2006 MERCEDES-BENZ SPRINTER Service Manual

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Page 545 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
13 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Test.
Did this test pass?All
Ye s!Go To 14
No!Replace the Fuel Pressure Solenoid in accord

TEST ACTION APPLICABILITY
13 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Test.
Did this test pass?All
Ye s!Go To 14
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
14 With the DRBIIIt, select System Tests, then perform the Rail Press Control Valve
Variation Test.
Did this test pass?All
Ye s!Go To 15
No!Replace the Fuel Pressure Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
15 With the DRBIIIt, select System Test, then High Pressure Pump.
NOTE: During this test engine speed is set at 1,400 rpm and initial fuel
pressure at approximately 6,800 psi. During the test fuel pressure is
instantly set to above 20,000 psi. to test the performance of the Fuel
Injection Pump.
NOTE: After the test is completed, the DRB display fuel pressure in 30
counter steps. If the fuel pressure increases from approximately 6,800 psi to
above 20,000 psi in one counter step, the injection pump passes the test.
Did the fuel pressure increase to above 20,000 psi within one counter step on the
DRB?All
Ye s!Replace the Fuel Quantity Solenoid in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace Fuel Injection Pump in accordance with the Service
Information.
Perform ROAD TEST VERIFICATION - VER-2.
16WARNING: 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 and at normal operating temperature, monitor the DRB IIIt
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.
122
DRIVEABILITY - DIESEL
P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED Ð
Continued

Page 546 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
17 Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel p

Page 547 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
21 Turn the ignition off.
Replace the Fuel Quantity Solenoid in accordance with the Service Information.
Turn the ignition on.
With the DRBIIIt, erase the ECM DTCs.
Attempt t

Page 548 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Symptom:
P2025-INTAKE PRESSURE SENSOR PLAUSIBILITY
When Monitored and Set Condition:
P2025-INTAKE PRESSURE SENSOR PLAUSIBILITY
When Monitored: With the ignition on.
Set Condition: The Intake Pressure

Page 549 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
3NOTE: Inspect all air intake and turbocharger related tubes for damage,
restriction or poor connection. Any of these conditions can cause a this DTC
to set.
Turn the ignitio

Page 550 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
7WARNING: 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: Th

Page 551 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Symptom List:
P2025-INTAKE PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH
P2030-INTAKE PRESSURE SENSOR CIRCUIT FAULT
P2030-INTAKE PRESSURE SENSOR OPEN CIRCUIT
P2030-INTAKE PRESSURE SENSOR SIGNAL VOLTAGE TOO

Page 552 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage between gro

TEST ACTION APPLICABILITY
2 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Turn the ignition on.
Measure the voltage between ground and the Intake Pressure Sensor Signal circuit.
Is the voltage above 1.0 volt?All
Ye s!Go To 3
No!Go To 4
3 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
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 between ground and the Intake Pressure Sensor Signal circuit.
Is the voltage above 1.0 volt?All
Ye s!Repair the Intake Pressure Sensor Signal circuit for a short to
voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No!Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
4 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
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 between ground and the Intake Pressure Sensor Ground circuit.
Is the voltage above 1.0 volt?All
Ye s!Repair the Intake Pressure Sensor Ground circuit for a short to
voltage. Note: The ECM will need to be checked for proper
operation before the repair is completed. A short to voltage on a
ground circuit can damage the ECM.
Perform ROAD TEST VERIFICATION - VER-2.
No!Go To 5
5 Turn the ignition off.
Disconnect the Intake Pressure Sensor harness connector.
Disconnect the ECM harness connectors.
Measure the resistance of the Sensor Ground circuit.
Is the resistance below 10.0 ohms?All
Ye s!Go To 6
No!Repair the Intake Pressure Sensor Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
129
DRIVEABILITY - DIESEL
P2025-INTAKE PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH Ð
Continued

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