fuel reserve MERCEDES-BENZ SPRINTER 2006 Service Manual

3.3.4 HANDLING NO TROUBLE CODE
PROBLEMS
After reading Section 3.0 (System Description
and Functional Operation), you should have a bet-
ter understanding of the theory and operation of the
on-board diagnostics and how this relates to the
diagnosis of a vehicle that may have a driveability-
related symptom or complaint. When there are no
trouble codes present, refer to the no trouble code
(*) tests.
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading the DTCs, erasing the
DTCs, lab scope usage and other DRBIIItfunc-
tions.
3.4.1 DRBIIITDOES NOT POWER UP
If the LEDs 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 at data link
connector cavity 16. A minimum of 11.0 volts is
required to adequately power the DRBIIIt. Check
for proper ground connection at data link connector
cavities 4 and 5.
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 of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate diagnostic manual.
3.4.2 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 latest
information 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: HIGH-PRESSURE FUEL LINES
DELIVER DIESEL FUEL UNDER 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. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE 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.
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 AREA 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 drive
wheels.
When servicing a vehicle, always wear eye pro-
tection and remove any metal jewelry such as
watchbands or bracelets that might make electrical
contact.
When diagnosing powertrain system problems, it
is important to follow approved procedures where
applicable. These procedures can be found in the
8
GENERAL INFORMATION

Do not blend other specific fuel additives with die-
sel fuel. They only result in unnecessary cost, and
may be harmful to the engine operation.
POWER STEERING FLUID
No fluid service required. Filled with Power Steer-
ing Fluid approved to MB 236.3, such as Mobil
ATF-D (Exxon Mobil Corporation) or equivalent.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
ENGINE COOLANT
10 Liters 10.5 Quarts
ENGINE OIL
9.0L without Filter Re-
placement9.5 Quarts with Filter
Replacement
AUTOMATIC TRANSMISSION
Service Fill - NAG1 5.0 L (10.6 pts.)
O-haul Fill - NAG1 7.7 L (16.3 pts.)
Dry fill capacity Depending on type and size of inter-
nal cooler, length and inside diameter of cooler lines,
or use of an auxiliary cooler, these figures may vary.
(Refer to appropriate 21 - TRANSMISSION/AUTO-
MATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE  .03L (1 oz.)
8 1/2 1.8 L (4.0 pts.)
FUEL TANK
Primary 100 L (26.4 gal.)*
Reserve 10.5 L (2.8 gal.)*
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to manufac-
turing tolerance and refill procedure
DESCRIPTION SPECIFICATION
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cool-
er options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed proce-
dures.
FLUID FILL / CHECK LOCA-
TIONS
INSPECTION - FLUID FILL / CHECK LOCA-
TIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle. Support the vehicle in the raised
position with jack stands at the front and rear ends
of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
VALUBRICATION & MAINTENANCE 0 - 5

circuit board. The fuel gauge is serviced as a unit
with the instrument cluster.
OPERATION
The fuel gauge gives an indication to the vehicle
operator of the level of fuel in the fuel tank. This
gauge is controlled by the instrument cluster circuit
board based upon cluster programming and a hard
wired input received by the cluster from the fuel
level sensor in the fuel tank. The fuel gauge is an air
core magnetic unit that receives battery current on
the instrument cluster electronic circuit board when
the instrument cluster detects that the ignition
switch is in the On position. The cluster is pro-
grammed to move the gauge needle back to the low
end of the scale after the ignition switch is turned to
the Off position. The instrument cluster circuitry
controls the gauge needle position and provides the
following features:
²Fuel Level Sensor Input (At Ignition On)-
When the cluster detects the ignition switch has been
turned to the On position, the cluster moves the
gauge needle to the proper relative position on the
gauge scale as signaled by the fuel level sensor with-
out any electronic damping.
²Fuel Level Sensor Input (After Ignition On)
- After the ignition switch has been turned to the On
position, the cluster applies an algorithm to the input
from the fuel level sensor to electronically dampen
gauge needle movement against the negative effect
that fuel sloshing within the fuel tank can have on
accurate gauge readings.
²Fuel Level Sensor Input Open- If the fuel
level sensor input to the instrument cluster is an
open circuit, the cluster will move the fuel gauge nee-
dle to the ªEº (Empty) position on the gauge scale,
but the low fuel indicator will not be illuminated.
The fuel level sensor in the fuel tank provides a
hard wired input to the instrument cluster circuitry
through the fuel level sense circuit. The fuel level
sensor is a potentiometer that changes resistance
according to the fuel level. The instrument cluster
applies a fuel tank characteristic curve and fuel tank
reserve valve setting to the fuel level sensor input,
which must be configured when the cluster is initial-
ized. These characteristics determine the algorithm
the cluster uses to display the fuel level data on the
fuel gauge and the control for the low fuel warning
indicator. As the fuel level decreases, the resistance
through the fuel level sensor increases. The fuel level
sensor and the fuel level sense circuit to the instru-
ment cluster can be diagnosed using conventional
diagnostic tools and methods. For proper diagnosis of
the instrument cluster circuitry that controls the fuel
gauge, a diagnostic scan tool is required. Refer to the
appropriate diagnostic information.
GEAR SELECTOR INDICATOR
DESCRIPTION
An electronic automatic transmission gear selector
indicator is standard equipment on all instrument
clusters. The gear selector indicator information is
displayed in the center of the multi-function indicator
Liquid Crystal Display (LCD) located near the lower
edge of the instrument cluster, directly below the
speedometer. The gear selector indicator displays the
following characters as they are selected: ªP,º ªR,º
ªN,º ªD,º ª4,º ª3,º ª2,º and ª1.º Respectively, these
characters represent the currently selected park,
reverse, neutral, drive, fourth gear, third gear, second
gear, and first gear positions of the transmission gear
selector lever on the instrument panel.
The indications of the gear selector indicator are
not visible unless the multi-function indicator LCD is
illuminated and the engine is running. When illumi-
nated, each indication appears as a dark character
silhouetted against an amber field. When the exterior
lighting is turned Off, the display is illuminated at
maximum brightness. When the exterior lighting is
turned On, the display illumination level can be
adjusted in concert with the cluster general illumina-
tion lighting using the ª+º (plus) and ª2º (minus)
multi-function indicator push buttons. The gear
selector indicator is serviced as a unit with the
instrument cluster.
OPERATION
The electronic gear selector indicator gives an indi-
cation to the vehicle operator of the transmission
gear that is currently selected with the automatic
transmission gear selector lever. This indicator is
controlled by the instrument cluster circuit board
based upon cluster programming and electronic mes-
sages received from the Transmission Control Module
(TCM) over the Controller Area Network (CAN) data
bus. The gear selector indicator information is dis-
played by the multi-function indicator Liquid Crystal
Display (LCD) unit on the instrument cluster elec-
tronic circuit board. The multi-function indicator
LCD is completely controlled by the instrument clus-
ter logic circuit, and that logic will only allow the
gear selector indicator information to be displayed
when the instrument cluster detects that the ignition
switch is in the On position. Therefore, the gear
selector indicator will always be off when the ignition
switch is in any position except On.
The TCM continually monitors the transmission
range sensor, then sends the proper gear selector
indicator position messages to the instrument cluster.
For proper diagnosis of the transmission range sen-
sor, the TCM, the CAN data bus, or the electronic
message inputs to the instrument cluster that control
the gear selector indicator, a diagnostic scan tool is
8J - 18 INSTRUMENT CLUSTERVA

through the fuel level sense circuit. The fuel level
sensor is a potentiometer that changes resistance
according to the fuel level. As the fuel level
decreases, the resistance through the fuel level sen-
sor increases. The instrument cluster applies a fuel
tank characteristic curve and fuel tank reserve valve
setting to the fuel level sensor input, which must be
configured when the cluster is initialized. These
characteristics determine the algorithm the cluster
uses to display the fuel level data on the fuel gauge
and the control for the low fuel warning indicator.
The fuel level sensor and the fuel level sense circuit
to the instrument cluster can be diagnosed using con-
ventional diagnostic tools and methods. For proper
diagnosis of the instrument cluster circuitry that con-
trols the fuel gauge, a diagnostic scan tool is
required. Refer to the appropriate diagnostic infor-
mation.
LOW OIL LEVEL INDICATOR
DESCRIPTION
A low oil level indicator is standard equipment on
all instrument clusters. The low oil level indicator is
located near the lower edge of the instrument cluster,
to the left of the multi-function indicator display. The
low oil level indicator consists of the International
Control and Display Symbol icon for ªEngine Oilº
imprinted within a rectangular cutout in the opaque
layer of the instrument cluster overlay. The dark
outer layer of the overlay prevents the indicator from
being clearly visible when it is not illuminated. A red
Light Emitting Diode (LED) behind the cutout in the
opaque layer of the overlay causes the icon to appear
silhouetted against a red field through the translu-
cent outer layer of the overlay when the indicator is
illuminated from behind by the LED, which is sol-
dered onto the instrument cluster electronic circuit
board. The low oil level indicator is serviced as a unit
with the instrument cluster.
OPERATION
The low oil level indicator gives an indication to
the vehicle operator when the engine oil level is low.
This indicator is controlled by a transistor on the
instrument cluster electronic circuit board based
upon cluster programming and electronic messages
received by the cluster from the Engine Control Mod-
ule (ECM) over the Controller Area Network (CAN)
data bus. The low oil level indicator Light Emitting
Diode (LED) is completely controlled by the instru-
ment cluster logic circuit, and that logic will only
allow this indicator to operate when the instrument
cluster detects that the ignition switch is in the On
position. Therefore, the LED will always be off when
the ignition switch is in any position except On. The
LED only illuminates when it is provided a path toground by the instrument cluster transistor. The
instrument cluster will turn on the low oil level indi-
cator for the following reasons:
²Bulb Test- Each time the ignition switch is
turned to the On position the low oil level indicator
is illuminated for about two seconds as a bulb test.
²Engine Oil Level Low Message- Once the
engine has been started, each time the cluster
receives a message from the ECM indicating that the
engine oil level is at or near the ªMinimumº mark on
the dipstick, the low oil level indicator is illuminated.
The indicator remains illuminated briefly at first, but
will remain illuminated for longer periods as subse-
quent messages indicate that the oil level has
dropped further. Eventually, the indicator will
remain illuminated solid until the engine oil level is
corrected, or until the ignition switch is turned to the
Off position, whichever occurs first.
The instrument cluster also supplements the oil
level indicator by displaying an engine oil icon along
with alpha-numeric messages in the multi-function
indicator Liquid Crystal Display (LCD) advising the
vehicle operator how much oil is required to correct
the engine oil level, and when the ªMaximumº engine
oil level has been exceeded. See the owner's manual
in the vehicle glove box for more information on this
feature.
The ECM continually monitors the engine oil level
and temperature sensor to determine the engine oil
level. The ECM then sends the proper engine oil
level messages to the instrument cluster. If the
instrument cluster turns on the indicator after the
bulb test, even after the engine oil level is sufficient,
it may indicate that the engine or the engine oiling
system requires service. For proper diagnosis of the
engine oil level and temperature sensor, the ECM,
the CAN data bus, or the electronic message inputs
to the instrument cluster that control the low oil
level indicator, a diagnostic scan tool is required.
Refer to the appropriate diagnostic information.
MAINTENANCE INDICATOR
DESCRIPTION
An Active Service SYSTem (ASSYST) engine oil
maintenance indicator is optional equipment on all
instrument clusters. In vehicles so equipped, a sec-
ond, dedicated ASSYST microprocessor is integral to
the cluster electronic circuit board. The ASSYST indi-
cations are displayed and can be toggled with the
clock indication on the right side of the multi-func-
tion indicator Liquid Crystal Display (LCD) located
near the lower edge of the instrument cluster,
directly below the speedometer. The ASSYST displays
include numeric values combined with several icons
to indicate actual engine oil level, and reminders in
time (days) or distance (miles or kilometers) until the
8J - 20 INSTRUMENT CLUSTERVA

OPERATION
The Negative Temperature Coefficient (NTC)
resister located within the intake air temperature
sensor alters it's resistance in line with the charge
air temperature. If the engine is cold, the value
equals ambient temperature. For a temperature of
68ÉF (20ÉC) the resistance is approximately 6000
ohms. For a temperature of 104ÉF (40ÉC) the resis-
tance is approximately 3300 ohms (Fig. 20).
REMOVAL
(1) Disconnect the negative battery cable.
(2) Unplug the wiring harness connector at the
intake air temperature sensor.
(3) Press together the sensor locking arms and
remove the sensor from the charge air pipe (Fig.
21).
INSTALLATION
(1) Position the intake air temperature sensor
above the charge air pipe access hole.
(2) Press together the sensor locking tabs, seat the
sensor to the pipe and release tabs (Fig. 21).
(3) Connect negative battery cable.
INTAKE AIR PRESSURE SEN-
SOR
DESCRIPTION
An absolute pressure sensor is mounted to the air
cleaner housing. The sensor is used by the ECM to
adjust for changes in altitude and for air intake
obstructions due to a clogging air cleaner.
OPERATION
The ECM uses the intake air pressure sensor to
monitor the intake pressure. Monitoring this pres-
sure allows better control of the variable geometry
turbocharger to suit the driving environment and
preserve turbocharger durability.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor electrical connector.
(3) Remove the air intake pressure sensor.
Fig. 20 INLET AIR TEMPERATURE SENSOR
1 - INTAKE AIR TEMPERATURE SENSOR
2 - PIPE
Fig. 21 BOOST PRESSURE AND INLET AIR
TEMPERATURE SENSORS
1 - CHARGE AIR DUCT
2 - INTAKE AIR TEMPERATURE SENSOR
3 - BOOST PRESSURE SENSOR
VAFUEL INJECTION 14 - 43