Mercedes-Benz Sprinter / Dodge Sprinter. Manual - part 128

TEST

ACTION

APPLICABILITY

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 III

t 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: Refer to the Service Information and perform the Air Bleed Proce-
dure before continuing diagnosis.
Turn the ignition on.
With the DRBIII

t, erase the ECM DTCs.

Start and idle the engine while monitoring for ECM DTC’s.
If the DTC does not reset at idle condition, test drive the vehicle under various load
and speed conditions to attempt to duplicate the fault.
NOTE: Driving the vehicle up and down steep hills or rapid cornering with
a low fuel level can cause this DTC to set. Verify with customer if Low Fuel
Light was illuminated when fault occurred.
With the DRBIII

t, read the ECM DTCs.

Does the DRBIII

t display this DTC?

All

Yes

→ Go To 6

→ Go To 16

Start the engine.
With the DRBIII

t in Sensors, compare the Fuel Pressure Setpoint with the Actual

Fuel Pressure readings.
NOTE: If there is air in the fuel system, the Actual Fuel Pressure will
oscillate above and below the Fuel Pressure Setpoint.
Does Actual Fuel Pressure oscillate above and below the Fuel Pressure Setpoint?

All

Yes

→ Refer to the Service Information to purge air from the fuel system.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 7

Start the engine.
With the DRBIII

t in Sensors, compare the Fuel Pressure Setpoint with the Actual

Fuel Pressure readings.
NOTE: A sticking Fuel Pressure Solenoid is indicated by Actual Fuel
Pressure gradually dropping below the Fuel Pressure Setpoint then sud-
denly increasing (spiking) above the Fuel Pressure Setpoint.
Does Actual Fuel Pressure gradually decrease then suddenly increase (spike) above
the Fuel Pressure

All

Yes

→ Replace the Fuel Pressure Solenoid in accordance with the

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

→ Go To 8

120

DRIVEABILITY - DIESEL

P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED —

Continued

TEST

ACTION

APPLICABILITY

Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel pressure to
deviate from specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, failed fuel lift pump, failed fuel sending unit, contami-
nated fuel, faulty injector.
Were there any problems with the Fuel Delivery System?

All

Yes

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 9

Refer to each of the following symptoms in the Driveability category.
CHECKING THE FUEL PRESSURE SOLENOID CIRCUITS
CHECKING THE FUEL QUANTITY SOLENOID CIRCUITS
CHECKING THE FUEL PRESSURE SENSOR CIRCUITS
Were any problems found?

All

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 10

NOTE: An injector that sticks open can cause this DTC. A sticking injector
will cause the engine to misfire and emit excessive black smoke from the
exhaust system.
Refer to the Service Information and perform the Fuel Injector Leak Quantity Test.
Were any problems found?

All

Yes

→ Using the Service Information, remove and inspect the Fuel

Injectors for signs of damage or debris that may cause the injector
to stick. Sticking injectors may cause the combustion chamber to
become black and oil soaked. Replace Injector(s) as necessary.
Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 11

With the DRBIII

t, select System Test, Smooth Eng Run Check, then Correction

Quantity Check.
Perform this test at Idle, 2000 rpm and 3000 rpm.
NOTE: Readings per cylinder should be below ± 0.00450 mm

/stroke for each

cylinder at each engine speed.
Did any of the cylinders exceed ± 0.00450 mm

/stroke during this test?

All

Yes

→ Replace Fuel Injector of the cylinder(s) that had readings above ±

0.00450 mm

/stroke.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 12

With the DRBIII

t, select System Test, Smooth Eng Run Check, then Cylinder Speed

Check.
NOTE: Readings for all cylinders should be close to each other. Look for one
or two cylinders to differ high or low from the other cylinders.
Did any of the cylinders differ significantly from the majority of the other cylinders?

All

Yes

→ Replace Fuel Injector of the cylinder(s) that had readings signif-

icantly above or below the other fuel injectors.
Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 13

121

DRIVEABILITY - DIESEL

P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED —

Continued

TEST

ACTION

APPLICABILITY

With the DRBIII

t, select System Tests, then perform the Rail Press Control Valve

Test.
Did this test pass?

All

Yes

→ Go To 14

→ Replace the Fuel Pressure Solenoid in accordance with the

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

With the DRBIII

t, select System Tests, then perform the Rail Press Control Valve

Variation Test.
Did this test pass?

All

Yes

→ Go To 15

→ Replace the Fuel Pressure Solenoid in accordance with the

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

With the DRBIII

t, select System Test, then High Pressure Pump.

NOTE: During this test engine speed is set at 1,400 rpm and initial fuel
pressure at approximately 6,800 psi. During the test fuel pressure is
instantly set to above 20,000 psi. to test the performance of the Fuel
Injection Pump.
NOTE: After the test is completed, the DRB display fuel pressure in 30
counter steps. If the fuel pressure increases from approximately 6,800 psi to
above 20,000 psi in one counter step, the injection pump passes the test.
Did the fuel pressure increase to above 20,000 psi within one counter step on the
DRB?

All

Yes

→ Replace the Fuel Quantity Solenoid in accordance with the

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

→ Replace Fuel Injection Pump in accordance with the Service

Information.
Perform ROAD TEST VERIFICATION - VER-2.

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 and at normal operating temperature, monitor the DRB III

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.

→ Test Complete.

122

DRIVEABILITY - DIESEL

P2015-FUEL RAIL PRESSURE MALFUNCTION MAXIMUM FUEL FLOW
EXCEEDED —

Continued

TEST

ACTION

APPLICABILITY

Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel
Delivery System table.
NOTE: The following is a list of problems that can cause fuel pressure to
deviate from specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, air in fuel system, failed fuel sending unit, contaminated
fuel, faulty injector.
Were there any problems with the Fuel Delivery System?

All

Yes

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 18

All

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 19

All

Yes