fuel MERCEDES-BENZ SPRINTER 2006 Owner's Guide

small
mass air flow sensor positive deviation
mass air flow sensor signal circuit open or shorted
mass air flow sensor signal voltage too high
mass air flow sensor signal voltage too high
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor supply voltage too high
mass air flow sensor supply voltage too low
misfire cylinder #1
misfire cylinder #1
misfire cylinder #2
misfire cylinder #2
misfire cylinder #3
misfire cylinder #3
misfire cylinder #4
misfire cylinder #4
misfire cylinder #5
misfire cylinder #5
misfire detected
no message received from skreem
o2 circuit fault
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too low
o2 sensor circuit calibration value too low
o2 sensor circuit calibration value too low
o2 sensor circuit fault
o2 sensor circuit fault
o2 sensor circuit open circuit
o2 sensor circuit open circuit
o2 sensor circuit signal voltage too high
o2 sensor circuit signal voltage too high
o2 sensor circuit signal voltage too low
o2 sensor circuit signal voltage too low
o2 sensor heater circuit fault
o2 sensor low o2 concentration
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor signal circuit signal voltage too high
o2 sensor signal circuit signal voltage too high
o2 sensor signal circuit signal voltage too high
o2 sensor signal fault
o2 sensor signal plausibility
s/c excessive acceleration
s/c excessive deceleration
s/c vehicle speed plausibility
sensor supply 1 voltage is too high
sensor supply 1 voltage is too low
sensor supply 2 voltage is too high
sensor supply 2 voltage is too low
sensor supply 3 voltage is too highsensor supply 3 voltage is too low
starter relay circuit ecm thermal overload
starter relay circuit open or shorted to voltage
starter relay circuit short circuit
starter relay circuit short to ground
steering angle sensor plausibility
tcm dtc 1-2 and 4-5 shift solenoid fault present
tcm dtc 2-3 shift solenoid fault present
tcm dtc 3-4 shift solenoid fault present
tcm dtc can msg implausible fault present
tcm dtc ewm can message fault present
tcm dtc internal fault present
tcm dtc modulating pressure solenoid fault present
tcm dtc negative gear comparison fault present
tcm dtc not unequivocal fault present
tcm dtc right rear wheel speed implausible fault
present
tcm dtc shift pressure solenoid fault present
tcm dtc speed sensor voltage fault present
tcm dtc tcc excessive power consumption fault
present
tcm dtc torque converter clutch solenoid fault
present
tcm dtc transmission ratio error fault present
tcm dtc valve voltage supply fault present
tcm message error
tcm no can message
torque reduction message from abs -can plausibility
torque reduction message from abs -message error
torque reduction message from abs -messages miss-
ing
torque reduction message from abs -no communica-
tion
torque reduction message from abs -plausibility #1
torque reduction message from abs plausibility #2
torque reduction message from hvac switch signal
plausibility
torque reduction message from hvac-parity error
torque reduction message from hvac-switch signal
error
torque reduction message from tcm -can plausibil-
ity
torque reduction message from tcm -engine stop
torque reduction message from tcm -message error
torque reduction message from tcm -messages miss-
ing
torque reduction message from tcm -plausibility
torque reduction message from tcm -tcm dtc #1
torque reduction message from tcm -tcm dtc #2
water in fuel sensor signal error
water in fuel sensor -water in fuel
wheel speed sensor plaus -can bus message from
abs
write error to eeprom
7
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

ohmmeter
voltmeter
jumper wires and probes
oscilloscope
6.0 GLOSSARY OF TERMS
A/Cair conditioning
APPaccelerator pedal position (sensor)
BCMbody control module
BPboost pressure (sensor)
CKPcrankshaft position (sensor)
CMPcamshaft position (sensor)
CTMcentral timer module
DLCdata link connector
ECMengine control module
ECTengine coolant temperature (sensor)
EGRexhaust gas recirculation (solenoid/
valve)
EOSengine oil sensor
IATintake air temperature (sensor)
IPintake pressure sensorMAFmass air flow (sensor)
MILmalfunction indicator lamp
msmillisecond(s)
O2oxygen sensor
PDCpower distribution center
S/Cspeed control
SKREEMsentry key remote entry module
SRCsignal range check
WIFwater in fuel (sensor)
10
GENERAL INFORMATION

Symptom List:
P-1105 ATMOSPHERIC PRESSURE SENSOR PLAUSIBILITY WITH
BOOST PRESSURE SENSOR
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE
TOO HIGH
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE
TOO LOW
P1617- ECM READ/WRITE ERROR
P1617- ECM WRITE ERROR
P1617-ECM INCORRECT VALUE
P1617-ECM READ ERROR
P2122-INTERNAL ERROR COUNTER FAULT
P2122-INTERNAL ERROR ENGINE SHUT OFF
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING
P2123-INJECTOR BANK ERROR
P2124-INJECTOR BANK ERROR
P2139-ECM INJECTOR OUTPUT STAGE #1
P2139-ECM INJECTOR OUTPUT STAGE #1 SHORT CIRCUIT
P2140-ECM INJECTOR OUTPUT STAGE #2
P2140-ECM INJECTOR OUTPUT STAGE #2 SHORT CIRCUIT
P2149-ECM A/D CONVERTER HIGH
P2149-ECM A/D CONVERTER LOW
P2149-ECM A/D CONVERTER PLAUSIBILITY
P2153-STARTER RELAY CIRCUIT ECM THERMAL OVERLOAD
P2197-FUEL QUANTITY SOLENOID ECM THERMAL OVERLOAD
P2214-CAN MESSAGE ERROR
P2319-ECM INTERNAL ERROR 1
P2319-ECM INTERNAL ERROR 2
P2319-ECM INTERNAL ERROR 3
P2319-ECM INTERNAL ERROR 4
P2321-ECM INTERNAL ERROR 5
P2323-ECM INTERNAL ERROR
P2324-ECM INJECTOR MONITORING 1
P2324-ECM INJECTOR MONITORING 2
P2324-ECM INJECTOR MONITORING 3
P2324-ECM INJECTOR MONITORING 4
P2324-ECM INJECTOR UNDERVOLTAGE
P2325-ECM INTERNAL ERROR 1
P2325-ECM INTERNAL ERROR 2
P2325-ECM INTERNAL ERROR 3
P2325-ECM INTERNAL ERROR 4
P2329-ECM INTERNAL ERROR 1
P2330-ECM INTERNAL ERROR 1
P2340-ECM INJECTION QUANTITY ERROR
P2342-ECM INTERNAL ERROR 1
16
DRIVEABILITY - DIESEL

P2342-ECM INTERNAL ERROR 2
P2350-INTERNAL VOLTAGE ERROR
P2352-INJECTION FAULT - EXCESSIVE TEMPERATURE
P2352-INJECTION FAULT - QUANTITY ERROR
P2352-INJECTION FAULT - TORQUE LIMIT
P2352-INJECTION FAULT EXCESSIVE ENGINE SPEED
P2354-ECM INTERNAL FAULT
P2356-ECM INTERNAL ERROR
P2357-ECM INTERNAL ERROR
P2358-ECM INTERNAL ERROR
P2500-FUEL PRESSURE SOLENOID CIRCUIT EXCESSIVE CUR-
RENT
P2514-CRANKCASE VENT HEATER EXCESSIVE CURRENT
P2526-BOOST PRESSURE SERVO MOTOR EXCESSIVE CURRENT
P2527-EGR VALVE EXCESSIVE CURRENT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P-1105 ATMOSPHERIC PRES-
SURE SENSOR PLAUSIBILITY WITH BOOST PRESSURE
SENSOR.
When Monitored and Set Condition:
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The ECM internal Atmospheric Pressure Sensor is faulty.
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The ECM internal Atmospheric Pressure Sensor is faulty.
P2500-FUEL PRESSURE SOLENOID CIRCUIT EXCESSIVE CURRENT
When Monitored: With the ignition on.
Set Condition: The ECM detects an open or short to ground on the Fuel Pressure Solenoid
Control circuit.
POSSIBLE CAUSES
ENGINE CONTROL MODULE
INTERMITTENT CONDITION
17
DRIVEABILITY - DIESEL
P-1105 ATMOSPHERIC PRESSURE SENSOR PLAUSIBILITY WITH
BOOST PRESSURE SENSOR Ð
Continued

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: If there are other DTC's set with this DTC repair other DTC's before
continuing with this diagnostic procedure.
NOTE: This DTC indicates an internal ECM problem except in the case of
DTC P2352 where it may indicate a fuel injector problem. Using the Service
Information, check the fuel injectors for leakage before replacing the ECM.
NOTE: This code can be caused by an intermittent problem in the wiring
and connectors to the Engine Control Module. Inspect the Engine Control
Module harness connector and associated wiring for signs of poor terminal
contact.
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 Engine Control Module in accordance
with the Service Information.
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 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.
18
DRIVEABILITY - DIESEL
P-1105 ATMOSPHERIC PRESSURE SENSOR PLAUSIBILITY WITH
BOOST PRESSURE SENSOR Ð
Continued

Symptom:
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLT-
AGE TOO HIGH
When Monitored and Set Condition:
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The fuel temperature sensor signal voltage is above 4.7 volts.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL TEMPERATURE SENSOR GROUND CIRCUIT OPEN
FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
FUEL TEMPERATURE SENSOR
FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: If multiple DTCs are present, the most likely cause is a 5-Volt Supply
or Sensor Ground circuit shorted to voltage or ground. Refer to the Service
Information Wiring section for circuits that would affect multiple DTCs.
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 DRB, monitor the Fuel Temperature Sensor voltage.
Is the Fuel Temperature Sensor voltage above 4.80 volts?All
Ye s!Go To 2
No!Go To 6
2 Turn the ignition off.
Disconnect the Fuel Temperature Sensor harness connector.
Turn the ignition on.
Measure the voltage on the Fuel Temperature Sensor Signal circuit.
Is the voltage above 5.5 volts?All
Ye s!Repair the Fuel Temperature Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
49
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Fuel Temperature Sensor harness connector.
Connect a jumper wire between the Fuel Temperature Sensor harness connector
cavities.
Turn the ignition on.
With the DRB, read the Fuel Temperature Sensor voltage.
Is the voltage below 1.0 volt?All
Ye s!Replace the Fuel Temperature Sensor in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4 Turn the ignition off.
Disconnect the Fuel Temperature Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Fuel Temperature Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 5
No!Repair the Fuel Temperature Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Fuel Temperature Sensor harness connector.
Measure the resistance of the Fuel Temperature Sensor Signal circuit.
Is the resistance below 10.0 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 Fuel Temperature Sensor Signal circuit for an open.
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.
50
DRIVEABILITY - DIESEL
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE
TOO HIGH Ð
Continued

Symptom List:
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLT-
AGE TOO LOW
P2625-FUEL TEMPERATURE SENSOR PLAUSIBILITY
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0180-FUEL TEMPERATURE
SENSOR CIRCUIT - SIGNAL VOLTAGE TOO LOW.
When Monitored and Set Condition:
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The fuel temperature sensor signal voltage is below 0.8 volt.
P2625-FUEL TEMPERATURE SENSOR PLAUSIBILITY
When Monitored: With the ignition on.
Set Condition: The Mass Air Flow Sensor Signal voltage is above 4.8 volts.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL TEMPERATURE SENSOR
FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL TEMPERATURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER
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.
Turn the ignition on.
With the DRB, monitor the Fuel Temperature Sensor voltage.
Is the Fuel Temperature Sensor voltage below 0.10 volt?All
Ye s!Go To 2
No!Go To 5
51
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the Fuel Temperature Sensor harness connector.
Turn the ignition on.
With the DRB, read the Fuel Temperature Sensor voltage.
Is the voltage above 4.0 volts?All
Ye s!Replace the Fuel Temperature Sensor in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Fuel Temperature Sensor harness connector.
Measure the resistance between ground and the Fuel temperature Sensor Signal
circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 4
No!Repair the Fuel Temperature Sensor Signal circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Fuel Temperature Sensor harness connector.
Measure the resistance between the Fuel Temperature Sensor Signal circuit and
Sensor Ground 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 Fuel Temperature Sensor Signal and Ground circuits
for a short together.
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.
52
DRIVEABILITY - DIESEL
P0180-FUEL TEMPERATURE SENSOR CIRCUIT - SIGNAL VOLTAGE
TOO LOW Ð
Continued