2006 MERCEDES-BENZ SPRINTER engine

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Remove the Starter Motor Relay from the Fuse/Relay Block.
Using a 12-volt test light connected to ground, check the Ignition Switch Output
(Start) circuit in the Starter Motor Relay connector in the Fuse/Relay Block while
turning the ignition to the Crank/Start position.
Did the test light illuminate while turning the ignition to the Crank/Start position?All
Ye s!Go To 4
No!Repair the Ignition Switch Output (Start) circuit for an open.
Perform NO START VERIFICATION - VER-1.
4 Turn the ignition off.
Remove the Starter Motor Relay from the Fuse/Relay Block.
Install a substitute relay in place of the Starter Motor Relay.
Attempt to start the engine.
Does the engine crank?All
Ye s!Replace the Starter Motor Relay.
Perform NO START VERIFICATION - VER-1.
No!Go To 5
5 Turn the ignition off.
Remove the Starter Motor Relay from the Fuse/Relay Block.
Disconnect the Starter Motor Relay Output wire from the Starter Solenoid.
Connect the Starter Motor Relay Output wire (at the Starter) to ground.
Using a 12-volt test light connected to 12-volts, check the Starter Motor Relay Output
circuit at the Starter Motor Relay connector in the Fuse/Relay Block.
Does the test light illuminate brightly?All
Ye s!Go To 6
No!Repair the Starter Relay Output circuit for an open.
Perform NO START VERIFICATION - VER-1.
6 Using the Service Information, check the battery cables for high resistance.
Did either battery cable have a voltage drop greater than 0.2 volts?All
Ye s!Replace the battery cable(s).
Perform NO START VERIFICATION - VER-1.
No!Go To 7
7 Turn the ignition off.
Attempt to manually rotate the crankshaft 360É.
Is the crankshaft able to rotate 360É?All
Ye s!Replace the Starter Motor.
Perform NO START VERIFICATION - VER-1.
No!Repair the engine mechanical problem.
Perform NO START VERIFICATION - VER-1.
243
DRIVEABILITY - DIESEL
*ENGINE WILL NOT CRANK ÐContinued

TEST ACTION APPLICABILITY
8NOTE: 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.
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 9
9 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 SKREEM.
Perform NO START VERIFICATION - VER-1.
No!Go To 10
10 Turn the ignition on.
With the DRBIIIt, read the TCM DTCs.
Does the DRBIIItdisplay any TCM DTCs?All
Ye s!Refer to symptom list for problems related to TCM.
Perform NO START VERIFICATION - VER-1.
No!Go To 11
11 Perform the Checking the ECM Power and Grounds test.
Were any problems found?All
Ye s!Repair as necessary.
Perform NO START VERIFICATION - VER-1.
No!Go To 12
12 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the Starter Motor Relay from the Fuse/Relay Block
Remove the Engine Control Relay from the Fuse Block No.1.
Using a jumper wire, connect Engine Control Relay connector cavities 30 and 87 in
the Fuse Block No.1.
Turn the ignition on.
Measure the voltage of the Starter Motor Relay Control circuit.
Is the voltage above 1.0 volt?All
Ye s!Repair the Starter Relay Control circuit for a short to voltage.
Perform NO START VERIFICATION - VER-1.
No!Go To 13
244
DRIVEABILITY - DIESEL
*ENGINE WILL NOT CRANK ÐContinued

TEST ACTION APPLICABILITY
13 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the Starter Motor Relay from the Fuse/Relay Block.
Measure the resistance of the Starter Motor Relay Control circuit between the ECM
harness connector and the Fuse/Relay Block connector.
Measure the resistance of the Starter Motor Relay 12-volt Supply circuit between the
ECM harness connector and the Fuse/Relay Block connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Go To 14
No!Repair the Starter Motor Relay circuit(s) for an open.
Perform NO START VERIFICATION - VER-1.
14 Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the Starter Motor Relay from the Fuse/Relay Block.
Measure the resistance between ground and the Starter Motor Relay Control circuit
at the Fuse/Relay Block connector.
Measure the resistance between ground and the Starter Motor Relay 12-volt Supply
circuit at the Fuse/Relay Block connector.
Is the resistance below 10.0 ohms for each measurement?All
Ye s!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform NO START VERIFICATION - VER-1.
No!Repair the Starter Motor Relay circuit(s) for a short to ground.
Perform NO START VERIFICATION - VER-1.
245
DRIVEABILITY - DIESEL
*ENGINE WILL NOT CRANK ÐContinued

Verification Tests
BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. Ensure that all accessories are turned off and the battery is fully charged.
3. NOTE: Refer to the service information for proper programming procedures if the
ABM; ACM; ATC; CTM; ECM; IC; SKREEM; SLA; or SSM was replaced.
4. If the SKREEM was replaced, program all RKE transmitters used with this vehicle.
5. NOTE: Perform the next 8 steps of this procedure if either diagnosing the
Automatic Temperature Control (ATC) system or if repairs were made to the ATC
system. All of the following criteria must be met in order to successfully run the ATC
Function Test.
6. With DRBIIIt, record and erase ATC DTCs.
7. Place the shift lever in Park.
8. Start the engine. Allow the engine to reach normal operating temperature.
9. Set the blower to high speed.
10. Press the Air Conditioning switch On.
11. With the DRBIIIt, verify that the ambient temperature is above 59ÉF (15ÉC), the refrigerant
pressure is between 29 and 348 PSI (2 and 24 bar), the evaporator temperature is above 36.5ÉF
(2.5ÉC), and the coolant temperature is above 158ÉF (70ÉC).
12. With the DRBIIItin ATC, select System Tests and select ATC Function Test. When the ATC
Function Test is complete, proceed to the next step of this procedure.
13. With the DRBIIIt, read active ATC DTCs. If any DTC is active or if the original condition
is still present, proceed to the conclusion question and answer Yes.
14. With the DRBIIIt, record and erase all DTCs from ALL modules. Start and run the engine
for 2 minutes. Operate all functions of the system that caused the original concern.
15. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIIIt, read
DTCs from ALL modules.
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.
NAG1 TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY
1. Reconnect any disconnected components.
2. Connect the DRBIIItto the Data Link Connector.
3. With the DRBIIIt, erase ABS DTCs.
4. With the DRBIIIt, erase ECM DTCs.
5. With the DRBIIIt, erase Transmission DTCs.
6. With the DRBIIIt, display Transmission Temperature. Start and run the engine until the
Transmission Temperature is HOT, above 43É C (110É F).
7. Check the Transmission fluid and adjust if necessary. Refer to the Service Information for the
proper Fluid Fill procedure.
8. NOTE: If internal repairs were performed and the shift quality is still poor, it may
be necessary to check the internal repair. Also check for any TSBs and/or Controller
Flash updates that may apply.
9. ROAD TEST PROCEDURE
10. Road test the vehicle. Make fifteen to twenty 1-2, 2-3, 3-4 and 4-5 upshifts.
11. Perform these shifts from a standing start to 72 km/h (45 MPH) with a constant throttle
opening of 20 to 25 degrees.
12. With speeds below 40 km/h (25 MPH), make five to eight wide open throttle kickdowns to
1st gear. Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown.
13. With the DRBIIIt, read Transmission DTCs.
Were there any Diagnostic Trouble Codes set?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
246
VERIFICATION TESTS

NO START VERIFICATION - VER-1 APPLICABILITY
1. NOTE: IMPORTANT! If the Engine Control Module or Sentry Key Immobilizer
Module has been replaced, ensure the programming procedure for the module has
been performed in accordance with the Service Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Turn the ignition off for at least 10 seconds.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
ROAD TEST VERIFICATION - VER-2 APPLICABILITY
1. Inspect the vehicle to ensure that all engine components are properly installed and
connected. Reassemble and reconnect components as necessary.
2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4. If not, proceed to step 5.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) has not been changed, perform steps 7 and 8, otherwise,
continue with step 9.
7. With the DRB IIIt, erase all diagnostic trouble codes (DTCs), then disconnect the DRB IIIt.
8. Turn the ignition off for at least 10 seconds.
9. If equipped with a Transfer Case Position Switch, perform step 10, otherwise, continue with
step 11.
10. With the ignition switch on, place the Transfer Case Shift Lever in each gear position,
stopping for 15 seconds in each position.
11. Ensure no DTCs remain by performing steps 12 through 15.
12. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
13. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
14. Upon completion of the road test, turn the engine off and check for DTCs with the DRB IIIt.
15. If the repaired DTC has set again, the repair is not complete. Check for any pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the
repair was successful and is now complete.
Are any DTCs or symptoms remaining?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
247
VERIFICATION TESTS
Verification Tests ÐContinued

BOOST PRESSURE SERVOMOTOR (OBD)CAV CIRCUIT FUNCTION
1 16YL/BK FUSED ENGINE CONTROL RELAY OUTPUT
2 16YL/WT GROUND
3- -
4 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL
5- -
CAMSHAFT POSITION SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 18RD/BL (EXCEPT OBD) CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
3 20RD/BL (OBD) CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
256
CONNECTOR PINOUTS

CONTROLLER ANTILOCK BRAKECAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
3- -
4- -
5 14BR GROUND
6 14RD FUSED B(+)
7- -
8 20BK/DG SENSOR SIGNAL
9 20YL/WT SENSOR SIGNAL
10 20YL/RD SENSOR SIGNAL
11 18BL/BK K-ABS/SHIFTER ASSEMBLY
12 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
13 - -
14 20WT LEFT REAR WHEEL SPEED SENSOR (+)
15 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)
16 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
17 - -
18 - -
19 - -
20 20WT BRAKE SWITCH OUTPUT
21 20BR GROUND
22 - -
23 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
24 20DG/WT CAN C BUS (+)
25 20BR SENSOR GROUND
26 20WT/GY BRAKE PRESSURE SENSOR SIGNAL
27 18BK/BL TCS SWITCH (ASR) SENSE
28 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
29 20BR LEFT REAR WHEEL SPEED SENSOR (-)
30 20BR RIGHT REAR WHEEL SPEED SENSOR (-)
31 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
32 18BK/RD BRAKE LAMP SWITCH OUTPUT
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 20RD/BL POWER INPUT
40 20DG CAN C BUS (-)
41 20DG/YL SENSOR SIGNAL
42 20WT/RD 5 VOLT SUPPLY
CRANKCASE HEATER - BLACKCAV CIRCUIT FUNCTION
1 18BR (EXCEPT OBD) GROUND
1 18BK/RD (OBD) CRANKCASE HEATER SIGNAL
2 16BK/RD (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 18BK/BR (OBD) CRANKCASE HEATER GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
257
CONNECTOR PINOUTS

CRANKSHAFT POSITION SENSOR - BLACKCAV CIRCUIT FUNCTION
1 20DG (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
1 20DG/WT (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG/WT (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
DATA LINK CONNECTOR - BLACKCAV CIRCUIT FUNCTION
1 20WT/DG K-SKREEM
2- -
3 20DG/YL ENGINE RPM
4 20BR GROUND
5 20BR GROUND
6- -
7 20BL/YL K-ECM
8 20BK/BL/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 20BL/BK K-ABS/SHIFTER ASSEMBLY
10 - -
11 20BL K-TCM/RADIO
12 20GY/DG/RD K-CTM/SSM
13 20BK/RD K-ACM
14 - -
15 20WT/GY K-IC/ATC/HBM/CHM
16 20RD/YL FUSED B(+)
EGR VALVE - BLACKCAV CIRCUIT FUNCTION
1 20RD/YL (EXCEPT OBD) EGR VALVE CONTROL
1 20DG/WT (OBD) EGR VALVE CONTROL
2 16BK/GY (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 16BK/DG (OBD) FUSED ENGINE CONTROL RELAY OUTPUT
3 18BR/BK (EXCEPT OBD) SENSOR GROUND
3 20BR/DG (OBD) SENSOR GROUND
4- -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
258
CONNECTOR PINOUTS