fuse MERCEDES-BENZ SPRINTER 2006 Manual PDF

TEST ACTION APPLICABILITY
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 high resistance.
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 high resistance.
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.
78
BRAKES (CAB)
SYSTEM UNDERVOLTAGE ÐContinued

9.0 CONNECTOR PINOUTS
BRAKE FLUID LEVEL SWITCHCAV CIRCUIT FUNCTION
1 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
2 16BR GROUND
BRAKE LAMP SWITCH C1 (EXCEPT ESP)CAV CIRCUIT FUNCTION
1 20WT BRAKE SWITCH OUTPUT
2 16RD/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 20BK/BL/RD BRAKE LAMP SWITCH
4- -
BRAKE LAMP SWITCH C2 (EXCEPT ESP) - BLACKCAV CIRCUIT FUNCTION
1 16BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 16BK/RD BRAKE LAMP SWITCH OUTPUT
3- -
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CONNECTOR PINOUTS

CONTROLLER ANTILOCK BRAKECAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
3- -
4- -
5 14BR GROUND
6 14RD FUSED B(+)
7- -
8 20BK/DG SENSOR SIGNAL
9 20YL/WT SENSOR SIGNAL
10 20YL/RD SENSOR SIGNAL
11 18BL/BK K-ABS/SHIFTER ASSEMBLY
12 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
13 - -
14 20WT LEFT REAR WHEEL SPEED SENSOR (+)
15 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)
16 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
17 - -
18 - -
19 - -
20 20WT BRAKE SWITCH OUTPUT
21 20BR GROUND
22 - -
23 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
24 20DG/WT CAN C BUS (+)
25 20BR SENSOR GROUND
26 20WT/GY BRAKE PRESSURE SENSOR SIGNAL
27 18BK/BL TCS SWITCH (ASR) SENSE
28 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
29 20BR LEFT REAR WHEEL SPEED SENSOR (-)
30 20BR RIGHT REAR WHEEL SPEED SENSOR (-)
31 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
32 18BK/RD BRAKE LAMP SWITCH OUTPUT
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 20RD/BL POWER INPUT
40 20DG CAN C BUS (-)
41 20DG/YL SENSOR SIGNAL
42 20WT/RD 5 VOLT SUPPLY
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CONNECTOR PINOUTS

INSTRUMENT CLUSTER C2 - WHITECAV CIRCUIT FUNCTION
1- -
2- -
3 20RD/YL FUSED B(+)
4 20BR/WT BRAKE WEAR SENSOR SIGNAL
5- -
6 18BR GROUND
7 20GY/DG/RD LAMP DRIVER
8 20BL/WT FUSED HIGH BEAM SWITCH OUTPUT
9 20BL/RD/WT VEHICLE SPEED SENSOR OUTPUT
10 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
12 - -
13 20BK/WT LEFT TURN SIGNAL
14 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
15 20BL GENERATOR FIELD DRIVER
16 20YL AIRBAG WARNING INDICATOR DRIVER
17 - -
18 20BL/VT D(+) RELAY NO. 1 CONTROL
18 20BL/VT D(+) RELAY NO. 1 CONTROL
STEERING ANGLE SENSORCAV CIRCUIT FUNCTION
1 20DG/WT CAN C BUS (-)
2- -
3 20DG CAN C BUS (+)
4- -
5 20BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
6 20BR GROUND
TCS SWITCH (ASR) - BLACKCAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2- -
3 18BK/BL TCS SWITCH (ASR) SENSE
4- -
5- -
6- -
7 16BK/BL/DG FUSED IGNITION SWITCH OUTPUT
8- -
9- -
10 16BR GROUND
WHEEL SPEED SENSOR-LEFT FRONTCAV CIRCUIT FUNCTION
1 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
2 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
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CONNECTOR PINOUTS

TABLE OF CONTENTS - Continued
*CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS...................233
*CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS....................234
*CHECKING THE POWER AND GROUNDS................................235
*ENGINE CRANKS BUT WILL NOT START.................................239
*ENGINE WILL NOT CRANK.............................................242
VERIFICATION TESTS
VERIFICATION TESTS..................................................246
8.0 COMPONENT LOCATIONS..............................................249
8.1CONTROL MODULES.............................................249
8.2CONTROLS AND SOLENOIDS......................................249
8.3DATA LINK CONNECTOR..........................................250
8.4SENSORS.......................................................251
8.5SWITCHES......................................................253
9.0 CONNECTOR PINOUTS................................................255
ACCELERATOR PEDAL POSITION SENSOR (OBD).........................255
AIRBAG CONTROL MODULE - YELLOW...................................255
BOOST PRESSURE SENSOR (OBD)......................................255
BOOST PRESSURE SERVOMOTOR (OBD)................................256
CAMSHAFT POSITION SENSOR - BLACK.................................256
CONTROLLER ANTILOCK BRAKE........................................257
CRANKCASE HEATER - BLACK..........................................257
CRANKSHAFT POSITION SENSOR - BLACK...............................258
DATA LINK CONNECTOR - BLACK........................................258
EGR VALVE - BLACK...................................................258
ENGINE CONTROL MODULE C1 (OBD)...................................259
ENGINE CONTROL MODULE C2 (OBD)...................................260
ENGINE COOLANT TEMPERATURE SENSOR - BLACK......................260
ENGINE OIL SENSOR - BLACK..........................................261
FUEL INJECTOR NO. 1 - BLACK.........................................261
FUEL INJECTOR NO. 2 - BLACK.........................................261
FUEL INJECTOR NO. 3 - BLACK.........................................261
FUEL INJECTOR NO. 4 - BLACK.........................................262
FUEL INJECTOR NO. 5 - BLACK.........................................262
FUEL PRESSURE SENSOR - BLACK.....................................262
FUEL PRESSURE SOLENOID............................................262
FUEL PUMP (OBD).....................................................262
FUEL PUMP RELAY (OBD)..............................................263
FUEL QUANTITY CONTROL VALVE (OBD).................................263
FUEL TEMPERATURE SENSOR..........................................263
ENGINE CONTROL RELAY (FUSE BLOCK NO. 1)...........................265
FUSES (FUSE BLOCK NO. 1)............................................265
FUSES (FUSE BLOCK NO. 2)............................................267
FUSES (FUSE/RELAY BLOCK)...........................................269
STARTER MOTOR RELAY (FUSE/RELAY BLOCK)...........................269
GLOW PLUG CONTROL MODULE C1 - BLACK.............................270
GLOW PLUG CONTROL MODULE C2 - BLACK.............................270
INTAKE AIR PRESSURE SENSOR (OBD)..................................270
INTAKE AIR TEMPERATURE SENSOR - BLACK............................270
x

TABLE OF CONTENTS - Continued
KICK DOWN SWITCH - BLACK...........................................271
MASS AIR FLOW SENSOR - BLACK......................................271
OXYGEN SENSOR (OBD)...............................................271
FUSED IGNITION SWITCH RUN-START RELAY (RELAY BLOCK)..............273
SPEED CONTROL SWITCH.............................................273
WATER IN FUEL SENSOR - BLACK.......................................273
10.0 SCHEMATIC DIAGRAMS................................................275
10.1ENGINE CONTROL MODULE.......................................275
10.2ENGINE CONTROL MODULE.......................................276
11.0 CHARTS AND GRAPHS................................................277
xi

service manual. Following these procedures is very
important to the safety of the individuals perform-
ing the 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 powertrain system are
intended to be serviced as an assembly only. At-
tempting to remove or repair certain system 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.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIITMULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLE FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND SPECIFICATION LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
± Do not use the DRBIIItif it has been dam-
aged.
± Do not use the test leads if the insulation is
damaged or if metal is exposed.
± To avoid electrical shock, do not touch the test
leads, tip or the circuit being tested.
± Choose the proper range and function for the
measurement. Do not try voltage or current
measurements that may exceed the rated ca-
pacity.
± Do not exceed the limits shown in the table
below:
FUNCTION INPUT LIMIT
Volts 0±500 peak volts AC
0±500 volts DC
Ohms (Resistance)* 0±1.12 megaohms
Frequency Measure
Frequency Generated0±10 kHz
Temperature ±58 ± +1100ÉF
±50 ± +600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only on a non-powered
circuit.± Voltage between any terminal and ground
must not exceed 500v DC or 500v peak AC.
± Use caution when measuring voltage above
25v DC or 25v AC.
± The circuit being tested must be protected by a
10 amp fuse or circuit breaker.
± Use the low current shunt to measure circuits
up to 10 amps. Use the high current shunt to
measure circuits exceeding 10 amps.
± When testing for the presence of voltage or
current, make sure the meter is functioning
correctly. Take a reading of a known voltage or
current before accepting a zero reading.
± When measuring current, connect the meter in
series with the load.
± Disconnect the live test lead before disconnect-
ing the common test lead.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not hang the DRBIIIT
from the rear view mirror. Do not attempt to
read the DRBIIITwhile driving. Have an
assistant available to operate the DRBIIIT.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is off. Failure to do so could
damage the module. When testing voltage or circuit
integrity at any control module, use the terminal
side (not the wire end) of the harness connector. Do
not probe through the insulation; this will damage
it and eventually cause it to fail because of corro-
sion.
Be careful when performing electrical test so as to
prevent accidental shorting of terminals. Such a
mistake can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box) scan tool
vacuum gauge
ammeter
9
GENERAL INFORMATION

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: 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.
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 DRBIIIt, erase the ECM DTCs.
Test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Does the DRB III display a Mass Air Flow Sensor DTC?All
Ye s!Go To 2
No!Go To 16
2NOTE: Check the ECM for other ECM DTC's related to circuits that are
open, shorted to ground or low voltage problems.
Does the DRB also display these type of DTC's?All
Ye s!Go To 3
No!Go To 4
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Turn the ignition on.
Connect a jumper wire between ground and the Engine Control Relay Signal circuit
in ECM C2 harness connector cavity 44.
Using a 12-volt test light connected to ground, check the Fused Engine Control Relay
Output circuits at the ECM C1 harness connector cavities 1, 3 and 5.
Does the test light illuminate brightly for each circuit?All
Ye s!Go To 4
No!Refer to symptom list and perform Checking the ECM Power and
Grounds.
Perform ROAD TEST VERIFICATION - VER-2.
4NOTE: A malfunctioning EGR system can cause this DTC to set. Refer to
symptom Checking the EGR System in the Driveability category to check
EGR system operation.
Turn the ignition off.
Disconnect the MAF Sensor harness connector.
Turn the ignition on.
Measure the voltage of the MAF Sensor 5 Volt Supply circuit in MAF Sensor harness
connector.
Is the voltage between 4.8 and 5.2 volts?All
Ye s!Go To 5
No!Go To 12
21
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW Ð
Continued

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
64
DRIVEABILITY - DIESEL
P0201-CYLINDER 1-INJECTOR CIRCUIT EXCESSIVE CURRENT Ð
Continued

TEST ACTION APPLICABILITY
3 Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Turn the ignition off.
Install a substitute relay in place of the Engine Control Relay.
Perform several ignition key cycles, pausing for at least 10 seconds between each
cycle.
Turn the ignition on.
With the DRB, read ECM DTCs.
Did this DTC set again?All
Ye s!Go To 4
No!Replace the Engine Control Relay.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Remove the Engine Control Relay.
Disconnect the ECM harness connectors.
Measure the resistance of the Engine Control Relay Control circuit while wiggling
the wiring harness and connectors between the ECM and the Fuse Block #1.
Was the resistance above 10.0 ohms at any time while wiggling the wiring harness
and connectors?All
Ye s!Repair the Engine Control Relay Control circuit for an intermit-
tent open.
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.
5WARNING: 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.
90
DRIVEABILITY - DIESEL
P1610-ENGINE CONTROL RELAY SHUTS OFF TOO EARLY ÐContinued