starter MERCEDES-BENZ SPRINTER 2006 Service Manual

ENGINE CONTROL MODULE C2 (OBD)CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
2 14BR GROUND
3 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
6 14BR GROUND
7 18RD S/C SWITCH 12 VOLT SUPPLY
8 18BR/WT HIGH IDLE ON SIGNAL
10 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
11 18WT/DG BOOST PRESSURE SENSOR SIGNAL
12 18BR/WT SENSOR GROUND
13 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
14 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
17 18BR/DG KICKDOWN SWITCH SIGNAL
18 20DG/YL ENGINE RPM
19 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
25 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
26 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
28 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
31 20BL/YL K-ECM
32 20DG ENHANCED ACCIDENT REPORT DRIVER
36 18VT IGNITION SWITCH OUTPUT (START)
37 18DG ACCEL/SET SIGNAL
38 18BK VERIFICATION SIGNAL
42 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
43 18BK/RD GLOW PLUG MODULE CONTROL
44 18YL/BL ENGINE CONTROL RELAY CONTROL
50 18YL DECEL/SET SIGNAL
51 18GY OFF SIGNAL
52 18BL RESUME SIGNAL
53 20DG/WT CAN C BUS (+)
54 20DG CAN C BUS (-)
55 18BR/RD FUEL PUMP RELAY CONTROL
58 18VT/DG STARTER MOTOR RELAY CONTROL
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CONNECTOR PINOUTS

ENGINE CONTROL MODULE C3 (EXCEPT OBD) - BLACKCAV CIRCUIT FUNCTION
1 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
2- -
3- -
4- -
5 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
6 18WT/DG BOOST PRESSURE SENSOR SIGNAL
7 20BR/YL MASS AIR FLOW SENSOR GROUND
8 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
9 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
10 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
11 - -
12 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
13 - -
14 - -
15 - -
16 - -
17 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
18 20YL/DG MASS AIR FLOW SENSOR SIGNAL
19 20BR/BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY
20 18VT IGNITION SWITCH OUTPUT (START)
21 - -
22 18BR/WT BOOST PRESSURE SENSOR GROUND
23 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
24 - -
25 18BK/RD GLOW PLUG MODULE CONTROL
26 - -
27 - -
28 20BL/YL K-ECM
29 - -
30 18RD/BL STARTER MOTOR RELAY 12 VOLT SUPPLY
31 - -
32 - -
33 20YL/RD MASS AIR FLOW SENSOR 12 VOLT SUPPLY
34 - -
35 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY
36 - -
37 - -
38 - -
39 - -
40 20DG/YL ENGINE RPM
41 - -
42 - -
43 18VT/DG STARTER MOTOR RELAY CONTROL
44 - -
45 - -
46 18YL/BL ENGINE CONTROL RELAY CONTROL
47 - -
48 20WT BOOST PRESSURE SOLENOID CONTROL
49 - -
50 - -
51 - -
52 - -
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CONNECTOR PINOUTS

TABLE OF CONTENTS - Continued
P1617- ECM WRITE ERROR..............................................16
P1617-ECM INCORRECT VALUE..........................................16
P1617-ECM READ ERROR...............................................16
P2122-INTERNAL ERROR COUNTER FAULT................................16
P2122-INTERNAL ERROR ENGINE SHUT OFF..............................16
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING...................16
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING...................16
P2123-INJECTOR BANK ERROR..........................................16
P2124-INJECTOR BANK ERROR..........................................16
P2139-ECM INJECTOR OUTPUT STAGE #1.................................16
P2139-ECM INJECTOR OUTPUT STAGE #1 SHORT CIRCUIT..................16
P2140-ECM INJECTOR OUTPUT STAGE #2.................................16
P2140-ECM INJECTOR OUTPUT STAGE #2 SHORT CIRCUIT..................16
P2149-ECM A/D CONVERTER HIGH.......................................16
P2149-ECM A/D CONVERTER LOW........................................16
P2149-ECM A/D CONVERTER PLAUSIBILITY................................16
P2153-STARTER RELAY CIRCUIT ECM THERMAL OVERLOAD................16
P2197-FUEL QUANTITY SOLENOID ECM THERMAL OVERLOAD...............16
P2214-CAN MESSAGE ERROR...........................................16
P2319-ECM INTERNAL ERROR 1..........................................16
P2319-ECM INTERNAL ERROR 2..........................................16
P2319-ECM INTERNAL ERROR 3..........................................16
P2319-ECM INTERNAL ERROR 4..........................................16
P2321-ECM INTERNAL ERROR 5..........................................16
P2323-ECM INTERNAL ERROR...........................................16
P2324-ECM INJECTOR MONITORING 1....................................16
P2324-ECM INJECTOR MONITORING 2....................................16
P2324-ECM INJECTOR MONITORING 3....................................16
P2324-ECM INJECTOR MONITORING 4....................................16
P2324-ECM INJECTOR UNDERVOLTAGE...................................16
P2325-ECM INTERNAL ERROR 1..........................................16
P2325-ECM INTERNAL ERROR 2..........................................16
P2325-ECM INTERNAL ERROR 3..........................................16
P2325-ECM INTERNAL ERROR 4..........................................16
P2329-ECM INTERNAL ERROR 1..........................................16
P2330-ECM INTERNAL ERROR 1..........................................16
P2340-ECM INJECTION QUANTITY ERROR.................................16
P2342-ECM INTERNAL ERROR 1..........................................16
P2342-ECM INTERNAL ERROR 2..........................................17
P2350-INTERNAL VOLTAGE ERROR.......................................17
P2352-INJECTION FAULT - EXCESSIVE TEMPERATURE......................17
P2352-INJECTION FAULT - QUANTITY ERROR..............................17
P2352-INJECTION FAULT - TORQUE LIMIT.................................17
P2352-INJECTION FAULT EXCESSIVE ENGINE SPEED.......................17
P2354-ECM INTERNAL FAULT............................................17
P2356-ECM INTERNAL ERROR...........................................17
P2357-ECM INTERNAL ERROR...........................................17
P2358-ECM INTERNAL ERROR...........................................17
P2500-FUEL PRESSURE SOLENOID CIRCUIT EXCESSIVE CURRENT..........17
P2514-CRANKCASE VENT HEATER EXCESSIVE CURRENT...................17
P2526-BOOST PRESSURE SERVO MOTOR EXCESSIVE CURRENT............17
P2527-EGR VALVE EXCESSIVE CURRENT.................................17
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW...............19
ii

TABLE OF CONTENTS - Continued
P2032-O2 SENSOR PLAUSIBILITY.......................................134
P2032-O2 SENSOR PLAUSIBILITY.......................................134
P2057-O2 SENSOR SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH...........134
P2058-O2 SENSOR SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH...........134
P2059-O2 SENSOR SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH...........134
P2090-O2 SENSOR PLAUSIBILITY.......................................134
P2090-O2 SENSOR SIGNAL FAULT.......................................134
P2091-O2 SENSOR LOW O2 CONCENTRATION............................134
P2091-O2 SENSOR SIGNAL PLAUSIBILITY................................134
P2195-O2 SENSOR HEATER CIRCUIT FAULT..............................134
P2353-O2 SENSOR PLAUSIBILITY.......................................134
P2366-O2 CIRCUIT FAULT..............................................134
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH...............138
P2034-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW................138
P2036-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH...............138
P2036-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW................138
P2038-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO HIGH...............138
P2038-O2 SENSOR CIRCUIT CALIBRATION VALUE TOO LOW................138
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN CIRCUIT.............140
P2043-CAMSHAFT POSITION SENSOR CIRCUIT OPEN OR SHORT CIRCUIT . . .140
P2045-CRANKSHAFT POSITION SENSOR CIRCUIT LOST SIGNAL............146
P2045-CRANKSHAFT POSITION SENSOR CIRCUIT SIGNAL PLAUSIBILITY.....146
P2322-CRANKSHAFT POSITION SENSOR PLAUSIBILITY....................146
P2343-CKP PLAUSIBILITY...............................................146
P2062-ENGINE OIL SENSOR MONITORING ERROR........................149
P2066-MASS AIR FLOW SENSOR PLAUSIBILITY...........................150
P2355-EGR FLOW RATE IS TOO HIGH....................................150
P2355-EGR FLOW RATE IS TOO LOW....................................150
P2066-MASS AIR FLOW SENSOR PLAUSIBILITY AIR MASS TOO HIGH........153
P2066-MASS AIR FLOW SENSOR PLAUSIBILITY AIR MASS TOO LOW.........153
P2087-INTAKE PRESSURE SENSOR INTAKE RESTRICTION.................156
P2100-FUEL PUMP RELAY CIRCUIT OPEN CIRCUIT........................157
P2100-FUEL PUMP RELAY CIRCUIT SHORTED TO GROUND.................157
P2100-FUEL PUMP RELAY CIRCUIT SHORTED TO VOLTAGE................159
P2100-FUEL PUMP RELAY EXCESSIVE CURRENT..........................159
P2104-STARTER RELAY CIRCUIT SHORT CIRCUIT.........................161
P2152-STARTER RELAY CIRCUIT SHORT TO GROUND.....................161
P2153-STARTER RELAY CIRCUIT OPEN OR SHORTED TO VOLTAGE.........161
P2110-BOOST PRESSURE SERVO MOTOR CIRCUIT SHORT CIRCUIT.........164
P2112-BOOST PRESSURE SERVO MOTOR CIRCUIT EXCESSIVE CURRENT . . .164
P2526-BOOST PRESSURE SERVO MOTOR SHORT TO VOLTAGE.............164
P2111-BOOST PRESSURE SERVO MOTOR CIRCUIT SHORT TO GROUND.....167
P2112-BOOST PRESSURE SERVO MOTOR CIRCUIT OPEN CIRCUIT..........167
P2510-BOOST PRESSURE SERVO MOTOR SHORT TO GROUND.............167
P2526-BOOST PRESSURE SERVO MOTOR OPEN CIRCUIT..................167
P2526-BOOST PRESSURE SERVO MOTOR SHORT TO GROUND.............167
P2132-GLOW PLUG CONTROL MODULE CIRCUIT OPEN CIRCUIT............171
P2132-GLOW PLUG CONTROL MODULE CIRCUIT SHORTED TO GROUND. . . .171
P2132-GLOW PLUG CONTROL MODULE CIRCUIT SHORTED TO VOLTAGE OR
OPEN................................................................171
P2132-GLOW PLUG CONTROL MODULE FAULT............................171
P2151-FUEL PRESS SOLENOID SIGNAL PLAUSIBILITY HIGH................173
P2151-FUEL PRESS SOLENOID SIGNAL PLAUSIBILITY LOW.................173
vii

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

small
mass air flow sensor positive deviation
mass air flow sensor signal circuit open or shorted
mass air flow sensor signal voltage too high
mass air flow sensor signal voltage too high
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor signal voltage too low
mass air flow sensor supply voltage too high
mass air flow sensor supply voltage too low
misfire cylinder #1
misfire cylinder #1
misfire cylinder #2
misfire cylinder #2
misfire cylinder #3
misfire cylinder #3
misfire cylinder #4
misfire cylinder #4
misfire cylinder #5
misfire cylinder #5
misfire detected
no message received from skreem
o2 circuit fault
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too high
o2 sensor circuit calibration value too low
o2 sensor circuit calibration value too low
o2 sensor circuit calibration value too low
o2 sensor circuit fault
o2 sensor circuit fault
o2 sensor circuit open circuit
o2 sensor circuit open circuit
o2 sensor circuit signal voltage too high
o2 sensor circuit signal voltage too high
o2 sensor circuit signal voltage too low
o2 sensor circuit signal voltage too low
o2 sensor heater circuit fault
o2 sensor low o2 concentration
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor plausibility
o2 sensor signal circuit signal voltage too high
o2 sensor signal circuit signal voltage too high
o2 sensor signal circuit signal voltage too high
o2 sensor signal fault
o2 sensor signal plausibility
s/c excessive acceleration
s/c excessive deceleration
s/c vehicle speed plausibility
sensor supply 1 voltage is too high
sensor supply 1 voltage is too low
sensor supply 2 voltage is too high
sensor supply 2 voltage is too low
sensor supply 3 voltage is too highsensor supply 3 voltage is too low
starter relay circuit ecm thermal overload
starter relay circuit open or shorted to voltage
starter relay circuit short circuit
starter relay circuit short to ground
steering angle sensor plausibility
tcm dtc 1-2 and 4-5 shift solenoid fault present
tcm dtc 2-3 shift solenoid fault present
tcm dtc 3-4 shift solenoid fault present
tcm dtc can msg implausible fault present
tcm dtc ewm can message fault present
tcm dtc internal fault present
tcm dtc modulating pressure solenoid fault present
tcm dtc negative gear comparison fault present
tcm dtc not unequivocal fault present
tcm dtc right rear wheel speed implausible fault
present
tcm dtc shift pressure solenoid fault present
tcm dtc speed sensor voltage fault present
tcm dtc tcc excessive power consumption fault
present
tcm dtc torque converter clutch solenoid fault
present
tcm dtc transmission ratio error fault present
tcm dtc valve voltage supply fault present
tcm message error
tcm no can message
torque reduction message from abs -can plausibility
torque reduction message from abs -message error
torque reduction message from abs -messages miss-
ing
torque reduction message from abs -no communica-
tion
torque reduction message from abs -plausibility #1
torque reduction message from abs plausibility #2
torque reduction message from hvac switch signal
plausibility
torque reduction message from hvac-parity error
torque reduction message from hvac-switch signal
error
torque reduction message from tcm -can plausibil-
ity
torque reduction message from tcm -engine stop
torque reduction message from tcm -message error
torque reduction message from tcm -messages miss-
ing
torque reduction message from tcm -plausibility
torque reduction message from tcm -tcm dtc #1
torque reduction message from tcm -tcm dtc #2
water in fuel sensor signal error
water in fuel sensor -water in fuel
wheel speed sensor plaus -can bus message from
abs
write error to eeprom
7
GENERAL INFORMATION

Symptom List:
P-1105 ATMOSPHERIC PRESSURE SENSOR PLAUSIBILITY WITH
BOOST PRESSURE SENSOR
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE
TOO HIGH
P1105-ATMOSPHERIC PRESSURE SENSOR SIGNAL VOLTAGE
TOO LOW
P1617- ECM READ/WRITE ERROR
P1617- ECM WRITE ERROR
P1617-ECM INCORRECT VALUE
P1617-ECM READ ERROR
P2122-INTERNAL ERROR COUNTER FAULT
P2122-INTERNAL ERROR ENGINE SHUT OFF
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING
P2122-INTERNAL ERROR ENGINE VOLTAGE MONITORING
P2123-INJECTOR BANK ERROR
P2124-INJECTOR BANK ERROR
P2139-ECM INJECTOR OUTPUT STAGE #1
P2139-ECM INJECTOR OUTPUT STAGE #1 SHORT CIRCUIT
P2140-ECM INJECTOR OUTPUT STAGE #2
P2140-ECM INJECTOR OUTPUT STAGE #2 SHORT CIRCUIT
P2149-ECM A/D CONVERTER HIGH
P2149-ECM A/D CONVERTER LOW
P2149-ECM A/D CONVERTER PLAUSIBILITY
P2153-STARTER RELAY CIRCUIT ECM THERMAL OVERLOAD
P2197-FUEL QUANTITY SOLENOID ECM THERMAL OVERLOAD
P2214-CAN MESSAGE ERROR
P2319-ECM INTERNAL ERROR 1
P2319-ECM INTERNAL ERROR 2
P2319-ECM INTERNAL ERROR 3
P2319-ECM INTERNAL ERROR 4
P2321-ECM INTERNAL ERROR 5
P2323-ECM INTERNAL ERROR
P2324-ECM INJECTOR MONITORING 1
P2324-ECM INJECTOR MONITORING 2
P2324-ECM INJECTOR MONITORING 3
P2324-ECM INJECTOR MONITORING 4
P2324-ECM INJECTOR UNDERVOLTAGE
P2325-ECM INTERNAL ERROR 1
P2325-ECM INTERNAL ERROR 2
P2325-ECM INTERNAL ERROR 3
P2325-ECM INTERNAL ERROR 4
P2329-ECM INTERNAL ERROR 1
P2330-ECM INTERNAL ERROR 1
P2340-ECM INJECTION QUANTITY ERROR
P2342-ECM INTERNAL ERROR 1
16
DRIVEABILITY - DIESEL

Symptom List:
P2104-STARTER RELAY CIRCUIT SHORT CIRCUIT
P2152-STARTER RELAY CIRCUIT SHORT TO GROUND
P2153-STARTER RELAY CIRCUIT OPEN OR SHORTED TO VOLT-
AGE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be P2104-STARTER RELAY CIR-
CUIT SHORT CIRCUIT.
When Monitored and Set Condition:
P2104-STARTER RELAY CIRCUIT SHORT CIRCUIT
When Monitored: During engine crank attempt.
Set Condition: The ECM detects too much current on the Starter Motor Relay Control
circuit.
POSSIBLE CAUSES
CHECKING THE ENGINE CONTROL RELAY SYSTEM
INTERMITTENT CONDITION
SUBSTITUTE STARTER RELAY
STARTER RELAY CONTROL CIRCUIT SHORTED TO GROUND
STARTER RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
ENGINE CONTROL MODULE
STARTER RELAY CONTROL CIRCUIT OPEN
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.
Attempt to start the engine several times, 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 2
No!Go To 8
161
DRIVEABILITY - DIESEL

TEST ACTION APPLICABILITY
2NOTE: If DTC P1611, P2306 or P2332 is present with this DTC, diagnose
DTCs P1611, P2306 or P2332 before diagnosing this DTC.
NOTE: 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 C2 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.
4 Turn the ignition off.
Install a substitute relay in place of the Starter Relay.
Turn the ignition on.
With the DRBIIIt, erase DTCs.
Attempt to start the engine several times, 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 5
No!Replace the Starter Relay.
Perform ROAD TEST VERIFICATION - VER-2.
5 Turn the ignition off.
Remove the Starter Relay.
Disconnect the ECM harness connectors.
Measure the resistance of the Starter Relay Control circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 6
No!Repair the Starter Relay Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6 Turn the ignition off.
Remove the Starter Relay.
Disconnect the ECM harness connectors.
Measure the resistance between ground and the Starter Relay Control circuit.
Is the resistance above 1000 ohms?All
Ye s!Go To 7
No!Repair the Starter Relay Control circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
162
DRIVEABILITY - DIESEL
P2104-STARTER RELAY CIRCUIT SHORT CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Remove the Starter Relay.
Disconnect the ECM harness connectors.
Remove the Engine Control Relay.
Connect a jumper wire between cavity 30 and cavity 87 of the Engine Control Relay
connector.
Turn the ignition on.
Measure the voltage of the Starter Relay Control circuit.
Is the voltage below 1.0 volt?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Repair the Starter Relay Control circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
8WARNING: 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.
163
DRIVEABILITY - DIESEL
P2104-STARTER RELAY CIRCUIT SHORT CIRCUIT ÐContinued