2006 MERCEDES-BENZ SPRINTER warning

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.
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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

9.0 CONNECTOR PINOUTS
A/C AUXILIARY FANCAV CIRCUIT FUNCTION
1 14DG/BK A/C AUXILIARY FAN RELAY OUTPUT
2 14BR GROUND
AIR OUTLET TEMPERATURE SENSORCAV CIRCUIT FUNCTION
1 18BR/GY AIR OUTLET TEMPERATURE SENSOR SIGNAL
2 18BR/BL SENSOR GROUND
AIRBAG CONTROL MODULE - YELLOWCAV CIRCUIT FUNCTION
1 20BL DRIVER SEAT BELT TENSIONER LINE 2
2 20BR/YL DRIVER SEAT BELT TENSIONER LINE 1
3 20BL PASSENGER SEAT BELT TENSIONER LINE 2
4 20BR PASSENGER SEAT BELT TENSIONER LINE 1
5 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 20BR GROUND
7 20YL AIRBAG WARNING INDICATOR DRIVER
8- -
9 20BK/RD K-ACM
10 20DG DRIVER AIRBAG SQUIB 1 LINE 2
11 20VT DRIVER AIRBAG SQUIB 1 LINE 1
12 - -
13 20BL/DG PASSENGER AIRBAG SQUIB 1 LINE 2
14 20BR/DG PASSENGER AIRBAG SQUIB 1 LINE 1
15 - -
16 - -
17 - -
18 - -
19 - -
20 20DG ENHANCED ACCIDENT REPORT DRIVER
21 -
22 -
23 -
24 -
25 -
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CONNECTOR PINOUTS

INSTRUMENT CLUSTER C1CAV CIRCUIT FUNCTION
1 20BR FUEL LEVEL SENSOR SIGNAL RETURN
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN
4 20WT/GY K-IC/ATC/HBM/CHM
5 20BR/BK PARK BRAKE INDICATOR SIGNAL
7 20BK/DG RIGHT TURN SIGNAL
10 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
11 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
14 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
15 20BR/WT FRONT COURTESY LAMPS CONTROL
16 20YL/RD SEAT BELT SWITCH SIGNAL
17 20DG CAN C BUS (-)
18 20DG/WT CAN C BUS (+)
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
INTRUSION SENSOR NO. 1 - BLACKCAV CIRCUIT FUNCTION
1 20BR GROUND
2 20DG/BK INTRUSION SENSOR 1 SIGNAL
3 20DG/YL INTRUSION SENSOR INTERFACE
4 20RD/DG FUSED B(+)
INTRUSION SENSOR NO. 2 - BLACKCAV CIRCUIT FUNCTION
1 20BR GROUND
2 20GY/BK INTRUSION SENSOR 2 SIGNAL
3 20DG/YL INTRUSION SENSOR INTERFACE
4 20RD/DG FUSED B(+)
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CONNECTOR PINOUTS

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX-STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 INDENTIFICATION OF SYSTEM............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1ESP ..............................................................1
3.2ABS ..............................................................1
3.3BRAKE ASSIST SYSTEM (HBA).......................................2
3.4TCS (ASR).........................................................2
3.5ELECTRONIC BRAKE DISTRIBUTION (EBD)............................2
3.6VEHICLE CONTROLLING (FZR).......................................2
3.7SYSTEM COMPONENTS.............................................2
3.7.1ABS AND TCS (ASR) INDICATORS............................3
3.7.2CONTROLLER ANTILOCK BRAKE (CAB).......................3
3.7.3HYDRAULIC CONTROL UNIT (HCU)...........................3
3.7.4SWITCHES/SENSORS.......................................3
3.7.5SELF TESTS...............................................4
3.8USING THE DRBIIIT.................................................4
3.9DRBIIITERROR MESSAGES.........................................4
3.9.1DRBIIITDOES NOT POWER UP (BLANK SCREEN)...............5
3.9.2DISPLAY IS NOT VISIBLE....................................5
4.0 DISCLAIMERS, SAFETY, WARNINGS.......................................5
4.1DISCLAIMERS......................................................5
4.2SAFETY...........................................................5
4.2.1TECHNICIAN SAFETY INFORMATION..........................5
4.2.2VEHICLE PREPARATION FOR TESTING........................5
4.2.3SERVICING SUB-ASSEMBLIES...............................5
4.2.4DRBIIITSAFETY INFORMATION...............................6
4.3WARNING.........................................................6
4.3.1VEHICLE DAMAGE WARNINGS...............................6
4.3.2ROAD TESTING A COMPLAINT VEHICLE.......................6
4.4DIAGNOSIS........................................................6
5.0 REQUIRED TOOLS AND EQUIPMENT......................................7
6.0 GLOSSARY OF TERMS...................................................7
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES............................9
BRAKES (CAB)
ANTI-LOCK BRAKE MODULE INTERNAL...................................10
CAB INTERNAL.........................................................10
BRAKE FLUID LEVEL....................................................13
BRAKE PRESSURE SENSOR CIRCUIT.....................................15
BRAKE SWITCH CIRCUIT................................................17
CAB CHECK SUM......................................................21
CAB OPTION...........................................................23
CAN COMMUNICATION ERROR..........................................25
i

²Four Wheel Speed Sensors/Tone Wheel assem-
blies
²ABS warning indicator
²TCS (ASR) event indicator
²TCS (ASR) warning indicator
²Steering Angle Sensor
²Lateral Acceleration/Yaw Rate Sensor
²Brake Pressure Sensor
²ESP event indicator
²Brake Fluid Level switch
²Brake Switch (BS)
²Brake Lamp Switch (BLS)
²TCS Switch (TCSS)
²K - ABS
²CAN C Bus
²Fuses, grounds, and wiring
3.7.1 ABS AND TCS (ASR) INDICATORS
This system is equipped with an ABS warning
indicator, TCS (ASR) warning indicator, and TCS
(ASR) event indicator to alert the driver of a
malfunction/event it has detected. The CAB can
request the illumination of the ABS warning indi-
cator, TCS (ASR) warning indicator, and TCS (ASR)
event indicator via CAN C BUS. The CAB controls
the ABS warning indicator by:
²Light steady during an initial test at the begin-
ning of an ignition cycle to function as a bulb
check
²Light steady when a system malfunction exists
(DTC)
²Light steady - If you have not met the speed
required to reset/retest the ABS components
The Instrument Cluster (IC) controls the indica-
tors. The Instrument Cluster transmits a message
over the CAN C Bus relating to diagnostics and
current lamp status for the ABS and TCS (ASR)
indicators. The CAB can control the operation of
TCS warning and TCS event indicators by:
²Both light steady with engine off and both go out
with engine running
²TCS warning indicator lights steady when a TCS
malfunction exists
²TCS event indicator will flash when TCS is in an
active event
3.7.2 CONTROLLER ANTILOCK BRAKE
(CAB)
The CAB is mounted directly to the Hydraulic
Control Unit (HCU) that includes a microprocessor
and twelve solenoids that control valves that con-trol brake pressure during antilock braking or trac-
tion control events. The CAB also has circuits that
monitor the following:
²Double brake switch outputs are monitored to
determine whether or not to prepare for possible
ABS braking
²Wheel Speed Sensors are monitored to determine
when a wheel is tending to lock up. The CAB will
operate the valves in the HCU to control braking
pressure during ABS braking
²Detect ABS system related problems and take
diagnostic action
²Able to execute self-tests and output control com-
mands
When equipped with Electronic Stability (ESP),
the CAB also monitors the following:
²The ESP looks at the Steering Angle Sensor value
and monitors the speed of the inner and outer
wheels to ensure that the values are plausible.
The Steering Angle Sensor also monitors the
speed that the steering wheel is turned.
²The Lateral Acceleration/Yaw Rate Sensor is con-
tained in one unit. The sensor measures side to
side (lateral) motion and rotational motion (how
fast the vehicle is turning).
²The ESP uses data from the Brake Pressure
Sensor to analyze how hard and fast that the
driver wants to brake.
3.7.3 HYDRAULIC CONTROL UNIT (HCU)
The HCU on the Bosch 5.7 has an integral valve
body for controlling the front and rear brakes.
Within the HCU are inlet, outlet, and shuttle
valves, to release brake pressure as required to
avoid wheel lockup, keeping the wheels rolling, and
maintain optimum deceleration with stability. The
Pump Motor is attached to the HCU which works
with the ABS and TCS and is controlled by the
CAB. The primary function is to provide extra
amount of fluid when needed.
3.7.4 SWITCHES/SENSORS
BRAKE SWITCH (BS):This switch prepares the
CAB for a possible antilock event. The CAB uses an
output state voltage from the BS when the brake
pedal is either released/depressed. The Fused Igni-
tion Switch Output circuit supplies 12 volts to the
BS. A released brake pedal will close the BS circuit
and the BS Output circuit supplies 12 volts to the
CAB. When the driver depresses the brake pedal,
the BS Output circuit voltage drops to 0 volts and
the CAB senses the brake pedal state. This tells the
CAB what position the brake pedal is currently in to
make an ABS event possible. When using the
DRBIIItin Inputs/Outputs, the BS and BLS will
3
GENERAL INFORMATION

read opposite switch states.Note: The BS and
BLS are in the same switch housing.
BRAKE LAMP SWITCH (BLS):This switch pre-
pares the CAB for a possible antilock event. The
CAB uses an output state voltage from the BLS
when the brake pedal is either depressed/released.
The Fused Ignition Switch Output circuit supplies
12 volts to the BLS. A depressed brake pedal will
close the BLS circuit and the BLS Output circuit
supplies 12 volts at the CAB. When the driver
releases the brake pedal, the BLS Output circuit
voltage drops to 0 volts and the CAB senses the
brake pedal state. This tells the CAB what position
the brake pedal is currently in to make an ABS
event possible. When using the DRBIIItin Inputs/
Outputs, the BS and BLS will read opposite switch
states.Note: The BS and BLS are in the same
switch housing.
TRACTION CONTROL SYSTEM SWITCH
(TCSS):This switch signals the CAB to either turn
ON or OFF the TCS. The driver can toggle the
TCSS, which receives 12 volts from the D (+) Relay
Output circuit. Depending on the position of the
TCSS, open or closed, the CAB receives the TCSS
state voltage on the TCS Switch Sense circuit.
When 12 volts are applied to the TCS Switch Sense
circuit, the TCS is OFF. When no voltage is present,
the TCS is ON.
WHEEL SPEED SENSORS AND TONE
WHEELS:The Bosch 5.7 system uses one passive
WSS on each wheel. The sensor measures the wheel
speed by monitoring a rotating tone wheel. As the
teeth of the tone wheel move through the magnetic
field of the sensor an AC voltage and amperage is
generated. This signal frequency increases or de-
creases proportionally to the speed of the wheel.
The CAB monitors this signal to check for a sudden
change in single or multiple wheel decelerations. If
the deceleration of one or more wheels is not within
a predetermined amount, the CAB takes control for
antilock action through the HCU. Each WSS has a
magnetic inductive pick up coil (WSS) that is
mounted to a fixed component. There is an air gap
between the tone wheel and the speed sensor as-
sembly. Diagnostically, the coils of the Wheel Speed
Sensors have the same amount of resistance. When
measured across the CAB harness connector termi-
nals, the resistance should be between 1100 - 1800
ohms. Refer to service manual for WSS replacement
and air gap specifications.
Correct ABS operation is dependent on Tone
Wheel speed signal from the WSS. The vehicle
wheels and tires should all be the same size and
type to get accurate signals. In addition, all tires
should be at recommended tire pressures.3.7.5 SELF TESTS
The system software includes several self tests
that are performed every time the ignition is turned
on and the vehicle is driven. Some of the self tests
occur immediately, while others occur under normal
driving conditions while not in antilock operation.
The CAB checks continuously for a missing or
erratic WSS signals/circuits, tone wheels, solenoids,
pump motor or solenoid relay by performing several
tests such as: dynamic, static, ohmic, voltage drop,
and timed response. If any component exhibits a
fault during testing, the CAB will request to illumi-
nate the ABS and TCS warning indicators.
As an additional check of the ESP system, a road
test procedure is available on the DRBIIIt. This
test should be carried out when any ESP component
is replaced in order to ensure proper function. Since
the wheel speed sensors are required inputs to the
ESP, this test should also be performed if the wheel
speed sensors are replaced.
First, the brakes are applied with the vehicle
stationary. Then, the vehicle is driven at approxi-
mately 6 MPH. The driver has to make left and
right turns, with a minimum 90 degree steering
turning angle. If the indicator lamp goes out, every-
thing is in order. If the lamp remains illuminated,
the DRBIIItwill display the fault codes that are
causing the test to fail. The road test function is set
in the ESP control module, and can only be deacti-
vated once there are no more fault codes detected.
The Steering Angle Sensor must be initialized. A
procedure is carried out using the DRBIIItto
ensure that the module detects the exact position of
the sensor. The sensor must be calibrated any time
wheel alignment is changed, the steering column is
removed and re-installed, or the sensor is replaced.
3.8 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading diagnostic trouble
codes, erasing diagnostic trouble codes and other
DRBIIItfunctions.
3.9 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
Ð User-Requested WARM Boot or User-Requested
COLD Boot.
If the DRBIIItshould display any other error
message, record the entire display and call the
STAR Center for information and assistance. This
is a sample of such an error message display:
4
GENERAL INFORMATION

ver: 2.14
date: 26 Jul93
file: key_iff.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this display
and the application screen.
Press F4 when done noting information.
3.9.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's 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 (data link
16-way connector cavity 16). A minimum of 11 volts
is required to adequately power the DRBIIIt. Also
check for a good ground at DLC.
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 or a faulty cable or
vehicle wiring.
3.9.2 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 latestinformation 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: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS 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 front
drive wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing an antilock brake or adjustable
pedals system problem, it is important to follow
approved procedures where applicable. These pro-
cedures can be found in the service manual. Follow-
ing these procedures is very important to safety of
individuals performing 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 antilock brake and trac-
tion control are intended to be serviced in assembly
only. Attempting to remove or repair certain 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.
5
GENERAL INFORMATION