Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 154

Symptom:

P2521-IMPROPER START ATTEMPT

POSSIBLE CAUSES

VERIFY ACTIVE DTC

ENGINE CONTROL MODULE

TEST

ACTION

APPLICABILITY

1

NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
NOTE: This DTC indicates that engine rotation has occurred without an
ignition switch Start input. This can occurred when an attempt to start the
vehicle using a push start method.
NOTE: Consult with the customer to determine if a push start has been
attempted.
Turn the ignition on.
With the DRBIII

t, erase ECM DTCs.

Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIII

t, read the ECM DTCs.

Did this DTC set again?

All

Yes

→ Replace and program the Engine Control Module in accordance

with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Test complete.

Perform ROAD TEST VERIFICATION - VER-2.

224

DRIVEABILITY - DIESEL

Symptom:

P2527-EGR VALVE SIGNAL CIRCUIT SHORTED TO VOLTAGE

POSSIBLE CAUSES

INTERMITTENT CONDITION

EGR SOLENOID

EGR VALVE CONTROL SHORTED TO VOLTAGE

ENGINE CONTROL MODULE - INTERNAL

ENGINE CONTROL MODULE - INTERNAL SHORT TO VOLTAGE

TEST

ACTION

APPLICABILITY

1

NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Test drive the vehicle and monitor the DRB for ECM DTCs.
Did this DTC set again?

All

Yes

→ Go To 2

No

→ Go To 5

2

Turn the ignition off.
Disconnect the EGR Valve harness connector.
Turn the ignition on.
With the DRB, erase ECM DTCs.
Monitor the DRB for ECM DTCs.
Does the DRB display an EGR OPEN CIRCUIT DTC?

All

Yes

→ Replace the EGR Solenoid.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 3

3

Turn the ignition off.
Disconnect the EGR Valve harness connector.
Turn the ignition on.
Measure the voltage of the EGR Valve Control circuit at the EGR Valve harness
connector.
Is the voltage below 0.5 volt?

All

Yes

→ Replace and program the Engine Control Module in accordance

with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Go To 4

225

DRIVEABILITY - DIESEL

TEST

ACTION

APPLICABILITY

4

NOTE: If DTC P1611 or P2306 is present with this DTC, diagnose DTCs P1611
and P2306 before diagnosing this DTC.
Turn the ignition off.
Disconnect the EGR Valve 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 of the EGR Valve Control circuit.
Is the voltage below 0.5 volt?

All

Yes

→ Replace and program the Engine Control Module in accordance

with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.

No

→ Repair the EGR Valve Control circuit for a short to voltage.

Perform ROAD TEST VERIFICATION - VER-2.

5

WARNING: 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 at normal operating temperature, monitor the DRB
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

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

No

→ Test Complete.

226

DRIVEABILITY - DIESEL

P2527-EGR VALVE SIGNAL CIRCUIT SHORTED TO VOLTAGE —

Continued

Symptom List:

P2531-FUEL INJECTOR 1 READ TOO LARGE
P2531-FUEL INJECTOR 1 READ TOO LARGE
P2531-FUEL INJECTOR 1 READ TOO SMALL
P2531-FUEL INJECTOR 1 READ TOO SMALL
P2532-FUEL INJECTOR 2 READ TOO LARGE
P2532-FUEL INJECTOR 2 READ TOO LARGE
P2532-FUEL INJECTOR 2 READ TOO SMALL
P2532-FUEL INJECTOR 2 READ TOO SMALL
P2533-FUEL INJECTOR 3 READ TOO LARGE
P2533-FUEL INJECTOR 3 READ TOO LARGE
P2533-FUEL INJECTOR 3 READ TOO SMALL
P2533-FUEL INJECTOR 3 READ TOO SMALL
P2534-FUEL INJECTOR 4 READ TOO LARGE
P2534-FUEL INJECTOR 4 READ TOO LARGE
P2534-FUEL INJECTOR 4 READ TOO SMALL
P2534-FUEL INJECTOR 4 READ TOO SMALL
P2535-FUEL INJECTOR 5 READ TOO LARGE
P2535-FUEL INJECTOR 5 READ TOO LARGE
P2535-FUEL INJECTOR 5 READ TOO SMALL
P2535-FUEL INJECTOR 5 READ TOO SMALL

Test Note:

All symptoms listed above are diagnosed using the same tests.

The title for the tests will be P2531-FUEL INJECTOR 1 READ
TOO LARGE.

POSSIBLE CAUSES

FUEL INJECTOR

INTERMITTENT CONDITION

227

DRIVEABILITY - DIESEL