2003-2006 Dodge™ Sprinter 2.7L CDI shop manual

Product Information

Table of Contents

1.0 Introduction

• 1.1 System Coverage
• 1.2 Six-Step Troubleshooting Procedure

2.0 Identification of System

3.0 System Description and Functional Operation

• 3.1 Airbag System
  • 3.1.1 Driver Airbag
  • 3.1.2 Passenger Airbag
  • 3.1.3 Sidebags
  • 3.1.4 Seat Belt Tensioners
  • 3.1.5 Diagnostic Trouble Codes
  • 3.1.6 Active Codes
  • 3.1.7 Stored Codes
• 3.2 Communication K-Lines
  • 3.2.1 CAN Bus
• 3.3 Heating, Automatic Temperature Control (ATC)
  • 3.3.1 Component Description
  • 3.3.2 Front Heater
  • 3.3.3 Heater Booster
  • 3.3.4 System Diagnostics
• 3.4 Central Locking System
  • 3.4.1 System Description
  • 3.4.2 Component Description
  • 3.4.3 Vehicle Security System (VSS)
• 3.5 Driver Door Lock Actuator
  • 3.5.1 Rear Door Lock Actuator
• 3.6 Instrument Cluster
  • 3.6.1 Component Description
  • 3.6.2 System Operation
  • 3.6.3 Diagnosis
  • 3.6.4 Active Codes
  • 3.6.5 Stored Codes

4.0 Disclaimers, Safety, Warnings

• 4.1 Disclaimers
  • 4.2.1 Technician Safety Information
  • 4.2.2 Mechanical Safety Information
  • 4.2.3 System Safety Information
• 4.2 Vehicle Damage Warnings
  • 4.3.1 Engine Damage Warnings
  • 4.3.2 Road Testing a Compliant Vehicle

5.0 Required Tools and Equipment

6.0 Glossary of Terms

7.0 Diagnostic Information and Procedures

• Airbag
  • AIRBAG WARNING INDICATOR - DRIVER HIGH
  • AIRBAG WARNING INDICATOR - DRIVER LOW
  • DRIVER SEAT BELT TENSIONER - INCORRECT FEEDBACK
  • DRIVER SQUIB 1 - INCORRECT FEEDBACK
  • DRIVER SQUIB 2 - INCORRECT FEEDBACK
  • INTERNAL
  • PASSENGER SEAT BELT TENSIONER - INCORRECT FEEDBACK
  • STORED ENERGY FIRING - INCORRECT FEEDBACK
  • STORED ENERGY FIRING
  • SQUIB 1
  • SQUIB 2
  • DRIVER SEAT BELT TENSIONER CIRCUIT OPEN
  • DRIVER SEAT BELT TENSIONER SHORT TO BATTERY
  • DRIVER SEAT BELT TENSIONER SHORT TO GROUND
  • PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN
  • PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY
  • PASSENGER SEAT BELT TENSIONER SHORT TO GROUND
• Cabin Heater
  • COMBUSTION FAN MOTOR - SHORT TO BATTERY
  • COMBUSTION FAN MOTOR - SHORT TO GROUND
  • COMBUSTION FAULT
  • CONTROL UNIT FAULT
  • COOLANT FAN RELAY - CONTROL CIRCUIT OPEN
  • COOLANT FAN RELAY - SHORT TO BATTERY
  • COOLANT FAN RELAY - SHORT TO GROUND
  • FAN MOTOR FAULT
  • FLAME SENSOR FAULT
  • FLAME SENSOR SHORTED
  • GLOW PLUG CIRCUIT OPEN
  • GLOW PIN SHORTED
  • HEATER IN LOCKOUT MODE
  • HEATER OVERHEATED
  • HEATER S/W SHORTED
  • OVER VOLTAGE
  • SUCESSIVE OVERHEATING
  • TEMPERATURE SENSOR OPEN
  • TEMPERATURE SENSOR SHORTED
  • UNDER VOLTAGE

8.0 Communication

• NO RESPONSE FROM AIRBAG CONTROL MODULE
• NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL
• NO RESPONSE FROM CABIN HEATER MODULE
• NO RESPONSE FROM CENTRAL LOCKING MODULE
• NO RESPONSE FROM CLUSTER - BRAKE
• NO RESPONSE FROM INSTRUMENT CLUSTER
• NO RESPONSE FROM TRANSMISSION CONTROL MODULE

9.0 Heating and Air Conditioning

• A/C COMPRESSOR CONTROL HIGH OR OPEN (STORED)
• A/C COMPRESSOR CONTROL SHORTED LOW (STORED)
• AIR INLET CONTROL S/ROTOR HIGH OR OPEN (ACTIVE)
• AIR INLET CONTROL S/ROTOR SHORTED LOW (ACTIVE)
• AIR OUTLET TEMP SENSOR HIGH OR OPEN (ACTIVE)
• AIR OUTLET TEMP SENSOR SHORTED LOW (ACTIVE)
• AUX A/C FUNCTION TEST FAILURE
• AUX A/C RELAY CONTROL HIGH OR OPEN (ACTIVE)
• AUX A/C RELAY CONTROL SHORTED LOW (ACTIVE)
• CAN MESSAGE - BRAKE (ACTIVE)
• CAN MESSAGE - CLUSTER (ACTIVE)
• CAN MESSAGE - GROUND (ACTIVE)
• CAN MESSAGE - WIPER (ACTIVE)
• CLUTCH FUNCTION TEST FAILURE
• COMP CONTROL RELAY CIRCUIT OPEN
• COOLANT FAN RELAY CONTROL SHORTED TO GROUND
• COOLANT FAN RELAY CONTROL SHORTED TO BATTERY
• FUNCTION TEST FAILURE
• NO COMMUNICATION BUS (ACTIVE)
• REAR AIR SOLENOID CONTROL HIGH OR OPEN (ACTIVE)
• REAR AIR SOLENOID CONTROL SHORTED LOW (ACTIVE)
• REAR AIR SOLENOID FUNCTION TEST FAILURE
• RECIRC AIR S/R S/C HIGH OR OPEN (ACTIVE)
• RECIRC AIR S/R S/C SHORTED LOW (ACTIVE)
• SHUT DOWN FAULT
• WATER CYCLE VALVE CONTROL SHORTED LOW (STORED)
• WATER CYCLE VALVE CONTROL SHORTED TO GROUND (STORED)
• WATER CYCLE VALVE CONTROL SHORTED LOW (STORED)

10.0 Instrument Cluster

• FUEL SENSOR CIRCUIT OPEN
• FUEL LEVEL SENSOR SHORT TO GROUND
• INSTRUMENT CLUSTER CIRCUIT OPEN
• INSTRUMENT CLUSTER SHORT TO GROUND
• INSTRUMENT CLUSTER VOLTAGE MISSING
• NO COMMUNICATION WITH EWS
• NO COMMUNICATION WITH SRS
• SERVICE INTERVAL DISPLAY
• SMS INDICATOR LAMP FAILURE

11.0 Vehicle Theft/Security

• DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND
• DRIVER CYLINDER LOCK SWITCH CIRCUIT SHORT TO GROUND
• REAR DOOR LOCK SWITCH CIRCUIT SHORT TO GROUND
• DOOR SWITCH
• DOOR SWITCH CIRCUIT SHORT TO GROUND
• SWITCH - INTERNAL ERROR
• SWITCH - INTERIOR LIGHTS
• SWITCH - INTERIOR LIGHTS (ACTIVE)
• TOWING INCLINATION SENSOR BEYOND LIMITS
• TOWING INCLINATION SENSOR CIRCUIT OPEN
• TOWING INCLINATION SENSOR CIRCUIT SHORT TO GROUND
• TOWING INCLINATION SENSOR VOLTAGE MISSING
• TRUNK INTRUSION SENSOR CIRCUIT OPEN
• TRUNK INTRUSION SENSOR SHORT TO GROUND
• TRUNK SWITCH OPEN (ACTIVE)
• TRUNK SWITCH SHORT TO GROUND
• TRUNK SWITCH SHORT TO VOLTAGE
• VEHICLE SECURITY SYSTEM INTERFACE FAULT
• SECURITY SYSTEM INTERFACE FAULT - SSM
• WINDSHIELD WIPER & WASHER
• VERIFY OPERATION
• VERIFICATION TESTS
• VEHICLE THEFT SYSTEMS

12.0 Component Locations

• AIRBAG SYSTEM
  • 12.1 Airbag System Module
  • 12.2 Airbag System
• AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM
  • 12.3 ATC System Component Locations
• BODY CONTROL MODULE
  • 12.4 Body Control Module

  • 12.5 Body Control Module Connectors

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