warning MERCEDES-BENZ SPRINTER 2006 Manual Online

Symptom:
OVER VOLTAGE
When Monitored and Set Condition:
OVER VOLTAGE
When Monitored: With the engine running.
Set Condition: This DTC will set if the heater's power supply exceed 15.9 volts for longer
than 20 seconds.
POSSIBLE CAUSES
VEHICLE'S CHARGING SYSTEM OVERCHARGING
CABIN HEATER OR HEATER BOOSTER CONTROL UNIT
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY THE
HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST PRIOR TO
PERFORMING ANY OTHER TEST FOR THE RESULT TO BE VALID.
Check the vehicle's charging system for proper operation in accordance with the
Service Information.
Is the vehicle's charging system operating properly?All
Ye s!Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
No!Repair the vehicle's charging system in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
96
CABIN HEATER

Symptom List:
OVERHEATING SENSOR OPEN
OVERHEATING SENSOR SHORTED
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be OVERHEATING SENSOR OPEN.
When Monitored and Set Condition:
OVERHEATING SENSOR OPEN
When Monitored: During heater activation and operation.
Set Condition: This DTC will set if the Overheating Sensor's resistance is not within the
expected parameters.
OVERHEATING SENSOR SHORTED
When Monitored: During heater activation and operation.
Set Condition: This DTC will set if the Overheating Sensor's resistance is not within the
expected parameters.
POSSIBLE CAUSES
OVERHEATING SENSOR
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
View repairAll
Repair
Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
97
CABIN HEATER

Symptom List:
TEMP SENSOR OPEN
TEMP SENSOR SHORTED
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be TEMP SENSOR OPEN.
When Monitored and Set Condition:
TEMP SENSOR OPEN
When Monitored: During heater activation and operation.
Set Condition: This DTC will set if the Temperature Sensor's resistance is not within the
expected parameters.
TEMP SENSOR SHORTED
When Monitored: During heater activation and operation.
Set Condition: This DTC will set if the Temperature Sensor's resistance is not within the
expected parameters.
POSSIBLE CAUSES
TEMPERATURE SENSOR
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
View repairAll
Repair
Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
98
CABIN HEATER

Symptom:
UNDER VOLTAGE
When Monitored and Set Condition:
UNDER VOLTAGE
When Monitored: With the engine running.
Set Condition: This DTC will set if the heater's power supply voltage drops below 10.2
volts for longer than 20 seconds.
POSSIBLE CAUSES
VEHICLE'S BATTERY SYSTEM
VEHICLE'S CHARGING SYSTEM NOT OPERATING PROPERLY
CABIN HEATER OR HEATER BOOSTER CONTROL UNIT
FUSED B+ CIRCUIT HIGH RESISTANCE
CABIN HEATER OR HEATER BOOSTER CONTROL UNIT
TEST ACTION APPLICABILITY
1WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
Turn the ignition off.
Inspect the vehicle's battery terminals, cable terminals, and cables for corrosion and
damage in accordance with the Service Information.
Test the vehicle's battery in accordance with the Service Information.
Is the vehicle's battery system Ok?All
Ye s!Go To 2
No!Clean/repair the vehicle's battery system in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
2WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
Check the vehicle's charging system for proper operation in accordance with the
Service Information.
Is the vehicle's charging system operating properly?All
Ye s!Go To 3
No!Repair the vehicle's charging system in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
99
CABIN HEATER

TEST ACTION APPLICABILITY
3WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Turn the ignition on.
With the DRBIIItin Sensors, record the Cabin Heater's or Heater Booster's
Operating Voltage.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater or Heater Booster harness connector.
Measure the voltage between the Fused B+ circuit and ground.
Is there more than 1.0 volt difference between the Operating Voltage and the Fused
B+ voltage?All
Ye s!Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
No!Go To 4
100
CABIN HEATER
UNDER VOLTAGE ÐContinued

TEST ACTION APPLICABILITY
4WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Reconnect the Cabin Heater or Heater Booster harness connector.
Connect a suitable voltmeter to the vehicle's battery. Position the voltmeter where it
can be monitored while operating the DRBIIIt.
Turn the ignition on.
Set the blend control to the max heat position and the mode control to the floor
position.
Start the engine.
Allow the engine to idle.
NOTE: Do not disconnect the vehicle's battery or the heater's main power
supply while the heater is in operation or in run-down mode. Failure to
follow these instructions can result in excess emissions from the heater
during heater operation.
Switch the Cabin Heater or Heater Booster on. If necessary, allow the heater to run
through at least one cycle of operation (approximately 10 minutes), and then turn the
heater off.
With the DRBIIItin Sensors, monitor the voltmeter and the Cabin Heater's or
Heater Booster's Operating Voltage while the heater is operational.
Switch the heater off.
Turn the engine off.
Was there more than 1.5 volts difference between Operating & battery voltage?All
Ye s!Repair the high resistance in the Fused B+ circuit.
Perform HEATER VERIFICATION TEST - VER 1.
No!Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
101
CABIN HEATER
UNDER VOLTAGE ÐContinued

Symptom:
*NO RESPONSE FROM AIRBAG CONTROL MODULE
POSSIBLE CAUSES
CHECK POWERS AND GROUNDS TO THE AIRBAG CONTROL MODULE
K-ACM CIRCUIT SHORTED TO GROUND
K-ACM CIRCUIT SHORTED TO VOLTAGE
K-ACM CIRCUIT OPEN
AIRBAG CONTROL MODULE
TEST ACTION APPLICABILITY
1WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY OR DEATH.
Disconnect the Airbag Control Module harness connector.
Check each power and ground circuit to the module.
Were any problems found?All
Ye s!Refer to the wiring diagrams located in the service information to
help isolate an open or shorted condition. Repair as necessary.
Perform __AIRBAG VERIFICATION TEST - VER 1.
No!Go To 2
2WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY OR DEATH.
Disconnect the ACM harness connector.
Disconnect the DRBIIItfrom the DLC.
Measure the resistance between ground and the K-ACM circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the K-ACM circuit for a short to ground.
Perform __AIRBAG VERIFICATION TEST - VER 1.
No!Go To 3
3WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY OR DEATH.
Disconnect the DRBIIItfrom the DLC.
Disconnect the ACM harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, probe the K-ACM circuit.
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!Repair the K-ACM circuit for a short to voltage.
Perform __AIRBAG VERIFICATION TEST - VER 1.
No!Go To 4
102
COMMUNICATION

TEST ACTION APPLICABILITY
4WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY OR DEATH.
Disconnect the ACM harness connector.
Disconnect the DRBIIItfrom the DLC.
Measure the resistance of the K-ACM circuit between the ACM connector and the
DLC.
Is the resistance below 5.0 ohms?All
Ye s!Replace the Airbag Control Module in accordance with the Service
Information.
Perform __AIRBAG VERIFICATION TEST - VER 1.
No!Repair the K-ACM circuit for an open.
Perform __AIRBAG VERIFICATION TEST - VER 1.
103
COMMUNICATION
*NO RESPONSE FROM AIRBAG CONTROL MODULE ÐContinued

Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the ignition off.
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from
ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system
that was malfunctioning.
5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read
DTC's from ALL modules.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. NOTE: If the CAB/HCU was replaced, ensure the CAB has been initialized
8. NOTE: If the SKREEM or ECM was replaced, refer to the service information for
proper programming procedures.
9. NOTE: For Sensor Circuit/Signal and Pump Motor faults, the CAB must sense all 4
wheels at 12 km/h (8 mph) before it will extinguish the ABS Indicator.
10. If there are no DTC's present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
11. CAUTION: Ensure braking capability is available before road testing.
12. Again, with the DRBIIItread DTC's. If any DTC's are present, return to Symptom list.
13. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can
no longer be duplicated, the repair is complete.
Are any DTC's present or is the original concern still present?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
AIRBAG VERIFICATION TEST - VER 1 APPLICABILITY
1. Remove any special tools or jumper wires and reconnect all previously disconnected
components - except the Battery.
2. WARNING: TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON,
THEN RECONNECT THE BATTERY.
3. Connect the DRBIIItto the Data Link Connector - use the most current software available.
4. Use the DRBIIItand erase the stored codes in all airbag system modules.
5. Turn the ignition off, and wait 15 seconds, then turn the ignition on.
6. Wait one minute, and read active codes and if there are none present read the stored codes.
7. Note: If equipped with Airbag On - Off switch, read the DTC's in all switch positions.
8. Note: Read the DTC's in all airbag system related modules.
9. If the DRBIIItshows any active or stored codes, return to the Symptom list and follow path
specified for that trouble code. If no active or stored codes are present, the repair is complete.
Are any DTC's present or is the original condition still present?All
YES
Repair is not complete, refer to appropriate symptom list.
NO
Repair is complete.
244
VERIFICATION TESTS

HEATER VERIFICATION TEST - VER 1 APPLICABILITY
1. WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA THAT DOES
NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE HEATER's
EXHAUST WHEN OPERATING THE HEATER. FAILURE TO FOLLOW THESE IN-
STRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH.
3. NOTE: The heater's control unit will store up to five DTCs in its memory.
4. NOTE: If the heater's control unit detects a new fault in the system, one that is not
already stored in its memory, it will clear the oldest of the five stored DTCs, and it
will store the new fault's DTC.
5. NOTE: If the heater's control unit detects a reoccurrence of a stored fault, it will
overwrite that fault's DTC with the most recent occurrence.
6. Verify that the vehicle's battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle's fuel tank. Add fuel, if
necessary.
8. Verify that all heater's coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of air
in accordance with the Service Information.
11. Turn the ignition on.
12. Verify that the Cabin Heater or Heater Booster is switched off.
13. Ensure that all accessories are turned off.
14. Set the blend control to the max heat position and the mode control to the floor position.
15. If a fuel system service requiring fuel to drain out of the heater's fuel line was performed,
prime the heater's Dosing Pump in accordance with the Service Information.
16. With the DRBIIIt, record and erase all DTCs from the Cabin Heater Module or Heater
Booster Module. Turn the ignition off, wait 5 seconds, then turn start the engine.
17. Allow the engine to idle.
18. NOTE: Do not disconnect the vehicle's battery or the heater's main power supply
while the heater is in operation or in run-down mode. Failure to follow these
instructions can result in excess emissions from the heater during heater operation.
19. Switch the Cabin Heater or Heater Booster on. Allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then turn the heater off.
20. With the DRBIIIt, read the Cabin Heater or Heater Booster Module's DTC.
21. Turn the engine off.
Are any DTC's present or is the original condition still present?All
Ye s!Repair is not complete, refer to the appropriate symptom.
No!Repair is complete.
246
VERIFICATION TESTS
Verification Tests ÐContinued