2002-2006 Dodge Sprinter Service & Repair 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 CAN BUS ..................................................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 DRBIIIT ERROR MESSAGES.........................................11 3.9 DRBIIIT DOES 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 DRBIIIT SAFETY 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 NO START .............................................................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 RADIO ..........................................118 *NO RESPONSE FROM SECURITY SYSTEM MODULE ......................120 *NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE .............122 *NO RESPONSE FROM SHIFTER ASSEMBLY ..............................124 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE ................126 HEATING & A/C A/C COMPRESSOR CONTROL HIGH OR OPEN (ACTIVE) ....................128 A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED) ...................130 A/C COMPRESSOR CONTROL SHORTED LOW (STORED) ...................130 AIR OUTLET TEMP SENSOR HIGH OR OPEN (STORED) ....................130 AIR OUTLET TEMP SENSOR SHORTED LOW (STORED) ....................130 AUX FAN RELAY CONTROL HIGH OR OPEN (STORED) .....................130 AUX FAN RELAY CONTROL SHORTED LOW (STORED) .....................130 BLOWER STAGE 1 HIGH OR OPEN (STORED) .............................130 BLOWER STAGE 1 SHORTED LOW (STORED) .............................130 CABIN HEATER CONTROL HIGH OR OPEN (STORED) ......................130 CABIN HEATER CONTROL SHORTED LOW (STORED) ......................130 CIRC PUMP CONTROL HIGH OR OPEN (STORED) .........................130 CIRC PUMP CONTROL SHORTED LOW (STORED) .........................130 EVAP TEMP SENSOR HIGH OR OPEN (STORED) ..........................130 EVAP TEMP SENSOR SHORTED LOW (STORED) ..........................130 NO COMMUNICATION BUS (STORED) ....................................130 NO COMMUNICATION WITH ECM (STORED) ..............................130 NO COMMUNICATION WITH IC (STORED) .................................130 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (STORED) ...............130 RECIRC AIR SOLENOID CONTROL SHORTED LOW (STORED) ...............130 REFRIG PRESS SENSOR HIGH OR OPEN (STORED) .......................130 REFRIG PRESS SENSOR SHORTED LOW (STORED) .......................130 WATER CYCLE VALVE CONTROLHIGH OR OPEN (STORED) ................130 WATER CYCLE VALVE CONTROLSHORTED LOW (STORED) ................130 iii

TABLE OF CONTENTS - Continued A/C COMPRESSOR CONTROL SHORTED LOW (ACTIVE) ....................132 AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE) .....................134 AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE) .....................136 ATC FUNCTION TEST COOL FAILURE ....................................138 ATC FUNCTION TEST FAILURE ..........................................138 ATC FUNCTION TEST HEAT FAILURE.....................................138 AUX FAN RELAY CONTROL HIGH OR OPEN (ACTIVE) ......................140 AUX FAN RELAY CONTROL SHORTED LOW (ACTIVE) ......................142 BLOWER STAGE 1 HIGH OR OPEN (ACTIVE) ..............................144 BLOWER STAGE 1 SHORTED LOW (ACTIVE) ..............................146 CABIN HEATER CONTROL HIGH OR OPEN (ACTIVE) .......................148 CABIN HEATER CONTROL SHORTED LOW (ACTIVE) .......................150 CIRC PUMP CONTROL HIGH OR OPEN (ACTIVE) ..........................152 CIRC PUMP CONTROL SHORTED LOW (ACTIVE) ..........................154 EVAP TEMP SENSOR HIGH OR OPEN (ACTIVE) ...........................156 EVAP TEMP SENSOR SHORTED LOW (ACTIVE) ...........................158 NO COMMUNICATION BUS (ACTIVE) .....................................160 NO COMMUNICATION WITH ECM (ACTIVE) ...............................163 NO COMMUNICATION WITH IC (ACTIVE) ..................................165 RECIRC AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE) ................167 RECIRC AIR SOLENOID CONTROL SHORTED LOW (ACTIVE) ................169 REFRIG PRESS SENSOR HIGH OR OPEN (ACTIVE) ........................171 REFRIG PRESS SENSOR SHORTED LOW (ACTIVE) ........................173 WATER CYCLE VALVE CONTROLHIGH OR OPEN (ACTIVE) .................175 WATER CYCLE VALVE CONTROLSHORTED LOW (ACTIVE) .................177 INSTRUMENT CLUSTER AMBIENT TEMP SENSOR OPEN/SHORT TO BATTERY ......................179 AMBIENT TEMP SENSOR SHORT TO GROUND ............................181 FUEL LEVEL SENSOR OPEN/SHORT TO BATTERY .........................182 FUEL LEVEL SENSOR SHORT TO GROUND ...............................184 INSTRUMENT CLUSTER INTERNAL FAILURE B1043 ........................185 INSTRUMENT CLUSTER INTERNAL FAILURE B1053 ........................186 INSTRUMENT CLUSTER OVERVOLTAGE ..................................187 NO CAN COMMUNICATION WITH ABS ....................................188 NO CAN COMMUNICATION WITH ECM ...................................190 NO CAN COMMUNICATION WITH TCM....................................192 PREGLOW INDICATOR LAMP FAILURE ...................................194 SRS INDICATOR LAMP FAILURE .........................................195 POWER DOOR LOCKS/RKE DRIVER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND ......196 PASSENGER DOOR AJAR INDICATOR DRIVER CIRCUIT SHORT TO GROUND .198 REPLACE CONTROL MODULE ..........................................200 RKE INTERFACE CIRCUIT SHORT TO GROUND - CTM ......................201 RKE INTERFACE CIRCUIT SHORT TO GROUND - SKREEM ..................203 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - CTM .....................205 RKE INTERFACE CIRCUIT SHORT TO VOLTAGE - SKREEM..................206 THE ACM HAS UNLOCKED THE DOORS ..................................208 UNKNOWN TROUBLE CODE UNKNOWN DTC TYPE 2 ......................209 *RKE INOPERATIVE ....................................................210 *RKE POOR RANGE ...................................................211 iv

TABLE OF CONTENTS - Continued VEHICLE THEFT/SECURITY DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND ............212 DRIVER CYLINDER UNLOCK SWITCH CIRCUIT SHORT TO GROUND .........214 FRONT DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ................216 INTERNAL ERROR - SSM ...............................................218 TOWING INCLINATION SENSOR BEYOND LIMITS ..........................218 TOWING INCLINATION SENSOR VALUE IS INVALID.........................218 TOWING INCLINATION SENSOR VALUE IS MISSING ........................218 INTRUSION SENSOR 1 CIRCUIT OPEN/SHORT TO GROUND ................220 INTRUSION SENSOR 1 GROUND CIRCUIT OPEN ..........................222 INTRUSION SENSOR 2 CIRCUIT OPEN/SHORT TO GROUND ................223 INTRUSION SENSOR 2 GROUND CIRCUIT OPEN ..........................225 INTRUSION SENSOR 3 CIRCUIT OPEN/SHORT TO GROUND ................226 INTRUSION SENSOR 3 GROUND CIRCUIT OPEN ..........................228 REAR OR SLIDING DOOR JAMB SWITCH CIRCUIT SHORT TO GROUND ......229 RKE INTERFACE CIRCUIT FAILURE - SSM ................................231 SECURITY SYSTEM INTERFACE FAILURE - SSM...........................233 SIREN CIRCUIT OPEN/SHORTED TO GROUND ............................235 SIREN INTERNAL FAILURE .............................................237 SIREN SIGNAL CONTROL CIRCUIT SHORT TO GROUND ....................238 WINDSHIELD WIPER & WASHER CHECKING THE RAIN SENSOR/WIPER OPERATION ........................239 VERIFICATION TESTS VERIFICATION TESTS ..................................................244 8.0 COMPONENT LOCATIONS ..............................................249 8.1 AIRBAG SYSTEM .................................................249 8.2 AIRBAG CONTROL MODULE .......................................249 8.3 DRIVER AIRBAG SQUIB ...........................................249 8.4 CLOCKSPRING ..................................................250 8.5 SEAT BELT TENSIONER ...........................................250 8.6 HEATING & A/C...................................................250 8.6.1 AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM COMPONENTS ...........................................250 8.6.2 CABIN HEATER & HEATER BOOSTER SYSTEM COMPONENTS .251 8.6.3 AUTO TEMP CONTROL, CABIN HEATER, & HEATER BOOSTER FUSES & RELAYS ........................................251 8.6.4 EVAP TEMP SENSOR & AIR OUTLET TEMP SENSOR ..........251 8.7 INSTRUMENT CLUSTER ...........................................252 8.7.1 AMBIENT TEMPERATURE SENSOR .........................252 8.8 POWER DOOR LOCKS/RKE ........................................252 8.8.1 CENTRAL TIMER MODULE .................................252 8.8.2 SENTRY KEY REMOTE ENTRY MODULE .....................253 8.8.3 DOOR LOCK MOTOR/AJAR SWITCH ........................253 8.8.4 CONTACT PLATES ........................................253 8.8.5 DOOR LOCK MOTOR/AJAR SWITCH CONNECTORS ...........254 v

TABLE OF CONTENTS - Continued 8.9 VEHICLE THEFT SECURITY SYSTEM ................................254 8.9.1 SECURITY SYSTEM MODULE ..............................254 8.9.2 INTRUSION SENSORS ....................................254 8.9.3 SWITCHES ..............................................255 8.9.4 SIREN ..................................................255 9.0 CONNECTOR PINOUTS ................................................257 A/C AUXILIARY FAN ....................................................257 AIR OUTLET TEMPERATURE SENSOR ...................................257 AIRBAG CONTROL MODULE - YELLOW...................................257 AIRBAG SQUIB-DRIVER - YELLOW .......................................258 AIRBAG SQUIB-PASSENGER - YELLOW ..................................258 AMBIENT TEMPERATURE SENSOR ......................................258 AUTOMATIC TEMPERATURE CONTROL MODULE C1 - BROWN ..............259 AUTOMATIC TEMPERATURE CONTROL MODULE C2 .......................259 AUXILIARY HEATER CONTROL ..........................................259 BLOWER MOTOR RESISTOR BLOCK .....................................259 BLOWER MOTOR-FRONT - BLACK .......................................260 C205 - YELLOW (DASH SIDE) ...........................................260 C205 - YELLOW (MAIN BODY SIDE) ......................................260 CENTRAL TIMER MODULE C1 - PINK .....................................260 CENTRAL TIMER MODULE C2 - LT. GREEN ...............................261 CIRCULATION PUMP (CABIN HEATER MODULE) ...........................261 CIRCULATION PUMP (REST SYSTEM) ....................................261 CIRCULATION PUMP DIODE ............................................261 CLOCKSPRING C2 - YELLOW ...........................................262 CONTROLLER ANTILOCK BRAKE ........................................262 CYLINDER LOCK SWITCH-DRIVER .......................................263 DATA LINK CONNECTOR - BLACK........................................263 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C1 .................263 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C2 .................263 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C1 ...........263 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C2 ...........264 DOOR LOCK MOTOR/AJAR SWITCHASSEMBLY-PASSENGER C1 ............264 DOOR LOCK MOTOR/AJAR SWITCHASSEMBLY-PASSENGER C2 ............264 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C1 ...................264 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C2 ...................264 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C1 ..........265 DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C2 ..........265 DOSING PUMP ........................................................265 ENGINE CONTROL MODULE C1 (EXCEPT OBD) - BLACK ...................265 ENGINE CONTROL MODULE C2 (EXCEPT OBD) - BLACK ...................266 ENGINE CONTROL MODULE C2 (OBD) ...................................267 ENGINE CONTROL MODULE C3 (EXCEPT OBD) - BLACK ...................268 EVAPORATOR TEMPERATURE SENSOR ..................................269 FUEL LEVEL SENSOR ..................................................269 FUSES (FUSE BLOCK NO. 1) ............................................271 FUSE BLOCK NO. 1 C1 .................................................271 FUSE BLOCK NO. 1 C2 .................................................271 FUSE BLOCK NO. 1 C3 - BLACK .........................................272 FUSE BLOCK NO. 1 C4 - BLACK .........................................272 FUSE BLOCK NO. 1 C5 - BLACK .........................................272 vi

TABLE OF CONTENTS - Continued FUSES (FUSE BLOCK NO. 2) ............................................274 FUSES (FUSE BLOCK NO. 3) ............................................276 FUSES (FUSE/RELAY BLOCK) ...........................................278 HOOD AJAR SWITCH - BLACK...........................................278 HORN (VTSS) .........................................................278 IGNITION LOCK SWITCH - BLACK........................................278 INSTRUMENT CLUSTER C1 .............................................279 INSTRUMENT CLUSTER C2 - WHITE .....................................279 INTRUSION SENSOR NO. 1 - BLACK .....................................279 INTRUSION SENSOR NO. 2 - BLACK .....................................279 INTRUSION SENSOR NO. 3 - BLACK .....................................280 MASTER DOOR LOCK SWITCH ..........................................280 PANIC ALARM SWITCH - BLACK .........................................280 FUSES (PDC) .........................................................281 RADIO C1 - BLACK ....................................................282 RADIO C2 ............................................................282 RECIRCULATED AIR SOLENOID VALVE ...................................282 REFRIGERANT PRESSURE SENSOR .....................................282 A/C AUXILIARY FAN RELAY (RELAY BLOCK) ...............................284 CIRCULATION PUMP RELAY-CABIN HEATER MODULE (RELAY BLOCK) .......284 D+ RELAY NO. 2 (RELAY BLOCK) ........................................284 FAN STAGE 1 RELAY (RELAY BLOCK) ....................................284 OPTIONAL EQUIPMENT RELAY (RELAY BLOCK) ...........................284 REMOTE KEYLESS ENTRY ANTENNA ....................................284 SEAT BELT SWITCH ...................................................284 SEAT BELT TENSIONER-DRIVER - YELLOW ...............................285 SEAT BELT TENSIONER-PASSENGER - YELLOW ...........................285 SECURITY SYSTEM MODULE C1 - BROWN ...............................285 SECURITY SYSTEM MODULE C2 - LT. GREEN .............................286 SENTRY KEY REMOTE ENTRY MODULE (SKREEM) ........................286 SHIFTER ASSEMBLY - BLACK ...........................................286 SIREN - BLACK .......................................................286 STEERING ANGLE SENSOR ............................................287 TOWING/INTRUSION SENSOR ON/OFF SWITCH ...........................287 TRANSMISSION CONTROL MODULE C1 - BLACK ..........................287 TRANSMISSION CONTROL MODULE C2 - BLACK ..........................288 WATER CYCLE VALVE..................................................288 WINDOW DEFOGGER-LEFT REAR .......................................288 WINDOW DEFOGGER-RIGHT REAR ......................................288 10.0 SCHEMATIC DIAGRAMS................................................289 10.1 AIRBAG SYSTEM .................................................289 10.2 COMMUNICATION ................................................290 10.2.1 COMMUNICATION K-LINES ................................290 10.2.2 CAN BUS NETWORK ......................................291 10.3 HEATING & A/C...................................................292 10.3.1 AUTOMATIC TEMPERATURE CONTROL (ATC) ................292 10.3.2 CABIN HEATER MODULE (CHM) ............................293 10.3.3 HEATER BOOSTER MODULE (HBM) .........................294 10.4 INSTRUMENT CLUSTER ...........................................295 vii

TABLE OF CONTENTS - Continued 10.5 POWER DOOR LOCKS/RKE ........................................296 10.5.1 FRONT DOORS ..........................................296 10.5.2 SLIDING AND REAR DOORS ...............................297 10.5.3 SWITCH AND MISCELLANEOUS CIRCUITS ...................298 10.6 VEHICLE THEFT SECURITY SYSTEM ................................299 10.7 RAIN SENSOR SYSTEM ...........................................300 11.0 CHARTS AND GRAPHS ................................................301 11.1 EVAP TEMP SENSOR RESISTANCE TO TEMPERATURE SPECIFICATIONS .................................................301 11.2 AIR OUTLET TEMP SENSOR RESISTANCE TO TEMPERATURE SPECIFICATIONS .................................................301 11.3 WIPER SWITCH/WASHER SWITCH VOLTAGE SIGNALS ................302 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 DRBIIIt is communicating with the appropriate modules; i.e., if the DRBIIIt displays 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 appropriate service information for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added: carryover systems 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 diagnostic 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) • Wiper/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 communication only, the DRBIIIt utilizes 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 following 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 severity 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 circuits 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 notification. 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 DRBIIIt can 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

2002-2006 Dodge Sprinter Service & Repair Manual

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