Mercedes-Benz Sprinter 2003 User manual

TABLE OF CONTENTS
1.0 INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0 IDENTIFICATION OF SYSTEM .............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1
3.1 AIRBAG SYSTEM ...................................................1
3.1.1 DRIVER AIRBAG............................................2
3.1.2 CLOCKSPRING.............................................3
3.1.3 PASSENGER AIRBAG .......................................3
3.1.4 SEAT BELT TENSIONERS....................................3
3.1.5 SPECIAL TOOLS............................................3
3.1.6 DIAGNOSTIC TROUBLE CODES ..............................4
3.1.6.1 ACTIVE CODES ............................................4
3.1.6.2 STORED CODES ...........................................4
3.2 COMMUNICATION ..................................................4
3.2.1 COMMUNICATION K-LINES ..................................4
3.2.2 CANBUS..................................................5
3.3 HEATING & A/C SYSTEM ............................................5
3.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC) ..................5
3.3.1.1 SYSTEM CONTROLS........................................5
3.3.1.2 SYSTEM DIAGNOSTICS .....................................5
3.3.2 CABIN HEATER MODULE (CHM) & HEATER BOOSTER MODULE
(HBM).....................................................7
3.3.2.1 SYSTEM DESCRIPTION .....................................7
3.3.2.2 VENTING THE HEATER’S EXHAUST...........................8
3.3.2.3 SYSTEM DIAGNOSTICS .....................................8
3.4 INSTRUMENT CLUSTER.............................................9
3.5 POWER DOOR LOCKS/RKE..........................................9
3.5.1. CENTRAL LOCKING.........................................9
3.5.2 REMOTE KEYLESS ENTRY (RKE).............................9
3.5.3 AUTO DOOR LOCKS .......................................10
3.5.4 ACCIDENT RESPONSE.....................................10
3.6 VEHICLE THEFT SECURITY SYSTEM (VTSS) ..........................10
3.7 USING THE DRBIIIT................................................11
3.8 DRBIIITERROR MESSAGES.........................................11
3.9 DRBIIITDOES NOT POWER UP (BLANK SCREEN)......................11
3.10 DISPLAY IS NOT VISIBLE ...........................................11
4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................11
4.1 DISCLAIMERS.....................................................11
4.2 SAFETY ..........................................................11
4.2.1 TECHNICIAN SAFETY INFORMATION.........................11
4.2.2 VEHICLE PREPARATION FOR TESTING.......................12
4.2.3 SERVICING SUB-ASSEMBLIES ..............................12
4.2.4 DRBIIITSAFETY INFORMATION .............................12
4.3 WARNINGS .......................................................12
4.3.1 VEHICLE DAMAGE WARNINGS ..............................12
4.3.2 ROAD TESTING A COMPLAINT VEHICLE......................12
i

TABLE OF CONTENTS - Continued
5.0 REQUIRED TOOLS AND EQUIPMENT .....................................13
6.0 GLOSSARY OF TERMS..................................................13
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................15
AIRBAG
AIRBAG WARNING INDICATOR - DRIVER HIGH .............................16
AIRBAG WARNING INDICATOR - DRIVER LOW..............................19
DRIVER SEAT BELT TENSIONER - INCORRECT FEEDBACK ..................22
DRIVER SQUIB 1 - INCORRECT FEEDBACK................................22
INTERNAL 1 ...........................................................22
INTERNAL 2 ...........................................................22
INTERNAL 3 ...........................................................22
PASSENGER SEAT BELT TENSIONER - INCORRECT FEEDBACK ..............22
PASSENGER SQUIB 1 - INCORRECT FEEDBACK............................22
STORED ENERGY FIRING 1..............................................22
STORED ENERGY FIRING 2..............................................22
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN............................24
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................26
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................28
DRIVER SEAT BELT TENSIONER SHORT TO GROUND.......................31
DRIVER SQUIB 1 CIRCUIT OPEN .........................................33
DRIVER SQUIB 1 CIRCUIT SHORT ........................................36
DRIVER SQUIB 1 SHORT TO BATTERY ....................................39
DRIVER SQUIB 1 SHORT TO GROUND ....................................42
LOSS OF IGNITION RUN - START .........................................45
PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN .......................47
PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT ......................49
PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY ..................51
PASSENGER SEAT BELT TENSIONER SHORT TO GROUND ..................54
PASSENGER SQUIB 1 CIRCUIT OPEN .....................................56
PASSENGER SQUIB 1 CIRCUIT SHORT....................................59
PASSENGER SQUIB 1 SHORT TO BATTERY................................62
PASSENGER SQUIB 1 SHORT TO GROUND ................................65
*AIRBAG WARNING INDICATOR FLASHING.................................68
CABIN HEATER
A. HEATER PRE-TEST...................................................69
CIRC PUMP CONTROL OPEN ............................................72
CIRC PUMP CONTROL SHORTED.........................................74
COMBUST FAN SHORTED ...............................................76
COMBUST FAN SPEED INCORRECT ......................................76
COMBUSTION FAN OPEN................................................76
CONTROL UNIT FAULTY.................................................77
DOSING PUMP OPEN ...................................................78
DOSING PUMP SHORTED ...............................................81
FAN STAGE 1 RELAY CONTROL OPEN ....................................83
FAN STAGE 1 RELAY CONTROL SHORTED.................................85
FLAME DETECT PRIOR TO COMBUST.....................................87
FLAME OUT ...........................................................88
NOSTART.............................................................88
FLAME SENSOR OPEN..................................................91
ii

TABLE OF CONTENTS - Continued
FLAME SENSOR SHORTED ..............................................91
GLOW PIN OPEN.......................................................91
GLOW PIN SHORTED ...................................................91
HEATER IN LOCKOUT MODE.............................................93
HEATER OVERHEATED..................................................93
SUCCESSIVE OVERHEATING ............................................93
OVER VOLTAGE........................................................96
OVERHEATING SENSOR OPEN...........................................97
OVERHEATING SENSOR SHORTED.......................................97
TEMP SENSOR OPEN...................................................98
TEMP SENSOR SHORTED ...............................................98
UNDER VOLTAGE ......................................................99
COMMUNICATION
*NO RESPONSE FROM AIRBAG CONTROL MODULE .......................102
*NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL..............104
*NO RESPONSE FROM CABIN HEATER MODULE ..........................106
*NO RESPONSE FROM CENTRAL TIMER MODULE.........................108
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ...................110
*NO RESPONSE FROM ENGINE CONTROL MODULE .......................112
*NO RESPONSE FROM HEATER BOOSTER MODULE .......................114
*NO RESPONSE FROM INSTRUMENT CLUSTER ...........................116
*NO RESPONSE FROM SECURITY SYSTEM MODULE ......................118
*NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE.............120
*NO RESPONSE FROM SHIFTER ASSEMBLY ..............................122
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE ................124
HEATING & A/C
A/C COMPRESSOR CONTROL HIGH OR OPEN (ACTIVE)....................126
A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED)...................128
A/C COMPRESSOR CONTROL SHORTED LOW (STORED)...................128
AIR OUTLET TEMP SENSOR HIGH OR OPEN (STORED) ....................128
AIR OUTLET TEMP SENSOR SHORTED LOW (STORED) ....................128
AUX FAN RELAY CONTROL HIGH OR OPEN (STORED) .....................128
AUX FAN RELAY CONTROL SHORTED LOW (STORED) .....................128
BLOWER STAGE 1 HIGH OR OPEN (STORED).............................128
BLOWER STAGE 1 SHORTED LOW (STORED).............................128
CABIN HEATER CONTROL HIGH OR OPEN (STORED) ......................128
CABIN HEATER CONTROL SHORTED LOW (STORED) ......................128
CIRC PUMP CONTROL HIGH OR OPEN (STORED) .........................128
CIRC PUMP CONTROL SHORTED LOW (STORED) .........................128
EVAP TEMP SENSOR HIGH OR OPEN (STORED) ..........................128
EVAP TEMP SENSOR SHORTED LOW (STORED) ..........................128
NO COMMUNICATION BUS (STORED) ....................................128
NO COMMUNICATION WITH ECM (STORED) ..............................128
NO COMMUNICATION WITH IC (STORED).................................128
RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (STORED) ...............128
RECIRC AIR SOLENOID CONTROL SHORTED LOW (STORED) ...............128
REFRIG PRESS SENSOR HIGH OR OPEN (STORED) .......................128
REFRIG PRESS SENSOR SHORTED LOW (STORED) .......................128
WATER CYCLE VALVE CONTROL HIGH OR OPEN (STORED) ................128
WATER CYCLE VALVE CONTROL SHORTED LOW (STORED) ................128
A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE)....................130
iii

TABLE OF CONTENTS - Continued
AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE) .....................132
AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE) .....................134
ATC FUNCTION TEST COOL FAILURE ....................................136
ATC FUNCTION TEST FAILURE..........................................136
ATC FUNCTION TEST HEAT FAILURE.....................................136
AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE) ......................138
AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE) ......................140
BLOWER STAGE 1 HIGH OR OPEN (ACTIVE) ..............................142
BLOWER STAGE 1 SHORTED LOW (ACTIVE) ..............................144
CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE) .......................146
CABIN HEATER CONTROL SHORTED LOW (ACTIVE) .......................148
CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE) ..........................150
CIRC PUMP CONTROL SHORTED LOW (ACTIVE) ..........................152
EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE) ...........................154
EVAP TEMP SENSOR SHORTED LOW (ACTIVE) ...........................156
NO COMMUNICATION BUS (ACTIVE) .....................................158
NO COMMUNICATION WITH ECM (ACTIVE) ...............................161
NO COMMUNICATION WITH IC (ACTIVE)..................................163
RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE) ................165
RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE) ................167
REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE) ........................169
REFRIG PRESS SENSOR SHORTED LOW (ACTIVE) ........................171
WATER CYCLE VALVE CONTROL HIGH OR OPEN (ACTIVE) .................173
WATER CYCLE VALVE CONTROL SHORTED LOW (ACTIVE) .................175
INSTRUMENT CLUSTER
AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY ......................177
AMBIENT TEMP SENSOR SHORT TO GROUND ............................179
FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY .........................180
FUEL LEVEL SENSOR SHORT TO GROUND ...............................182
INSTRUMENT CLUSTER INTERNAL FAILURE B1043 ........................183
INSTRUMENT CLUSTER INTERNAL FAILURE B1053 ........................184
INSTRUMENT CLUSTER OVERVOLTAGE..................................185
NO CAN COMMUNICATION WITH ABS....................................186
NO CAN COMMUNICATION WITH ECM ...................................188
NO CAN COMMUNICATION WITH TCM....................................190
PREGLOW INDICATOR LAMP FAILURE ...................................192
SRS INDICATOR LAMP FAILURE.........................................193
POWER DOOR LOCKS/RKE
DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND......194
PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO
GROUND.............................................................196
REPLACE CONTROL MODULE ..........................................198
RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM......................199
RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM ..................201
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM .....................203
RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM..................204
THE ACM HAS UNLOCKED THE DOORS ..................................206
UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2 ......................207
*RKE INOPERATIVE....................................................208
*RKE POOR RANGE ...................................................209
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TABLE OF CONTENTS - Continued
VEHICLE THEFT/SECURITY
DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND ............210
DRIVER CYLINDER UNLOCK SWITCH CIRCUIT SHORT TO GROUND .........212
FRONT DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ................214
INTERNAL ERROR - SSM ...............................................216
TOWING INCLINATION SENSOR BEYOND LIMITS ..........................216
TOWING INCLINATION SENSOR VALUE IS INVALID.........................216
TOWING INCLINATION SENSOR VALUE IS MISSING........................216
INTRUSION SENSOR 1 CIRCUIT OPEN/SHORT TO GROUND ................218
INTRUSION SENSOR 1 GROUND CIRCUIT OPEN ..........................220
INTRUSION SENSOR 2 CIRCUIT OPEN/SHORT TO GROUND ................221
INTRUSION SENSOR 2 GROUND CIRCUIT OPEN ..........................223
INTRUSION SENSOR 3 CIRCUIT OPEN/SHORT TO GROUND ................224
INTRUSION SENSOR 3 GROUND CIRCUIT OPEN ..........................226
REAR OR SLIDING DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ......227
RKE INTERFACE CIRCUIT FAILURE - SSM ................................229
SECURITY SYSTEM INTERFACE FAILURE - SSM...........................231
SIREN CIRCUIT OPEN/SHORTED TO GROUND ............................233
SIREN INTERNAL FAILURE .............................................235
SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND....................236
VERIFICATION TESTS
VERIFICATION TESTS..................................................237
8.0 COMPONENT LOCATIONS..............................................241
8.1 AIRBAG SYSTEM.................................................241
8.2 AIRBAG CONTROL MODULE .......................................241
8.3 DRIVER AIRBAG SQUIB ...........................................241
8.4 CLOCKSPRING ..................................................242
8.5 SEAT BELT TENSIONER ...........................................242
8.6 HEATING & A/C...................................................242
8.6.1 AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM
COMPONENTS...........................................242
8.6.2 CABIN HEATER & HEATER BOOSTER SYSTEM
COMPONENTS...........................................243
8.6.3 AUTO TEMP CONTROL, CABIN HEATER, & HEATER BOOSTER
FUSES & RELAYS ........................................243
8.6.4 EVAP TEMP SENSOR & AIR OUTLET TEMP SENSOR ..........243
8.7 INSTRUMENT CLUSTER...........................................244
8.7.1 AMBIENT TEMPERATURE SENSOR .........................244
8.8 POWER DOOR LOCKS/RKE........................................244
8.8.1 CENTRAL TIMER MODULE.................................244
8.8.2 SENTRY KEY REMOTE ENTRY MODULE.....................245
8.8.3 DOOR LOCK MOTOR/AJAR SWITCH ........................245
8.8.4 CONTACT PLATES........................................245
8.8.5 DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS...........246
8.9 VEHICLE THEFT SECURITY SYSTEM................................246
8.9.1 SECURITY SYSTEM MODULE ..............................246
8.9.2 INTRUSION SENSORS ....................................246
8.9.3 SWITCHES ..............................................247
8.9.4 SIREN ..................................................247
v

TABLE OF CONTENTS - Continued
9.0 CONNECTOR PINOUTS ................................................249
AIR OUTLET TEMPERATURE SENSOR ...................................249
AIRBAG CONTROL MODULE - YELLOW...................................249
AIRBAG SQUIB-DRIVER ................................................249
AIRBAG SQUIB-PASSENGER - YELLOW ..................................249
AMBIENT TEMPERATURE SENSOR ......................................250
AUXILIARY HEATER SWITCH............................................250
BLOWER MOTOR RESISTOR BLOCK.....................................250
BLOWER MOTOR-FRONT - BLACK.......................................250
C200 - BLACK (DASH SIDE) .............................................251
C200 - BLACK (MAIN BODY SIDE)........................................251
C205 - YELLOW (DASH SIDE) ...........................................251
C205 - YELLOW (MAIN BODY SIDE) ......................................252
C219 - (MAIN BODY SIDE) ..............................................252
C219 - BLACK (CABIN SIDE) ............................................252
CENTRAL TIMER MODULE C1 - PINK.....................................252
CENTRAL TIMER MODULE C2 - LT.GREEN ................................253
CIRCULATION PUMP (CABIN HEATER MODULE) ...........................253
CIRCULATION PUMP (REST SYSTEM) ....................................253
CLOCKSPRING C2.....................................................253
CONTROLLER ANTILOCK BRAKE ........................................254
CYLINDER LOCK SWITCH-DRIVER.......................................254
DATA LINK CONNECTOR - BLACK........................................254
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C1.................254
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C2.................255
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C1 ...........255
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C2 ...........255
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C1 ............255
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C2 ............255
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C1...................256
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C2...................256
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C1 ..........256
DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C2 ..........256
DOSING PUMP........................................................256
ENGINE CONTROL MODULE C2 - BLACK .................................257
ENGINE CONTROL MODULE C3 - BLACK .................................257
EVAPORATOR TEMPERATURE SENSOR ..................................257
FUEL LEVEL SENSOR..................................................258
FUSE BLOCK NO. 1 C2.................................................258
FUSES (FUSE BLOCK NO. 1)............................................260
FUSES (FUSE BLOCK NO. 2)............................................260
FUSES (FUSE BLOCK NO. 3)............................................261
FUSES (FUSE/RELAY BLOCK) ...........................................261
HOOD AJAR SWITCH - BLACK...........................................262
INSTRUMENT CLUSTER C1.............................................262
INSTRUMENT CLUSTER C2 - WHITE .....................................262
INTRUSION SENSOR NO. 1 - BLACK .....................................263
INTRUSION SENSOR NO. 2 - BLACK .....................................263
INTRUSION SENSOR NO. 3 - BLACK .....................................263
MASTER DOOR LOCK SWITCH..........................................263
PANIC ALARM SWITCH - BLACK .........................................263
RECIRCULATED AIR SOLENOID VALVE ...................................264
vi

TABLE OF CONTENTS - Continued
REFRIGERANT PRESSURE SENSOR.....................................264
A/C AUXILIARY FAN RELAY (IN RELAY BLOCK) ............................266
A/C AUXILIARY FAN....................................................266
CIRCULATION PUMP RELAY (RELAY BLOCK)..............................266
D(+) RELAY NO. 1 (RELAY BLOCK).......................................266
FAN STAGE 1 RELAY (RELAY BLOCK) ....................................266
HORN RELAY - (RELAY BLOCK) .........................................266
TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT (RELAY BLOCK).............266
TURN SIGNAL/ANTI-THEFT ALARM RELAY-RIGHT (RELAY BLOCK) ...........267
REMOTE KEYLESS ENTRY ANTENNA ....................................268
SEAT BELT TENSIONER-DRIVER - YELLOW ...............................268
SEAT BELT TENSIONER-PASSENGER - YELLOW...........................268
SECURITY SYSTEM MODULE C1 - BROWN ...............................269
SECURITY SYSTEM MODULE C2 - LT.GREEN .............................269
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) ........................269
SHIFTER ASSEMBLY - BLACK ...........................................270
SIREN - BLACK .......................................................270
TOWING/INTRUSION SENSOR ON/OFF SWITCH ...........................270
TRANSMISSION CONTROL MODULE C1 - BLACK ..........................270
TRANSMISSION CONTROL MODULE C2 - BLACK ..........................271
WATER CYCLE VALVE..................................................271
WINDOW DEFOGGER-LEFT REAR .......................................271
WINDOW DEFOGGER-RIGHT REAR......................................271
10.0 SCHEMATIC DIAGRAMS................................................273
10.1 AIRBAG SYSTEM.................................................273
10.2 COMMUNICATION ................................................274
10.2.1 COMMUNICATION K-LINES ................................274
10.2.2 CAN BUS NETWORK......................................275
10.3 HEATING & A/C...................................................276
10.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC) ................276
10.3.2 CABIN HEATER MODULE (CHM) ............................277
10.3.3 HEATER BOOSTER MODULE (HBM).........................278
10.4 INSTRUMENT CLUSTER...........................................279
10.5 POWER DOOR LOCKS/RKE........................................280
10.5.1 FRONT DOORS ..........................................280
10.5.2 SLIDING AND REAR DOORS ...............................281
10.5.3 SWITCH AND MISCELLANEOUS CIRCUITS...................282
10.6 VEHICLE THEFT SECURITY SYSTEM................................283
11.0 CHARTS AND GRAPHS ................................................285
11.1 EVAP TEMP SENSOR RESISTANCE TO TEMPERATURE
SPECIFICATIONS.................................................285
11.2 AIR OUTLET TEMP SENSOR RESISTANCE TO TEMPERATURE
SPECIFICATIONS.................................................285
vii

NOTES
viii

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 ‘‘Bus 6
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:
•verification of complaint
•verification of any related symptoms
•symptom analysis
•problem isolation
•repair of isolated problem
•verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
The vehicle systems that are part of the ‘‘body’’
system are:
•Airbag
•Automatic Temperature Control
•Communication
•Instrument Cluster
•Power Door Locks/RKE
•Vehicle Theft Security System (VTSS)
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:
•Airbag Control Module (ACM)
•Airbag Warning Indicator (SRS)
•Driver Airbags
•Clockspring
•Passenger Airbag
•Driver Seat Belt Tensioners
•Passenger 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
secured to the floor under the Driver seat and
1
GENERAL INFORMATION

receives power from the Fuse Block No. 1. When-
ever the ignition key is turned to the run or start
position, theACM performs a system test. TheACM
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, theACM 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 theAccident
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
theACM 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, theACM 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 theACM 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