fuel MERCEDES-BENZ SPRINTER 2006 Manual Online

Symptom:
P2351-ECM SUPPLY VOLTAGE TOO LOW
POSSIBLE CAUSES
ECM
ECM IGNITION CIRCUIT OPEN
STARTER OR LIFT PUMP RELAY CIRCUIT(S) SHORTED TO GROUND
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.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Turn the ignition off for 10 seconds.
Test drive the vehicle.
Monitor the DRB for ECM DTCs.
Did this DTC set again?All
Ye s!Go To 2
No!Go To 4
2 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the Starter Relay and disconnect the Fuel Lift Pump harness connector
Measure the resistance between ground and the Starter Relay control circuit.
Measure the resistance between ground and the Fuel Lift Pump Relay control circuit.
Did both circuits measure above 1000 ohms?All
Ye s!Go To 3
No!Repair the relay control circuit(s) that did not measure above
1000 ohms for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
3 Turn the ignition off.
Disconnect the ECM harness connectors.
Using the Service Wiring Information determine which circuits in the ECM harness
connector provide Ignition Switch power to the ECM.
Turn the ignition on.
Using a 12-volt test light connected to ground, check each Ignition Switch Output
circuits in the ECM harness connectors.
Does the test light illuminate brightly for each circuit?All
Ye s!Replace the ECM in accordance with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Ignition Supply circuit as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
214
DRIVEABILITY - DIESEL

Symptom List:
P2531-FUEL INJECTOR 1 READ TOO LARGE
P2531-FUEL INJECTOR 1 READ TOO LARGE
P2531-FUEL INJECTOR 1 READ TOO SMALL
P2531-FUEL INJECTOR 1 READ TOO SMALL
P2532-FUEL INJECTOR 2 READ TOO LARGE
P2532-FUEL INJECTOR 2 READ TOO LARGE
P2532-FUEL INJECTOR 2 READ TOO SMALL
P2532-FUEL INJECTOR 2 READ TOO SMALL
P2533-FUEL INJECTOR 3 READ TOO LARGE
P2533-FUEL INJECTOR 3 READ TOO LARGE
P2533-FUEL INJECTOR 3 READ TOO SMALL
P2533-FUEL INJECTOR 3 READ TOO SMALL
P2534-FUEL INJECTOR 4 READ TOO LARGE
P2534-FUEL INJECTOR 4 READ TOO LARGE
P2534-FUEL INJECTOR 4 READ TOO SMALL
P2534-FUEL INJECTOR 4 READ TOO SMALL
P2535-FUEL INJECTOR 5 READ TOO LARGE
P2535-FUEL INJECTOR 5 READ TOO LARGE
P2535-FUEL INJECTOR 5 READ TOO SMALL
P2535-FUEL INJECTOR 5 READ TOO SMALL
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2531-FUEL INJECTOR 1 READ
TOO LARGE.
POSSIBLE CAUSES
FUEL INJECTOR
INTERMITTENT CONDITION
227
DRIVEABILITY - DIESEL

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.
NOTE: This DTC indicates an internal ECM problem except in the case of
DTC P0606 where it may indicate a fuel injector problem. Using the Service
Information, check the fuel injectors for leakage before replacing the ECM.
Turn the ignition on.
With the DRBIIIt, erase ECM DTCs.
Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIIIt, read the ECM DTCs.
Did this DTC set again?All
Ye s!Replace the Fuel Injector identified in the DTC in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 2
2WARNING: 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.
228
DRIVEABILITY - DIESEL
P2531-FUEL INJECTOR 1 READ TOO LARGE ÐContinued

Symptom:
*CHECKING THE FUEL PRESSURE SENSOR CIRCUITS
POSSIBLE CAUSES
OPEN CIRCUITS
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Fuel Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires. Repair as necessary.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals. Repair as necessary.
Measure the resistance of each of the three Fuel Pressure Sensor circuits between the
ECM harness connector and the Fuel Pressure Sensor harness connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Test Complete.
No!Repair open circuit(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
232
DRIVEABILITY - DIESEL

Symptom:
*CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
POSSIBLE CAUSES
FUEL PRESSURE SOLENOID RESISTANCE
OPEN CIRCUITS
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Disconnect the ECM harness connectors.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires. Repair as necessary.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals. Repair as necessary.
Measure the resistance of both Fuel Pressure Solenoid circuits between the ECM
harness connector and the Fuel Pressure Solenoid harness connector.
Is the resistance below 10.0 ohms for both measurements?All
Ye s!Go To 2
No!Repair open circuit(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
2 Turn the ignition off.
Disconnect the Fuel Pressure Solenoid harness connector.
Measure the resistance of the Fuel Pressure Solenoid.
Is the resistance between 3.5 and 5.5 ohms?All
Ye s!Test Complete.
No!Replace the Fuel Pressure Solenoid.
Perform ROAD TEST VERIFICATION - VER-2.
233
DRIVEABILITY - DIESEL

Symptom:
*CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS
POSSIBLE CAUSES
OPEN CIRCUITS
TEST ACTION APPLICABILITY
1 Turn the ignition off.
Disconnect the Fuel Quantity Solenoid harness connector.
Disconnect the ECM harness connectors.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires. Repair as necessary.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals. Repair as necessary.
Measure the resistance of both Fuel Quantity Solenoid circuits between the ECM
harness connector and the Fuel Quantity Solenoid harness connector.
Is the resistance below 10.0 ohms for both measurements?All
Ye s!Test Complete.
No!Repair open circuit(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
234
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
8 Turn the ignition off.
Remove and inspect Fuse #16 from Fuse Block No.1
Is the fuse open?All
Ye s!Go To 9
No!Go To 11
9 Turn the ignition off.
Disconnect the ECM harness connectors.
Install a good fuse in place of Fuse #16 in Fuse Block No.1
Connect a jumper wire between ground and the Engine Control Relay Control circuit
in ECM C2 harness connector cavity 44.
Remove and inspect Fuse #16 from Fuse Block No.1.
Is the fuse open?All
Ye s!Repair the Engine Control Relay Output circuit for a short to
ground.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 10
10 The Fuel Injectors, Crankcase Heater, Water In Fuel Sensor and related circuits can
cause Fuse #16 in Fuse Block No.1 to open. Use the Service Information Wiring
Diagrams and check these circuits/components for shorted circuits.
Were any problems found.All
Ye s!Repair or replace shorted circuit/component as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the ECM in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
11 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.
Test Complete.
Test light is on for 1 or 2 circuits
Repair the Engine Control Relay Output circuit(s) for an open.
Perform ROAD TEST VERIFICATION - VER-2.
Light off for all circuits.
Go To 12
237
DRIVEABILITY - DIESEL
*CHECKING THE POWER AND GROUNDS ÐContinued

Symptom:
*ENGINE CRANKS BUT WILL NOT START
POSSIBLE CAUSES
CAMSHAFT POSITION SENSOR SIGNAL PROBLEM
CRANKSHAFT POSITION SENSOR SIGNAL PROBLEM
ECM CODES PRESENT
ECT SENSOR
ENGINE CONTROL MODULE
ENGINE DRIVE GEAR/SPROCKET
FUEL SUPPLY CONTAMINATION
FUEL SYSTEM PRESSURE MECHANICAL
FUEL SYSTEM RESTRICTION
GLOW PLUGS
SKIM CODES PRESENT
TEST ACTION APPLICABILITY
1NOTE: The ECM must have proper power and ground connections for the
following tests to be valid. Refer to Checking the ECM Power and Grounds
in the symptom list.
NOTE: A no-start condition may occur if the Fuel Temperature Sensor is
shorted or if the Fuel Temperature Sensor Signal circuit is shorted to
ground or shorted to Sensor Ground.
Turn the ignition on.
With the DRBIIIt, read the ECM DTCs.
Does the DRBIIItdisplay any ECM DTCs?All
Ye s!Refer to symptom list for problems related to ECM DTC.
Perform NO START VERIFICATION - VER-1.
No!Go To 2
2 Turn the ignition on.
With the DRBIIIt, read the SKREEM DTCs.
Does the DRBIIItdisplay any SKREEM DTCs?All
Ye s!Refer to symptom list for problems related to SKIM DTC.
Perform NO START VERIFICATION - VER-1.
No!Go To 3
3 Using a temperature probe, check the vehicle temperature near the ECT Sensor.
Turn the ignition on.
With the DRBIIItin Sensors, read the ECT Sensor temperature.
Compare the temperature probe reading with the DRBIIItreading.
Are the two readings within 10ÉC of each other?All
Ye s!Go To 4
No!Repair as necessary.
Perform NO START VERIFICATION - VER-1.
239
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
4NOTE: Prior to performing this test, be sure to check the Glow Plug Relay
operation. Refer to CHECKING GLOW PLUG OPERATION for the related
symptom(s).
Refer to the Service Information and check the Glow Plugs for proper operation.
Are the Glow Plugs operating properly?All
Ye s!Go To 5
No!Repair as necessary.
Perform NO START VERIFICATION - VER-1.
5 Inspect the fuel system lines for restrictions, leaks or other problems.
NOTE: Refer to the Service Information to ensure that the fuel system is
properly primed. An unprimed system or excessive air in the supply system
will cause a no-start condition.
Is there any evidence of problems?All
Ye s!Repair as necessary.
Perform NO START VERIFICATION - VER-1.
No!Go To 6
6 Refer to the Service Information and perform the fuel pressure test.
Is the fuel pressure within specification?All
Ye s!Go To 7
No!Repair as necessary.
Perform NO START VERIFICATION - VER-1.
7 Inspect the fuel supply for contamination.
Is the fuel contaminated?All
Ye s!Refer to the Service Information to remove and replace fuel
throughout the fuel system.
Perform NO START VERIFICATION - VER-1.
No!Go To 8
8 Turn the ignition off.
Using the DRBIIItlab scope, backprobe the CMP Sensor Signal circuit at the ECM
harness connector.
Start the engine, if the engine will not start, crank the engine for several seconds
while monitoring the DRBIIIt.
NOTE: Refer to Charts and Graphs to view a correct CMP Sensor signal.
Does the DRBIIItdisplay a steady clean CMP Signal pattern?All
Ye s!Go To 9
No!Perform Test for DTC P2043-Camshaft Position Sensor Circuit
Static Plausibility.
Perform NO START VERIFICATION - VER-1.
240
DRIVEABILITY - DIESEL
*ENGINE CRANKS BUT WILL NOT START ÐContinued

ENGINE CONTROL MODULE C1 (OBD)CAV CIRCUIT FUNCTION
1 16BL FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
2 16BL/WT FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL
3 16DG FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
4 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
8 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
10 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
11 20GY/BL ENGINE OIL SENSOR SIGNAL
12 20BR/RD INTAKE PRESSURE SENSOR GROUND
13 20VT/DG INTAKE PRESSURE SENSOR SIGNAL
14 20BR/DG CAMSHAFT POSITION SENSOR GROUND
15 20DG/BK O2 1/1 PUMP CELL SIGNAL
20 18BK/YL WATER IN FUEL SENSOR SIGNAL
21 18BK/RD CRANKCASE HEATER SIGNAL
25 16BK FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
26 16BK/WT FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL
28 18RD/BK FUEL QUANTITY SOLENOID 12 VOLT SUPPLY
31 20YL/BL MASS AIR FLOW SENSOR GROUND
32 18DG/BK FUEL TEMPERATURE SENSOR GROUND
35 20BR/BK SENSOR GROUND
36 20VT/RD INTAKE PRESSURE SENSOR 5 VOLT SUPPLY
37 20RD/BL CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
38 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
39 20GY O2 1/1 SENSOR CELL SIGNAL
40 20GY/WT O2 1/1 VIRTUAL GROUND
49 16BK/VT FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
50 16BK/DG FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
51 16BK/YL FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
52 20BK/WT FUEL PRESSURE SOLENOID CONTROL
55 18BR WATER IN FUEL SENSOR GROUND
56 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
57 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
59 20DG/VT FUEL PRESSURE SENSOR SIGNAL
61 20BR/VT MASS AIR FLOW SENSOR 5 VOLT SUPPLY
62 20DG/YL O2 1/1 PUMP CELL CONTROL
72 20GY/BL O2 1/1 HEATER CONTROL
73 16BK/RD FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
74 16BK/BL FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
76 18BR/YL FUEL QUANTITY SOLENOID CONTROL
79 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
84 20BR/GY FUEL PRESSURE SENSOR GROUND
85 20YL/DG MASS AIR FLOW SENSOR SIGNAL
86 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
87 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
88 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
90 20DG/WT EGR VALVE CONTROL
91 18BK/BR CRANKCASE HEATER GROUND
93 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL
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CONNECTOR PINOUTS