MERCEDES-BENZ SPRINTER 2006 Service Manual

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the ECT Sensor harness connector.
Measure the resistance between ground and the ECT Sensor Signal circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 4
No!Repair the ECT 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 ECT Sensor harness connector.
Measure the resistance between the ECT Sensor Signal circuit and Sensor Ground
circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 5
No!Repair the ECT Sensor Signal and Ground circuits for a short
together.
Perform ROAD TEST VERIFICATION - VER-2.
5 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module 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.
48
DRIVEABILITY - DIESEL
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE
TOO LOW 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

Symptom List:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE
TOO HIGH
P2008-FUEL PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE
TOO HIGH
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0190-FUEL PRESS SENSOR
CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH.
When Monitored and Set Condition:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH
When Monitored: With the ignition on.
Set Condition: The Fuel Rail Pressure Sensor Signal voltage is above 4.8 volts.
POSSIBLE CAUSES
ECM - FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - FUEL PRESSURE SENSOR SIGNAL OPEN
FUEL PRESSURE SENSOR SIGNAL CIRCUIT OPEN
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
SENSOR GROUND CIRCUIT OPEN
INTERMITTENT CONDITION
FUEL PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
FUEL PRESSURE SENSOR
ENGINE CONTROL MODULE
53
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
1WARNING: THE FUEL INJECTION PUMP SUPPLIES HIGH-PRESSURE
FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH-PRESSURE
FUEL LINES. FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN
AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING.
NOTE: 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.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Cycle the ignition key on and off several times, leaving the key on for at least 10
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
2 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Turn the ignition on.
Measure the voltage of the Fuel Pressure Sensor Signal circuit.
Select the appropriate voltage reading.All
Voltage is above 5.4 volts.
Go To 3
Voltage is between 4.7 and 5.4 volts.
Go To 4
Voltage is below 4.7 volts.
Go To 9
3 Turn the ignition off.
Disconnect the Fuel Pressure 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 Fuel Pressure 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 Fuel Pressure Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
54
DRIVEABILITY - DIESEL
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
HIGH Ð
Continued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 5
No!Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Fuel Pressure Sensor 5-Volt Supply circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 6
No!Repair the Fuel Pressure Sensor 5-volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the Fuel Pressure 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 Sensor Ground circuit at the Fuel Pressure Sensor and
ECM harness connectors.
Is the voltage above 1.0 volt at either connector?All
Ye s!Repair the Sensor Ground circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 7
NOTE: If the Sensor Ground circuit had a short to voltage on it, the ECM
could be damaged. Retest the Fuel Pressure Sensor circuit.
7 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Connect a jumper wire between the Fuel Pressure Sensor Signal circuit and the
Sensor Ground circuit in the Fuel Pressure Sensor harness connector.
Turn the ignition on and monitor the DRB for DTCs.
Is DTC P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
LOW present?All
Ye s!Replace the Fuel Pressure Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 8
8 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
55
DRIVEABILITY - DIESEL
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
HIGH Ð
Continued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Fuel Pressure 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 Pressure Sensor Signal circuit for an open.
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.
56
DRIVEABILITY - DIESEL
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
HIGH Ð
Continued

Symptom List:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE
TOO LOW
P2008-FUEL PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE
TOO LOW
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0190-FUEL PRESS SENSOR
CIRCUIT MALF SIGNAL VOLTAGE TOO LOW.
When Monitored and Set Condition:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW
When Monitored: With the ignition on.
Set Condition: The Fuel Rail Pressure Sensor Signal voltage is below 0.2 volt.
POSSIBLE CAUSES
FUEL PRESSURE SENSOR
INTERMITTENT CONDITION
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
ECM - FUEL PRESSURE SENSOR SIGNAL SHORTED TO GROUND
TEST ACTION APPLICABILITY
1WARNING: THE FUEL INJECTION PUMP SUPPLIES HIGH-PRESSURE
FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH-PRESSURE
FUEL LINES. FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN
AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING.
NOTE: 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.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Cycle the ignition key on and off several times, leaving the key on for at least 10
seconds at a time.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 6
57
DRIVEABILITY - DIESEL