fuel level can cause this DTC to set. Verify with customer if Low Fuel
Light was illuminated when fault occurred.
With the DRBIIIt, read the ECM DTCs.
Does the DRBIIItdisplay this DTC?All
Ye s!Go To 6
No!Go To 16
6 Start the engine.
With the DRBIIItin Sensors, compare the Fuel Pressure Setpoint with the Actual
Fuel Pressure readings.
NOTE: If there is air in the fuel system, the Actual Fuel Pressure will
oscillate above and below the Fuel Pressure Setpoint.
Does Actual Fuel Pressure oscillate above and below the Fuel Pressure Setpoint?All
Ye s!Refer to the Service Information to purge air from the fuel system.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 7
7 Start the engine.
With the DRBIIItin Sensors, compare the Fuel Pressure Setpoint with the Actual
Fuel Pressure readings.
NOTE: A sticking Fuel Pressure Solenoid is indicated by Actual Fuel
Pressure gradually dropping below the Fuel Pressure Setpoint then sud-
denly increasing (spiking) above the Fuel Pressure Setpoint.
Does Actual Fuel Pressure gradually decrease then suddenly increase (spike) above
the Fuel PressureAll
Ye s!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 8
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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.
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Continued

TEST ACTION APPLICABILITY
21 Turn the ignition off.
Replace the Fuel Quantity 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!Replace the Fuel Pump in accordance with the Service Informa-
tion.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
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DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued