check engine MERCEDES-BENZ SPRINTER 2006 Workshop Manual
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Page 487 of 2305
TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the ECM harness connectors.
Connect a jumper wire between ground and the Engine Control Relay Control circuit
in ECM C2 harness connector cavity 44.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Engine Control Relay
Output circuits at the ECM C2 harness connector cavities 1, 3 and 5.
Choose the appropriate result.All
Test light is on for all circuits.
Go To 3
Test light is on for 1 or 2 circuits
Repair the Engine Control Relay Output circuit(s) that did not
illuminate brightly for an open.
Perform ROAD TEST VERIFICATION - VER-2.
Light off for all circuits.
Refer to symptom Checking the ECM Power and Grounds.
Perform ROAD TEST VERIFICATION - VER-2.
3 Turn the ignition off.
Disconnect all of the Cylinder Fuel Injector harness connectors.
Disconnect the ECM harness connectors.
Remove the Engine Control Relay from Fuse Block No.1
Connect a jumper wire between cavity 30 and cavity 87 of the Engine Control Relay
connector in Fuse Block No.1.
Turn the ignition on.
Measure the voltage of all of the Fuel Injector Control circuit.
Is the voltage above 1.0 volt for any of the measurements?All
Ye s!Repair the appropriate Fuel Injector Control circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 4
4 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect all of the Fuel Injector harness connectors.
Measure the resistance between ground and all of the Fuel Injector Control circuit.
Is the resistance below 1000 ohms for any of the measurements?All
Ye s!Repair the Fuel Injector Control circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
5 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect all of the Cylinder Fuel Injector harness connectors.
Measure the resistance between Fuel Injector No. 1 harness connector cavities 1 and
2.
Repeat the previous step for injectors 2, 3, 4, and 5.
Is the resistance below 1000 ohms for any of the measurements?All
Ye s!Repair the Fuel Injector Control circuit and Common Driver
circuit for a short together.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 6
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DRIVEABILITY - DIESEL
P0201-CYLINDER 1-INJECTOR CIRCUIT EXCESSIVE CURRENT Ð
Continued
Page 489 of 2305
Symptom List:
P0300-MISFIRE DETECTED
P2113-MISFIRE CYLINDER #1
P2114-MISFIRE CYLINDER #2
P2115-MISFIRE CYLINDER #3
P2116-MISFIRE CYLINDER #4
P2117-MISFIRE CYLINDER #5
P2567-LEAKAGE CYLINDER #1
P2567-MISFIRE CYLINDER #1
P2568-LEAKAGE CYLINDER #2
P2568-MISFIRE CYLINDER #2
P2569-LEAKAGE CYLINDER #3
P2569-MISFIRE CYLINDER #3
P2570-LEAKAGE CYLINDER #4
P2570-MISFIRE CYLINDER #4
P2571-LEAKAGE CYLINDER #5
P2571-MISFIRE CYLINDER #5
P2573-GENERAL LEAKAGE
P2574-INJECTOR 1 INJECTION TIME ABOVE LIMIT
P2574-INJECTOR 1 INJECTION TIME BELOW LIMIT
P2575-INJECTOR 2 INJECTION TIME ABOVE LIMIT
P2575-INJECTOR 2 INJECTION TIME BELOW LIMIT
P2576-INJECTOR 3 INJECTION TIME ABOVE LIMIT
P2576-INJECTOR 3 INJECTION TIME BELOW LIMIT
P2577-INJECTOR 4 INJECTION TIME ABOVE LIMIT
P2577-INJECTOR 4 INJECTION TIME BELOW LIMIT
P2578-INJECTOR 5 INJECTION TIME ABOVE LIMIT
P2578-INJECTOR 5 INJECTION TIME BELOW LIMIT
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P0300-MISFIRE DETECTED.
When Monitored and Set Condition:
P0300-MISFIRE DETECTED
When Monitored: With the engine running.
Set Condition: The ECM detects multiple misfires from one or more cylinders.
POSSIBLE CAUSES
CHECKING FOR FUEL LEAKAGE
CHECKING INJECTOR CLASSIFICATION
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Page 490 of 2305
POSSIBLE CAUSES
CORRECTION QUANTITY CHECK
CYLINDER SPEED CHECK
ENGINE COMPRESSION
INJECTOR LEAKAGE
INTERMITTENT CONDITION
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.
With the DRBIIIt, erase ECM DTCs.
Test drive the vehicle and attempt to duplicate the problem.
With the DRB, read ECM DTC's.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 8
2 Start and idle the engine for 5 minutes.
Turn the ignition off.
Inspect the fuel rail, fuel pressure sensor, fuel pressure solenoid and all fuel injectors
for evidence of fuel leakage.
Is there fuel leakage near any of the injectors or the fuel rail?All
Ye s!Refer to the Service Information to repair fuel leakage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
3 Turn the ignition off.
With the DRBIIIt, perform the Cylinder Compression Test.
Is the cylinder compression within specification for all cylinders?All
Ye s!Go To 4
No!Repair as necessary in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Read and note the six-digit code located on the top of each injector.
Turn the ignition on.
With the DRBIIIt, check the current programmed injector classifications to the
six-digit codes from the vehicles current fuel injectors.
Are all of the Fuel Injectors classified correctly?All
Ye s!Go To 5
No!Using the DRB III, reset injectors to correct classification.
Perform ROAD TEST VERIFICATION - VER-2.
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DRIVEABILITY - DIESEL
P0300-MISFIRE DETECTED ÐContinued
Page 491 of 2305
TEST ACTION APPLICABILITY
5 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 6
6 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 7
7 Turn the ignition off.
Perform the INJECTOR LEAKAGE TEST in accordance with the Service Informa-
tion.
Were any problems found?All
Ye s!Repair or replace as necessary in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Test Complete.
8WARNING: 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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DRIVEABILITY - DIESEL
P0300-MISFIRE DETECTED ÐContinued
Page 492 of 2305
Symptom:
P0500-WHEEL SPEED SENSOR PLAUS - CAN BUS MESSAGE FROM
ABS
When Monitored and Set Condition:
P0500-WHEEL SPEED SENSOR PLAUS - CAN BUS MESSAGE FROM ABS
When Monitored: With the ignition on.
Set Condition: The Boost Pressure Sensor Signal voltage exceeds 4.85 volts for at least 2
seconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
CHECK FOR RELATED CONTROLLER ANTILOCK BRAKES DTCS
CHECK FOR RELATED TRANSMISSION CONTROL MODULE DTCS
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1NOTE: If the ECM displays multiple CAN Bus related DTC's, check the CAN
Bus circuits at the ECM harness connector for proper connection before
continuing with this test.
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.
Test drive the vehicle.
With the DRB, read the ECM DTC's.
Does the DRB display this DTC?All
Ye s!Go To 2
No!Go To 4
2 Turn the ignition on.
With the DRB, check for Controller Antilock Brakes DTCs.
NOTE: The ECM Receives vehicle speed messages via CAB Bus from the ABS
module. An interruption on the CAN Bus can cause this fault to set.
Are any related CAB DTCs present?All
Ye s!Refer to symptom list for problems related to CAB DTCs before
continuing.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 3
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DRIVEABILITY - DIESEL
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TEST ACTION APPLICABILITY
3NOTE: The TCM Receives vehicle speed messages via CAB Bus from the ABS
module. An interruption on the CAN Bus can cause this fault to set.
Turn the ignition on.
With the DRB, check the TCM for DTCs.
Are any ABS CAN Bus Message or Vehicle Speed related TCM DTCs present?All
Ye s!Replace the CAB in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
4WARNING: 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.
70
DRIVEABILITY - DIESEL
P0500-WHEEL SPEED SENSOR PLAUS - CAN BUS MESSAGE FROM ABS
Ð
Continued
Page 494 of 2305
Symptom:
P0600-CAN DATA BUS - BUS CIRCUIT FAULT
When Monitored and Set Condition:
P0600-CAN DATA BUS - BUS CIRCUIT FAULT
When Monitored: With the ignition on.
Set Condition: The ECM detects an open, short to ground or short to voltage on the CAN
Bus circuit.
POSSIBLE CAUSES
ENGINE CONTROL MODULE
INTERMITTENT CONDITION
CAN BUS COMMUNICATION DTCS
CAN BUS CIRCUITS OPEN TO TCM
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 DRBIIIt, erase the ECM DTCs.
Test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 4
2 With the DRBIIIt, read the active and stored DTCs for all modules that use CAN Bus
communication.
NOTE: Due to capabilities of certain controllers that use the CAN Bus, not
all modules report CAN Bus DTCs.
NOTE: If a total CAN Bus failure transpires, there will be multiple CAN Bus
DTCs present in many modules. If the other modules are reporting Engine
CAN Bus message faults or DTC's related to ECM CAN messages ONLY,
answer No for the following question.
Are other modules reporting active or stored CAN Bus communication DTCs?All
Ye s!Refer to symptom list for problems related to CAN Bus Failure.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
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DRIVEABILITY - DIESEL
Page 495 of 2305
TEST ACTION APPLICABILITY
3 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the ECM harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance of both the CAN C Bus (+) circuit and the CAN C Bus (-)
circuit between the TCM C2 harness connector and ECM harness connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Replace the Engine Control Module in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the CAN C Bus (+) and/or CAN C Bus (-) circuit for an
open.
Perform BODY VERIFICATION TEST - VER 1.
4WARNING: 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 BODY VERIFICATION TEST - VER 1.
No!Test Complete.
72
DRIVEABILITY - DIESEL
P0600-CAN DATA BUS - BUS CIRCUIT FAULT ÐContinued
Page 497 of 2305
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 APP Sensor is a device that contains 2 separate potentiometer
type sensors. Each sensor has its own 5-volt supply circuit, sensor ground
circuit and signal circuit. The APP Sensor no longer incorporates a low-idle
switch.
NOTE: The APP Sensor 2 signal should always be approximately 1/2 the
voltage of the APP Sensor 1 signal.
Turn the ignition on.
Using a voltmeter, backprobe the APP Sensor 1 and APP Sensor 2 Signal circuits at
the APP Sensor harness connector with the accelerator pedal in the at rest position.
Is the voltage between 0.28 and 0.37 volt for sensor 1 and 0.10 and 0.19 volt for sensor
2?All
Ye s!Go To 2
No!Go To 5
2 Turn the ignition on.
Fully depress the accelerator pedal.
Using a voltmeter backprobe the APP Sensor harness connector and read the voltage
for APP Sensor 1 and APP Sensor 2 Signal circuits.
Is the voltage between 4.45 and 4.75 volts for #1 and 2.15 and 2.45 volts for #2?All
Ye s!Go To 3
No!Go To 5
3 Turn the ignition on.
With the DRB, read the APP Sensor 1 and APP Sensor 2 percentages (%).
With the accelerator pedal in the idle position, slowly depress the accelerator pedal
until the pedal is fully depressed.
NOTE: The percentage readings for APP Sensors 1 and 2 should increase
smoothly as the pedal is depressed.
NOTE: This test can also performed using a voltmeter by back probing each
APP Sensor Signal circuit at the APP Sensor harness connector and
observing the voltmeter for a smooth voltage change through the entire
pedal travel.
Does the percentage (voltage) increase smoothly for both readings with the acceler-
ator pedal travel?All
Ye s!Go To 4
No!Replace the Accelerator Pedal Position Sensor in accordance with
the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
74
DRIVEABILITY - DIESEL
P1222-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued
Page 499 of 2305
TEST ACTION APPLICABILITY
8 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit between the APP Sensor and the
ECM.
Is the resistance below 10.0 ohms?All
Ye s!Go To 9
No!Repair the APP Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
9 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Using a 12-volt test light connected to 12-volts, check the Sensor Ground circuit of
the appropriate potentiometer.
Does the test light illuminate brightly?All
Ye s!Replace the Accelerator Pedal Position Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
10 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the APP Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 11
No!Repair the APP Sensor Signal circuit for an open
Perform ROAD TEST VERIFICATION - VER-2.
11 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the APP Sensor Signal circuit.
Is the resistance below 1000 ohms?All
Ye s!Repair the APP Sensor Signal circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 12
12 Turn the ignition off.
Disconnect the APP Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the APP Sensor Signal circuit and the Sensor
Ground circuit at the APP Sensor harness connector.
Is the resistance below 1000 ohms?All
Ye s!Repair the APP Sensor Signal and Sensor Ground circuits for a
short together.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 13
76
DRIVEABILITY - DIESEL
P1222-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ÐContinued