fuel MERCEDES-BENZ SPRINTER 2006 Workshop Manual

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
66
DRIVEABILITY - DIESEL

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.
67
DRIVEABILITY - DIESEL
P0300-MISFIRE DETECTED ÐContinued

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.
68
DRIVEABILITY - DIESEL
P0300-MISFIRE DETECTED ÐContinued

Symptom List:
P2009-WATER IN FUEL SENSOR - WATER IN FUEL
P2009-WATER IN FUEL SENSOR SIGNAL ERROR
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2009-WATER IN FUEL SENSOR
- WATER IN FUEL.
POSSIBLE CAUSES
12-VOLT SUPPLY CIRCUIT OPEN
CHECKING ECM POWER AND GROUNDS
CHECKING THE ENGINE CONTROL RELAY SYSTEM
ECM - WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - WATER IN FUEL SENSOR SIGNAL SHORT TO GROUND
SENSOR GROUND CIRCUIT OPEN
WATER IN FUEL SENSOR FAILURE
WATER IN FUEL SENSOR SIGNAL CIRCUIT OPEN
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO 12-VOLT SUPPLY
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTERMITTENT CONDITION
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: If you are here due to a P2009 indicating(Water In The Fuel Filter(
DTC, ensure that the fuel system is not contaminated with water or other
fluids before continuing.
NOTE: If the fuel system is contaminated, refer to the Service Information
to remove fuel, clean system and refill with known good fuel.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Start the engine several times, letting the engine run for at least 30 seconds at a
time.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 11
106
DRIVEABILITY - DIESEL

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 the Water In Fuel Sensor harness connector.
Turn the ignition on.
Measure the voltage of the Water In Fuel Sensor Signal circuit.
Select the appropriate voltage reading.All
Voltage is above 5.4 volts.
Go To 4
Voltage is between 4.7 and 5.4 volts.
Go To 6
Voltage is below 4.7 volts.
Go To 8
4 Turn the ignition off.
Disconnect the In Fuel Level 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 Water In Fuel Sensor Signal circuit.
Is the voltage below 1.0 volt?All
Ye s!Go To 5
No!Repair the Water In Fuel Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
107
DRIVEABILITY - DIESEL
P2009-WATER IN FUEL SENSOR - WATER IN FUEL ÐContinued

TEST ACTION APPLICABILITY
5 Turn the ignition off.
Disconnect the Water In Fuel Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance between the 12-volt supply circuit and the Water In Fuel
Sensor Signal 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 Water In Fuel Sensor Signal circuit for a short to the
12-volt Supply circuit.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the 12-Volt Supply circuit between the ECM harness
connector and the Water In Fuel Sensor harness connector.
Is the resistance below 10.0 ohms?All
Ye s!Go To 7
No!Repair the 12-Volt Supply circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Replace the Water In Fuel Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
8 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance of the Water In Fuel Sensor Signal circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 9
No!Repair the Water In Fuel Sensor Signal circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
9 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance between ground and the Water In Fuel Sensor Signal circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 10
No!Repair the Water In Fuel Sensor Signal circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
108
DRIVEABILITY - DIESEL
P2009-WATER IN FUEL SENSOR - WATER IN FUEL ÐContinued

TEST ACTION APPLICABILITY
10 Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Water In Fuel Sensor harness connector.
Measure the resistance between Sensor Ground and the Water In Fuel Sensor Signal
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 Water In Fuel Sensor Signal circuit for a short to the
Sensor Ground circuit.
Perform ROAD TEST VERIFICATION - VER-2.
11WARNING: 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.
109
DRIVEABILITY - DIESEL
P2009-WATER IN FUEL SENSOR - WATER IN FUEL ÐContinued

Symptom List:
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL
FLOW EXCEEDED
P2016-FUEL RAIL PRESSURE MALFUNCTION DECELERATION
ERROR
P2016-FUEL RAIL PRESSURE MALFUNCTION FUEL FLOW BE-
LOW MINIMUM QUANTITY
P2017-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS
TOO LOW
P2018-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS
TOO HIGH
P2019-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL
PRESSURE EXCEEDED
P2019-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS
TOO LOW
P2020-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE IS
TOO LOW
P2020-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE
TOO HIGH
P2021-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE
TOO LOW
P2023-FUEL RAIL PRESSURE MALFUNCTION RAIL PRESSURE
TOO HIGH
P2047-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL
PRESSURE EXCEEDED
P2049-FUEL RAIL PRESSURE MALFUNCTION DECELERATION
ERROR
P2051-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL
PRESSURE EXCEEDED
P2052-FUEL RAIL PRESSURE MALFUNCTION PLAUSIBILITY
WITH FUEL PRESSURE SOLENOID
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2015-FUEL RAIL PRESSURE
MALFUNCTION MAXIMUM FUEL FLOW EXCEEDED.
POSSIBLE CAUSES
AIR IN FUEL SYSTEM
CHECKING ELECTRICAL CIRCUITS-ENGINE RUNNING
CHECKING ELECTRICAL CIRCUITS-NO START
CHECKING FOR OTHER DTC'S
CHECKING THE FUEL DELIVERY SYSTEM
11 7
DRIVEABILITY - DIESEL

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
11 8
DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

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
11 9
DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued