wiring MERCEDES-BENZ SPRINTER 2006 Repair Manual

Symptom:
SECURITY SYSTEM INTERFACE FAILURE - SSM
When Monitored and Set Condition:
SECURITY SYSTEM INTERFACE FAILURE - SSM
When Monitored: Whenever the battery voltage is above 10.0 volts and the Security
System Module is connected.
Set Condition: If the Security System Module senses a poor or no connection to the Sentry
Key Remote Entry Module, this code will set.
POSSIBLE CAUSES
DTC PRESENT
SENTRY KEY REMOTE MODULE MODULE SHORTED
SECURITY SYSTEM INTERFACE WIRE SHORTED
SECURITY SYSTEM INTERFACE WIRE OPEN
SECURITY SYSTEM MODULE FAILURE
TEST ACTION APPLICABILITY
1 With the DRBIIIt, record and erase DTC's.
Cycle the ignition switch from ON to OFF to ON.
With the DRBIIIt, read DTC's.
Using the RKE transmitter, operate the Door Locks several times while observing the
DRBIIIt.
Wait 10 seconds.
Does the DRBIIItdisplay SECURITY SYSTEM INTERFACE CIRCUIT FAILURE?All
Ye s!Go To 2
No!Using the wiring diagram/schematic as a guide, inspect the
wiring and connectors for an intermittent condition. Using the
RKE transmitter, operate the door locks several times and re-
check for any DTC's.
Perform BODY VERIFICATION TEST - VER 1.
2 Turn the ignition off.
Disconnect the SENTRY KEY REMOTE ENTRY MODULE connector.
Measure the resistance between ground and the Security System Interface circuit.
Is the resistance between 5200.0 (5.2K) and 6800.0 (6.8K) ohms?All
Ye s!Replace the Sentry Key Remote Entry Module.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
233
VEHICLE THEFT/SECURITY

Symptom:
SIREN CIRCUIT OPEN/SHORTED TO GROUND
When Monitored and Set Condition:
SIREN CIRCUIT OPEN/SHORTED 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 the incorrect voltage on the Siren
Signal Control circuit.
POSSIBLE CAUSES
DTC PRESENT
FUSE 2 IN FUSE BLOCK 3
FUSED B(+) WIRE OPEN
GROUND CIRCUIT OPEN
SIREN SIGNAL CONTROL WIRE SHORTED
SIREN SIGNAL CONTROL WIRE OPEN
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 Check Fuse 2 in Fuse Block 3.
Is the fuse open?All
Ye s!Check for a short to ground and replace the fuse.
Perform BODY VERIFICATION TEST - VER 1.
No!Go To 3
3 Disconnect the Siren connector.
Measure the voltage of the Fused B(+) circuit.
Is the voltage above 10.0 volts?All
Ye s!Go To 4
No!Repair the Fused B(+) circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
235
VEHICLE THEFT/SECURITY

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.
237
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.
238
VEHICLE THEFT/SECURITY

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

ver: 2.14
date: 26 Jul93
file: key_iff.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.9.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage (data link
16-way connector cavity 16). A minimum of 11 volts
is required to adequately power the DRBIIIt. Also
check for a good ground at DLC.
If all connections are proper between the
DRBIIItand the vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
DRBIIItmay be the result or a faulty cable or
vehicle wiring.
3.9.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latestinformation available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive
vehicles; the parking brake does not hold the front
drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing an antilock brake or adjustable
pedals system problem, it is important to follow
approved procedures where applicable. These pro-
cedures can be found in the service manual. Follow-
ing these procedures is very important to safety of
individuals performing diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the antilock brake and trac-
tion control are intended to be serviced in assembly
only. Attempting to remove or repair certain sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
5
GENERAL INFORMATION

TEST ACTION APPLICABILITY
6 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
12
BRAKES (CAB)
ANTI-LOCK BRAKE MODULE INTERNAL ÐContinued

TEST ACTION APPLICABILITY
4 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
No!Test Complete.
14
BRAKES (CAB)
BRAKE FLUID LEVEL ÐContinued

TEST ACTION APPLICABILITY
2NOTE: This DTC will set if the Brake Switch, the Brake Lamp Switch, or
both switches are inoperative. It will be necessary to verify the functional-
ity of each switch.
NOTE: If the Brake Switch and the Brake Lamp Switch are inoperative, it
will be necessary to diagnose BOTH circuits.
Turn the ignition off.
Turn the ignition on.
With the DRBIIItin Inputs/Outputs, monitor the Brake Switch state while pressing
and releasing the brake pedal.
Does the DRBIIItdisplay change from CLOSED to OPEN as the brake pedal is
pressed and released?All
Ye s!Go To 3
No!Go To 4
3 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
4 Turn the ignition off.
Disconnect the C1 Brake Switch harness connector.
Turn the ignition on.
With the DRBIIItin Inputs/Outputs, monitor the Brake Switch state.
Connect a jumper wire between the Fused Ignition Switch Output circuit and Brake
Switch Output circuit in the C1 Brake Switch harness connector.
Does the DRBIIItdisplay a change from OPEN to CLOSED?All
Ye s!Replace the Brake Switch in accordance with the Service Infor-
mation.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 6
5 Turn the ignition off.
Disconnect the C2 Brake Lamp Switch harness connector.
Turn the ignition on.
With the DRBIIItin Inputs/Outputs, monitor the Brake Lamp Switch state.
Connect a jumper wire between the Fused Ignition Switch Output circuit and Brake
Lamp Switch Output circuit in the C2 Brake Lamp Switch harness connector.
Does the DRBIIItdisplay a change from OPEN to CLOSED?All
Ye s!Replace the Brake Lamp Switch in accordance with the Service
Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Go To 6
18
BRAKES (CAB)
BRAKE SWITCH CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the CAB harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fused Optional Equipment
Relay Output circuit at the CAB harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Go To 4
No!Repair the Fused Optional Equipment Relay Output circuit for an
open.
Perform ABS VERIFICATION TEST - VER 1.
4 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to ground, check both Fused B(+) circuits at the
CAB harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Go To 5
No!Repair the Fused B(+) circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the CAB harness connector.
Using a 12-volt test light connected to 12-volts, check the CAB harness connector
Ground circuits.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s!Replace the Controller Antilock Brake in accordance with the
Service Information.
Perform ABS VERIFICATION TEST - VER 1.
No!Repair the Ground circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
6 Turn the ignition off.
Visually inspect the related wiring harness.
Look for any chafed, pierced, pinched, or partially broken wires.
Look for broken, bent, pushed out, or corroded terminals.
Were any problems found?All
Ye s!Repair as necessary.
Perform ABS VERIFICATION TEST - VER 1.
No!Test Complete.
22
BRAKES (CAB)
CAB CHECK SUM ÐContinued