Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 22
Symptom:
FAN STAGE 1 RELAY CONTROL SHORTED
POSSIBLE CAUSES
FAN STAGE 1 RELAY
FAN STAGE 1 RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND
FAN STAGE 1 RELAY HIGH SIDE CONTROL CIRCUIT SHORTED TO GROUND CIRCUIT
CABIN HEATER CONTROL UNIT
TEST
ACTION
APPLICABILITY
1
WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
Install a substitute relay in place of the Fan Stage 1 Relay.
Turn the ignition on.
Verify that the Cabin Heater is switched off.
Set the blend control to the max heat position and the mode control to the floor
position.
With the DRBIII
t, erase the Cabin Heater Module’s DTCs.
Start the engine. Allow the engine to idle.
With the DRBIII, monitor for Cabin Heater Module DTCs while performing the
following step.
NOTE: Do not disconnect the vehicle’s battery or the heater’s main power
supply while the heater is in operation or in run-down mode. Failure to
follow these instructions can result in excess emissions from the heater
during heater operation.
Switch the Cabin Heater on. If necessary, allow the heater to run through at least one
cycle of operation (approximately 10 minutes), and then switch the heater off.
Turn the engine off.
Does the DRBIII
t display: FAN STAGE 1 RELAY CONTROL SHORTED?
All
Yes
→ Go To 2
No
→ Replace the original Fan Stage 1 Relay in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
85
CABIN HEATER
TEST
ACTION
APPLICABILITY
2
WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater harness connector.
Remove the substitute Fan Stage 1 Relay from the relay center.
Measure the resistance between ground and the Fan Stage 1 Relay High Side Control
circuit.
Is the resistance below 10K ohms?
All
Yes
→ Repair the Fan Stage 1 Relay High Side Control circuit for a short
to ground. Reinstall the original Fan Stage 1 Relay.
Perform HEATER VERIFICATION TEST - VER 1.
No
→ Go To 3
3
WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
Disconnect the Cabin Heater harness connector.
Remove the Fan Stage 1 Relay from the relay center.
Measure the resistance between the Fan Stage 1 Relay High Side Control circuit and
the Ground circuit (Fan Stage 1 Relay connector terminal 86 and 85).
Is the resistance below 10K ohms?
All
Yes
→ Repair the Fan Stage 1 Relay High Side Control circuit for a short
to the Ground circuit.
Perform HEATER VERIFICATION TEST - VER 1.
No
→ Replace the Cabin Heater Assembly in accordance with the
Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
86
CABIN HEATER
FAN STAGE 1 RELAY CONTROL SHORTED —
Continued
Symptom:
FLAME DETECT PRIOR TO COMBUST
When Monitored and Set Condition:
FLAME DETECT PRIOR TO COMBUST
When Monitored:
During heater start up.
Set Condition:
This DTC will set if the Flame Sensor’s resistance is not within the
expected parameters.
POSSIBLE CAUSES
HEATER’S AIR INTAKE/EXHAUST RESTRICTED
FLAME SENSOR
TEST
ACTION
APPLICABILITY
1
WARNING: NEVER OPERATE THE HEATER IN AN ENCLOSED AREA
THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE EXHAUST WHEN OPERATING THE HEATER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY
OR DEATH.
WARNING: ALLOW THE HEATER ASSEMBLY TO COOL BEFORE PER-
FORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL
INJURY OR DEATH.
CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE HEATER PRE-TEST. ALWAYS PERFORM THE HEATER PRE-TEST
PRIOR TO PERFORMING ANY OTHER TEST FOR THE RESULT TO BE
VALID.
Turn the ignition off.
Inspect the heater’s air intake pipe and exhaust pipe for restrictions and obstruc-
tions.
Is the heater’s air intake pipe and exhaust pipe Ok?
All
Yes
→ Replace the Cabin Heater Assembly or Heater Booster Assembly
in accordance with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
No
→ Repair the heater’s air intake/exhaust as necessary in accordance
with the Service Information.
Perform HEATER VERIFICATION TEST - VER 1.
87
CABIN HEATER
Symptom List:
FLAME OUT
NO START
Test Note:
All symptoms listed above are diagnosed using the same tests.
The title for the tests will be FLAME OUT.
When Monitored and Set Condition:
FLAME OUT
When Monitored:
After heater activation and during subsequent attempts to start the
heater.
Set Condition:
This DTC will set if the Flame Sensor’s resistance is not within the
expected parameters.
NO START
When Monitored:
After heater activation.
Set Condition:
This DTC will set if the Flame Sensor’s resistance is not within the
expected parameters 340 seconds after activation.
POSSIBLE CAUSES
LOW FUEL LEVEL IN VEHICLE’S FUEL TANK
HEATER’S FUEL LINE RESTRICTED/LEAKING/DAMAGED
DOSING PUMP
HEATER’S AIR INTAKE/EXHAUST RESTRICTED
CABIN HEATER ASSEMBLY OR HEATER BOOSTER ASSEMBLY
88
CABIN HEATER
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