MERCEDES-BENZ SPRINTER 2006 Service Manual

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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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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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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TEST ACTION APPLICABILITY
8 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, failed fuel lift pump, failed fuel sending unit, contami-
nated 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 9
9 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 10
10NOTE: 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 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 11
11 With the DRBIIIt, select System Test, Smooth Eng Run Check, then Correction
Quantity Check.
Perform this test at Idle, 2000 rpm and 3000 rpm.
NOTE: Readings per cylinder should be below   0.00450 mm
3/stroke for each
cylinder at each engine speed.
Did any of the cylinders exceed   0.00450 mm
3/stroke during this test?All
Ye s!Replace Fuel Injector of the cylinder(s) that had readings above  
0.00450 mm
3/stroke.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 12
12 With the DRBIIIt, select System Test, Smooth Eng Run Check, then Cylinder Speed
Check.
NOTE: Readings for all cylinders should be close to each other. Look for one
or two cylinders to differ high or low from the other cylinders.
Did any of the cylinders differ significantly from the majority of the other cylinders?All
Ye s!Replace Fuel Injector of the cylinder(s) that had readings signif-
icantly above or below the other fuel injectors.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 13
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TEST ACTION APPLICABILITY
13 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Test.
Did this test pass?All
Ye s!Go To 14
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
14 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Variation Test.
Did this test pass?All
Ye s!Go To 15
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
15 With the DRBIIIt, select System Test, then High Pressure Pump.
NOTE: During this test engine speed is set at 1,400 rpm and initial fuel
pressure at approximately 6,800 psi. During the test fuel pressure is
instantly set to above 20,000 psi. to test the performance of the Fuel
Injection Pump.
NOTE: After the test is completed, the DRB display fuel pressure in 30
counter steps. If the fuel pressure increases from approximately 6,800 psi to
above 20,000 psi in one counter step, the injection pump passes the test.
Did the fuel pressure increase to above 20,000 psi within one counter step on the
DRB?All
Ye s!Replace the Fuel Quantity Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace Fuel Injection Pump in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
16WARNING: 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 IIIt
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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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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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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Symptom:
P2025-INTAKE PRESSURE SENSOR PLAUSIBILITY
When Monitored and Set Condition:
P2025-INTAKE PRESSURE SENSOR PLAUSIBILITY
When Monitored: With the ignition on.
Set Condition: The Intake Pressure Sensor signal does not agree with the Atmospheric
Pressure Sensor signal in the ECM.
POSSIBLE CAUSES
AIR FILTER
AIR RESTRICTION
INTERMITTENT CONDITION
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR SIGNAL CIRCUIT
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR GROUND CIRCUIT
HIGH RESISTANCE IN THE INTAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT
ENGINE CONTROL MODULE
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.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Turn the ignition off, wait 30 seconds.
Test drive the vehicle.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 7
2 Turn the ignition off.
Remove and inspect the Air Filter for soiling or excessive dirt and debris which may
cause air flow restriction.
Were any of these problems found?All
Ye s!Replace the Air Filter element.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
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TEST ACTION APPLICABILITY
3NOTE: Inspect all air intake and turbocharger related tubes for damage,
restriction or poor connection. Any of these conditions can cause a this DTC
to set.
Turn the ignition off.
Inspect all air intake and turbocharger related tubes and connections.
were any problems found?All
Ye s!Repair or replace as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Intake Pressure Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 5
No!Repair the Intake Pressure Sensor Signal circuit for high resis-
tance.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Disconnect the Intake 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 6
No!Repair the Intake Pressure Sensor Ground circuit for high resis-
tance.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Intake Pressure Sensor 5-volt Supply 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 Intake Pressure Sensor 5 Volt Supply circuit for high
resistance.
Perform ROAD TEST VERIFICATION - VER-2.
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TEST ACTION APPLICABILITY
7WARNING: 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.
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