ECU MERCEDES-BENZ SPRINTER 2006 Workshop Manual

Symptom:
SIREN INTERNAL FAILURE
When Monitored and Set Condition:
SIREN INTERNAL FAILURE
When Monitored: Whenever the battery voltage is above 10.0 volts and the Security
System Module is connected.
Set Condition: If the Siren internal test fails this DTC will set.
POSSIBLE CAUSES
DTC PRESENT
SIREN ACTUATION
SIREN
TEST ACTION APPLICABILITY
1 With the DRBIIIt, record and erase DTC's.
Remove the ignition key.
Close and lock all doors and set the Vehicle Theft Security System.
Wait 1 minute.
Disarm the Vehicle Theft System.
With the DRBIIIt, read DTC's.
Does the DRBIIItdisplay the same DTC?All
Ye s!Go To 2
No!Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors for an intermittent condition.
Perform BODY VERIFICATION TEST - VER 1.
2 With the DRBIIIt, actuate the Siren.
Did the siren sound with the actuation and does the Siren function properly
otherwise?All
Ye s!This DTC can be ignored if there are no other complaints with the
operation of the Siren.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Siren.
Perform BODY VERIFICATION TEST - VER 1.
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VEHICLE THEFT/SECURITY

Symptom:
SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND
When Monitored and Set Condition:
SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND
When Monitored: Whenever the battery voltage is above 10.0 volts and the Security
System Module is connected.
Set Condition: The Security System Module detects a short to ground on the Siren Signal
Control circuit.
POSSIBLE CAUSES
DTC PRESENT
SIREN SIGNAL CONTROL WIRE SHORTED
SIREN
TEST ACTION APPLICABILITY
1 With the DRBIIIt, record and erase DTC's.
Remove the ignition key.
Close and lock all doors and set the Vehicle Theft Security System.
Wait 1 minute.
Disarm the Vehicle Theft System.
With the DRBIIIt, read DTC's.
Does the DRBIIItdisplay the same DTC?All
Ye s!Go To 2
No!Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors for an intermittent condition.
Perform BODY VERIFICATION TEST - VER 1.
2 Disconnect the Siren connector.
Disconnect the Security System Module C2 connector.
Measure the resistance between ground and the Siren Signal Control circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the Siren Signal Control circuit for a short to ground.
Perform BODY VERIFICATION TEST - VER 1.
No!Replace the Siren.
Perform BODY VERIFICATION TEST - VER 1.
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VEHICLE THEFT/SECURITY

Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the ignition off.
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from
ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system
that was malfunctioning.
5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read
DTC's from ALL modules.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. NOTE: If the CAB/HCU was replaced, ensure the CAB has been initialized
8. NOTE: If the SKREEM or ECM was replaced, refer to the service information for
proper programming procedures.
9. NOTE: For Sensor Circuit/Signal and Pump Motor faults, the CAB must sense all 4
wheels at 12 km/h (8 mph) before it will extinguish the ABS Indicator.
10. If there are no DTC's present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
11. CAUTION: Ensure braking capability is available before road testing.
12. Again, with the DRBIIItread DTC's. If any DTC's are present, return to Symptom list.
13. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can
no longer be duplicated, the repair is complete.
Are any DTC's present or is the original concern still present?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
AIRBAG VERIFICATION TEST - VER 1 APPLICABILITY
1. Remove any special tools or jumper wires and reconnect all previously disconnected
components - except the Battery.
2. WARNING: TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON,
THEN RECONNECT THE BATTERY.
3. Connect the DRBIIItto the Data Link Connector - use the most current software available.
4. Use the DRBIIItand erase the stored codes in all airbag system modules.
5. Turn the ignition off, and wait 15 seconds, then turn the ignition on.
6. Wait one minute, and read active codes and if there are none present read the stored codes.
7. Note: If equipped with Airbag On - Off switch, read the DTC's in all switch positions.
8. Note: Read the DTC's in all airbag system related modules.
9. If the DRBIIItshows any active or stored codes, return to the Symptom list and follow path
specified for that trouble code. If no active or stored codes are present, the repair is complete.
Are any DTC's present or is the original condition still present?All
YES
Repair is not complete, refer to appropriate symptom list.
NO
Repair is complete.
244
VERIFICATION TESTS

HEATER VERIFICATION TEST - VER 1 APPLICABILITY
1. WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES
NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE HEATER's
EXHAUST WHEN OPERATING THE HEATER. FAILURE TO FOLLOW THESE IN-
STRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
3. NOTE: The heater's control unit will store up to five DTCs in its memory.
4. NOTE: If the heater's control unit detects a new fault in the system, one that is not
already stored in its memory, it will clear the oldest of the five stored DTCs, and it
will store the new fault's DTC.
5. NOTE: If the heater's control unit detects a reoccurrence of a stored fault, it will
overwrite that fault's DTC with the most recent occurrence.
6. Verify that the vehicle's battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank. Add fuel, if
necessary.
8. Verify that all heater's coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of air
in accordance with the Service Information.
11. Turn the ignition on.
12. Verify that the Cabin Heater or Heater Booster is switched off.
13. Ensure that all accessories are turned off.
14. Set the blend control to the max heat position and the mode control to the floor position.
15. If a fuel system service requiring fuel to drain out of the heater's fuel line was performed,
prime the heater's Dosing Pump in accordance with the Service Information.
16. With the DRBIIIt, record and erase all DTCs from the Cabin Heater Module or Heater
Booster Module. Turn the ignition off, wait 5 seconds, then turn start the engine.
17. Allow the engine to idle.
18. NOTE: Do not disconnect the vehicle's battery or the heater's main power supply
while the heater is in operation or in run-down mode. Failure to follow these
instructions can result in excess emissions from the heater during heater operation.
19. Switch the Cabin Heater or Heater Booster on. Allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then turn the heater off.
20. With the DRBIIIt, read the Cabin Heater or Heater Booster Module's DTC.
21. Turn the engine off.
Are any DTC's present or is the original condition still present?All
Ye s!Repair is not complete, refer to the appropriate symptom.
No!Repair is complete.
246
VERIFICATION TESTS
Verification Tests ÐContinued

8.8.5 DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS
8.9 VEHICLE THEFT SECURITY SYSTEM
8.9.1 SECURITY SYSTEM MODULE
8.9.2 INTRUSION SENSORS
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COMPONENT LOCATIONS
8.8 POWER DOOR LOCKS/RKE (Continued)

SEAT BELT TENSIONER-DRIVER - YELLOWCAV CIRCUIT FUNCTION
1 20BL DRIVER SEAT BELT TENSIONER LINE 2
2 20BR/YL DRIVER SEAT BELT TENSIONER LINE 1
SEAT BELT TENSIONER-PASSENGER - YELLOWCAV CIRCUIT FUNCTION
1 20BL PASSENGER SEAT BELT TENSIONER LINE 2
2 20BR PASSENGER SEAT BELT TENSIONER LINE 1
SECURITY SYSTEM MODULE C1 - BROWNCAV CIRCUIT FUNCTION
1 16BK/WT LEFT TURN SIGNAL
2- -
3- -
4 16BK/DG RIGHT TURN SIGNAL
5 16BK/VT FAN STAGE 1 RELAY
6 16WT/RD WARM AIR AUXILIARY HEATER CONTROL
7 16RD/GY FUSED B(+)
8 16BK/GY FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
9 18VT/DG TOWING/INTRUSION SENSOR INDICATOR DRIVER
10 - -
11 16BR/YL FRONT COURTESY LAMPS CONTROL
12 16BR/WT DOOR AJAR SWITCH SENSE
13 16RD/DG FUSED B(+)
14 16BK/BL HOOD AJAR SWITCH SENSE
15 18GY/WT PANIC SWITCH SENSE
16 16BR GROUND
17 18GY/BR TOWING SENSOR SWITCH SENSE
18 18GY/YL INTRUSION SENSOR SWITCH SENSE
19 - -
20 16BK DRIVER CYLINDER UNLOCK SENSE
21 16RD DRIVER CYLINDER LOCK SENSEC
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CONNECTOR PINOUTS

SECURITY SYSTEM MODULE C2 - LT. GREENCAV CIRCUIT FUNCTION
1 16DG/YL INTRUSION SENSOR INTERFACE
2 16GY/BL WINDOW DEFOGGER-LEFT REAR OUTPUT
3 16GY WINDOW DEFOGGER RELAY-RIGHT REAR OUTPUT
4 20DG/BK INTRUSION SENSOR 1 SIGNAL
5- -
6- -
7 20GY/BK INTRUSION SENSOR 2 SIGNAL
8 16GY/DG K-CTM/SSM
9 18BK/BL SIREN SIGNAL CONTROL
10 20DG/WT/BL INTRUSION SENSOR 3 SIGNAL
11 16WT/BL RKE INTERFACE
12 16WT/BL/RD SECURITY SYSTEM INTERFACE
SENTRY KEY REMOTE ENTRY MODULE (SKREEM)CAV CIRCUIT FUNCTION
1 18YL RKE ANTENNA
2 16BR GROUND
3 16RD/YL FUSED B(+)
4 16BK/WT LEFT TURN SIGNAL
5 20DG/WT CAN C BUS (+)
6 20DG CAN C BUS (-)
7 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20WT/DG K-SKREEM
9 16WT/BL/RD (EXCEPT
VTSS)RKE INTERFACE
9 16WT/BL/RD (VTSS) SECURITY SYSTEM INTERFACE
10 18DG/YL TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT/RIGHT CONTROL
11 20BR TRANSPONDER COIL (+)
12 - TRANSPONDER COIL (-)
SHIFTER ASSEMBLY - BLACKCAV CIRCUIT FUNCTION
1- -
2 20GY/DG/RD LAMP DRIVER
3 20BL/DG K-ABS/SHIFTER ASSEMBLY
4 18BR GROUND
5 20BK/BL/RD BRAKE LAMP SWITCH
6 20DG/WT CAN C BUS (+)
7 20DG CAN C BUS (-)
8 18BK/DG TRANSMISSION RELAY OUTPUT
9 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 16WT/RD BACK-UP LAMP
SIREN - BLACKCAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
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CONNECTOR PINOUTS

10.6 VEHICLE THEFT SECURITY SYSTEM
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SCHEMATIC DIAGRAMS

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

Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the ignition off.
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from
ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system
that was malfunctioning.
5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read
DTC's from ALL modules.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. NOTE: If the CAB/HCU was replaced, ensure the CAB has been initialized
8. NOTE: If the SKREEM or ECM was replaced, refer to the service information for
proper programming procedures.
9. NOTE: For Sensor Circuit/Signal and Pump Motor faults, the CAB must sense all 4
wheels at 12 km/h (8 mph) before it will extinguish the ABS Indicator.
10. If there are no DTC's present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
11. CAUTION: Ensure braking capability is available before road testing.
12. Again, with the DRBIIItread DTC's. If any DTC's are present, return to Symptom list.
13. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can
no longer be duplicated, the repair is complete.
Are any DTC's present or is the original concern still present?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
79
VERIFICATION TESTS