2006 MERCEDES-BENZ SPRINTER service

SERVICE MANUAL2006
SPRINTER
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Copyright 2004 DaimlerChrysler Corporation
81-370-06070CD

CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN
ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies
innon-automotive applications should be repaired in accordance with instruc-
tions supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The
service procedures recommended and described in this publication were developed for pro-
fessional service personnel and are effective methods for performing vehicle repair. Following
these procedures will help assure efficient economical vehicle performance and service reli-
ability. Some of these service procedures require the use of special tools designed for specific
procedures. These special tools should be used when recommended throughout this publi-
cation.
Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless
removal may cause personal injury. Always wear safety goggles whenever work-
ing on vehicles or vehicle components.
It is important to note that this publication contains various CautionsandWarnings. These
should be carefully read in order to minimize the risk of personal injury, or the possibility that
improper service methods may damage the vehicle or render it unsafe. It is important to note
that these CautionsandWarnings cover only the situations and procedures Daimler-
Chrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation
could not possibly know, evaluate, and advise the
service trade of all conceivable ways that
service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler
Corporation has not undertaken any such broad service review. Accordingly, anyone who uses
a service procedure, or tool, that is not recommended in this publication must assure oneself
thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service
methods they select.
For other Service and Owner Manuals for Chrysler,
Plymouth, Dodge, Dodge Truck, and Jeep
Tvehicles, Call
(800) 890-4038 or FAX (440) 572-0815 to place an order. Or, visit our website at techauthority.daimlerchrysler.com.Tech Authority Online at our website offers you serviceinformation on a subscription basis.

UNITED STATES and CANADA
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-800-801-5420 FAX 1-800-578-7375
INTERNATIONAL
The special service tools referred to herein are required for certain service opera-
tions. These special service tools or their equivalent, if not obtainable through a local
source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-507-455-7320 FAX 1-800-578-7375

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

1.0 INTRODUCTION
The procedures contained in this manual include
all the specifications, instructions and graphics
needed to diagnose Sprinter body system problems.
The diagnostics in this manual are based on the
failure condition or symptom being present at the
time of diagnosis.
Please follow the recommendations below when
choosing your diagnostic path.
1. First make sure the DRBIIItis communicating
with the appropriate modules; i.e., if the
DRBIIItdisplays a ``No Response'' or a ``Bus6
Signals Open'' condition, you must diagnose that
first.
2. Read DTC's (diagnostic trouble codes) with the
DRBIIIt.
3. If no DTC's are present, identify the customer
complaint.
4. Once the DTC or customer complaint is identi-
fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.
All component location views are in Section 8.0.
All connector pinouts are in Section 9.0. All sche-
matics are in Section 10.0. All Charts and Graphs
are in Section 11.0.
An * placed before the symptom description indi-
cates a customer complaint without a DTC.
When repairs are required, refer to the appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added: carryover sys-
tems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
DIAGNOSTIC TROUBLE CODE. It is recom-
mended that you review the entire manual to be-
come familiar with all the new and changed diag-
nostic procedures.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or suggestions, please fill out
the form in the back of this book and mail it back to
us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
Sprinter vehicles.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the body system is done in six basic
steps:
²verification of complaint
²verification of any related symptoms
²symptom analysis
²problem isolation
²repair of isolated problem
²verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
The vehicle systems that are part of the ``body''
system are:
²Airbag
²Automatic Temperature Control
²Communication
²Instrument Cluster
²Power Door Locks/RKE
²Vehicle Theft Security System (VTSS)
²Wiper/Rain Sensor
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
The body system on the Sprinter consists of a
combination of modules that communicate with
each other using the CAN Bus (controller area
network). Through the CAN Bus, information about
the operation of vehicle components and circuits is
relayed quickly to the appropriate modules. Since
the CAN bus network is for intermodule communi-
cation only, the DRBIIItutilizes K-Lines to estab-
lish communications with each module. It is impor-
tant to note the CAN bus circuits are by no means
tied to the K-Lines. They are completely separate
from each other. For additional information on the
CAN bus and the K-Lines, refer to the Communi-
cation section of this general information.
3.1 AIRBAG SYSTEM
The Sprinter Airbag System contains the follow-
ing components:
²Airbag Control Module (ACM)
²Airbag Warning Indicator (SRS)
²Driver Airbags
²Clockspring
²Passenger Airbag
²Driver Seat Belt Tensioners
²Passenger Seat Belt Tensioners
The Airbag Control Module (ACM) has five major
functions: onboard diagnostics, determine the se-
verity of impacts, squib deployment and Accident
Response, K-Line communications. The ACM is
1
GENERAL INFORMATION

secured to the floor under the Driver seat and
receives power from the Fuse Block No. 1. When-
ever the ignition key is turned to the run or start
position, the ACM performs a system test. The ACM
cannot be repaired or adjusted.
The microprocessor in the ACM monitors the
internal and external airbag system electrical cir-
cuits to determine the system readiness. When a
monitored system is determine to be out of range,
the ACM will set both active and stored diagnostic
trouble codes (DTC). The ACM also contains an
energy-storage capacitor. This capacitor stores
enough electrical energy to deploy the front airbag
components for two seconds following a battery
disconnect or failure during an impact.
The Accelerometer in the ACM is used to sense
the rate of vehicle deceleration, provide verification
of the direction and severity of an impact. When the
preprogrammed conditions are met, the ACM sends
an electrical signal to deploy the appropriate front
airbag system components and a deployment noti-
fication.
To provide an accident response notification, the
ACM is hardwired to the Central Timer module
(CTM) and Engine Control Module (ECM). When a
deployment occurs the ACM provides a 50ms 10.0
volt pulse to the CTM and ECM. When the Accident
Report notification signal is received the CTM un-
locks the door locks and the ECM stalls the engine.
The Accident signal will set a DTC in the CTM and
the door locks will not work until the DTC has been
erased. The ECM will set a DTC if the Accident
Report circuit is shorted to battery voltage. The
ACM saves the deployment record and after three
deployments the ACM must be replaced. The
DRBIIItcan be used to test the Accident Report
Notification feature: select the SYSTEM TEST from
the ACM main menu. Then select the Analog Crash
Output System Test.
The ACM is hardwired to the Instrument Cluster
(MIC) to control Warning Indicator (SRS indicator).
When DTCs becomes activate, the ACM illuminates
the Warning Indicator by pulling the indicator
circuit low. The SRS indicator is the only point at
which the customer can observe symptoms of a
system malfunction.
As part of the system test the ACM illuminates
the Warning Indicator on for 4.0 second bulb test.
After the lamp check, if the indicator turns off, it
means that the ACM has checked the system and
found it to be free of discernible malfunctions.
NON-CRITICAL DTCs
If the lamp comes on and stays on for a period
longer than 4.0 seconds (about 10.0 seconds) is
usually a stored DTC (intermittent problem) in the
system.
CRITICAL DTCs
DTCs that could lead to a condition where the
safety devises may not deploy or incorrectly deploy.
In the event of such a DTC, the safety of the vehicle
occupants can no longer be guaranteed. If the lamp
remains on, there could be an active DTC in the
system. Some DTCs, Internal Module and squib
DTCs, will keep the indicator illuminated even if
the codes are no longer active.
ACM NOT CONFIGURED FOR PASSENGER
AIRBAG AND TENSIONER
If after replacing the ACM the Airbag Warning
Indicator flashes continuously the ACM must be
configured for the Passenger Airbag and Tensioner.
Select Miscellaneous from the ACM main menu and
configure the Passenger Airbag Tensioner squibs.
WARNING:THE AIRBAG SYSTEM IS A
SENSITIVE, COMPLEX ELECTROMECHANICAL
UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR
SERVICE ANY AIRBAG SYSTEM OR RELATED
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE. WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR
TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIRBAG SYSTEM. FAILURE TO
DO THIS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR KICK THE
AIRBAG CONTROL MODULE, AS IT CAN
DAMAGE THE IMPACT SENSOR OR AFFECT
ITS CALIBRATION.
WARNING: IF AN AIRBAG CONTROL
MODULE IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW
UNIT. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND
PERSONAL INJURY OR DEATH.
3.1.1 DRIVER AIRBAG
The airbag protective trim cover is the most
visible part of the driver side airbag system. The
airbag is mounted directly to the steering wheel.
Located under the trim cover are the airbag cushion
and the airbag cushion supporting components.
2
GENERAL INFORMATION

When supplied with the proper electrical signal, the
inflator discharged the gas directly into the cush-
ion. The airbag cannot be repaired, and must be
replaced if deployed or in any way damaged.
WARNING: THE DRIVER AIRBAG MODULE
CONTAINS ARGON GAS PRESSURIZED TO
OVER 17236.89 Kpa (2500 PSI). DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG
MODULE OR TAMPER WITH ITS INFLATOR.
DO NOT PUNCTURE, INCINERATE, OR
BRING INTO CONTACT WITH ELECTRICITY.
DO NOT STORE AT TEMPERATURE
EXCEEDING 93ÉC (200ÉF). REPLACE AIRBAG
SYSTEM COMPONENTS ONLY WITH PARTS
SPECIFIED IN THE CHRYSLER MOPAR
PARTS CATALOG. SUBSTITUTE PARTS MAY
APPEAR INTER-CHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN
INFERIOR OCCUPANT PROTECTION. THE
FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE AIRBAG
SYSTEM COMPONENTS HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE AIRBAG SYSTEM. THEY
MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANY TIME A NEW FASTENER
IS NEEDED, REPLACE IT WITH THE
CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
MOPAR PARTS CATALOG. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND PERSONAL INJURY OR
DEATH.
3.1.2 CLOCKSPRING
The clockspring is mounted on the steering col-
umn under the steering wheel. This assembly con-
sists of a plastic housing which contains a flat,
ribbon-like, electrically conductive tape that winds
and unwinds with the steering wheel rotation. The
clockspring is used to maintain a continuous elec-
trical circuit between the instrument panel wiring
and the driver airbag and the horn. The clockspring
must be properly centered when it is reinstalled on
the steering column following any service proce-
dure, or it could be damaged. The clockspring can-
not be repaired and it must be replaced.
3.1.3 PASSENGER AIRBAG
The Passenger Airbag is optional equipment.
When supplied with the proper electrical signal the
passenger airbag inflator discharges the gas di-rectly into the cushion. The airbag module cannot
be repaired, and must be replaced if deployed or in
any way damaged.
WARNING: THE PASSENGER AIRBAG
MODULE CONTAINS ARGON GAS
PRESSURIZED TO 17236.89 Kpa (2500 PSI).
DO NOT ATTEMPT TO DISMANTLE AN
AIRBAG MODULE OR TAMPER WITH ITS
INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT
WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURE EXCEEDING 93ÉC (200ÉF).
REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE
MOPAR PARTS CATALOG. SUBSTITUTE
PARTS MAY APPEAR INTER-CHANGEABLE,
BUT INTERNAL DIFFERENCES MAY RESULT
IN INFERIOR OCCUPANT PROTECTION. THE
FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE AIRBAG
SYSTEM COMPONENTS HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE AIRBAG SYSTEM. THEY
MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANY TIME A NEW FASTENER
IS NEEDED, REPLACE IT WITH THE
CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
MOPAR PARTS CATALOG. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND PERSONAL INJURY OR
DEATH.
3.1.4 SEAT BELT TENSIONERS
Front seat belt systems incorporate a Driver and
optional Passenger Seat Belt Tensioner Retractors.
At the onset of an impact event each tensioner uses
a pyrotechnic device, which is triggered simulta-
neously with the front airbags, to rapidly retract
the seat belts. With the slack removed, the occu-
pant's forward motion in an impact will be reduced
as will the likelihood of contacting interior compo-
nents. After an impact that deploys the airbag, the
seat belt tensioner assembly must be replaced. The
ACM module monitors the Seat Belt Tensioners
circuit resistance and reports active and stored
DTCs if any problem is found. Follow all of the
safety procedures when servicing tensioner.
3.1.5 SPECIAL TOOLS
Airbag load tools 8310 and 8443 are used in some
airbag diagnostic test. The load tools contain fixed
resistive loads, jumpers and adapters. The fixed
3
GENERAL INFORMATION

loads are connected to cables and mounted in a
storage case. The cables can be directly connected to
some airbag system connectors. Jumpers are used
to convert the load tool cable connectors to the other
airbag system connectors. The adapters are con-
nected to the module harness connector to open
shorting clips and protect the connector terminal
during testing. When using the load tool follow all of
the safety procedures in the service information for
disconnecting airbag system components. Inspect
the wiring, connector and terminals for damage or
misalignment. Substitute the airbag load tool in
place of a Driver or Passenger Airbag, seat belt
tensioner, clockspring (use a jumper if needed).
Then follow all of the safety procedures in the
service information for connecting airbag system
components. Read the module active DTCs. If the
module reports NO ACTIVE DTCs the defective
components has been removed from the system and
should be replaced. If the DTC is still active, con-
tinue this process until all components in the circuit
have been tested. Then disconnect the module con-
nector and connect the matching adapter to the
module connector. With all airbags disconnected
and the adapter installed the squib wiring can be
tested for open and shorted conditions.
3.1.6 DIAGNOSTIC TROUBLE CODES
Airbag diagnostic trouble codes consist of active
and stored codes. If more than one code exists,
diagnostic priority should be given to the active
codes. Each diagnostic trouble code is diagnosed by
following a specific testing procedure. The diagnos-
tic test procedures contain step-by-step instructions
for determining the cause of the trouble codes. It is
not necessary to perform all of the tests in this book
to diagnose an individual code. Always begin by
reading the diagnostic trouble codes with the
DRBIIIt. This will direct you to the specific test(s)
that must be performed. In certain test procedures
within this manual, diagnostic trouble codes are
used as a diagnostic tool.
3.1.6.1 ACTIVE CODES
If the lamp remains on, there could be an active
DTC in the system. The code becomes active as soon
as the malfunction is detected or key-on, whichever
occurs first. An active trouble code indicates an
on-going malfunction. This means that the defect is
currently there every time the airbag control mod-
ule checks that circuit or component. Some DTCs,
Internal Module and squib DTCs, will keep the
indicator illuminated even if they are no longer
active. If the lamp is on and no active codes are
present, cycling the ignition switch off and then on
will refresh the lamp state. It is impossible to erase
an active code.
3.1.6.2 STORED CODES
Airbag codes are automatically stored in the
ACM's memory as soon as the malfunction is de-
tected. A stored code indicates there was an active
code present at some time. Stored diagnostic trou-
ble code will remain stored until erased by the DRB.
If a malfunction is not active while performing a
diagnostic test procedure, the active code diagnostic
test will not locate the source of the problem. In this
case, the stored code can indicate an area to inspect.
Maintain a safe distance from all airbags while
performing the following inspection. If no obvious
problems are found, erase stored codes, and with
the ignition on wiggle the wire harness and connec-
tors, rotate the steering wheel from stop to stop.
Recheck for codes periodically as you work through
the system. This procedure may uncover a malfunc-
tion that is difficult to locate.
3.2 COMMUNICATION
3.2.1 COMMUNICATION K-LINES
The K-Lines are a group of circuits that connect
each control module to the Data Link Connector
(DLC). Each control module is connected to the DLC
with a single K-Line. The DRBIIItuses the K-Line
to communicate with each control module. With the
use of the K-Lines the DRBIIItis able to read each
control modules DTCs, sensor displays, I/Os etc. If
DRBIIItcommunications with a particular control
module is lost, one of the possible causes could be a
fault in the module's K-Line.
NOTE: It is important to note the DRBIIIT
uses the K-Lines for diagnostic and
monitoring functions and is no way
connected to the CAN data bus network.
The following modules that use the K-line on this
vehicle are:
²Airbag Control Module (ACM)
²Automatic Temperature Control (ATC)
²Cabin Heater Module (CHM)
²Central Timer Module (CTM)
²Controller Antilock Brake (CAB)
²Engine Control Module (ECM)
²Heater Booster Module (HBM)
²Instrument Cluster (IC)
²Shifter Assembly (SA)
²Security System Module (SSM)
²Sentry Key Remote Entry Module (SKREEM)
²Transmission Control Module (TCM)
4
GENERAL INFORMATION