en a ble t h e H CU t o per for m t h e br a ke flu id m a n a ge-
m en t con t r ol a s t h e com bin a t ion /pr opor t ion in g
va lves.
Th e Bosch 5.7 syst em u ses t h e CAB/H CU/P u m p
Mot or t o m a ke a n in t egr a l elect r on ic/h ydr a u lic u n it
wh ich sh a r es da t a wit h ot h er elect r on ic m odu les on
t h e veh icle via t h e CAN C Bu s n et wor k. To a ccess
DTCs fr om t h e CAB, t h e DRBIII
"
u ses t h e K-ABS
lin e loca t ed in t h e Da t a Lin k Con n ect or (DLC).
3.3 BRAKE ASSIST SYSTEM (HBA)
Th e Br a ke Assist Syst em (H BA) a n a lyzes h ow
h a r d a n d fa st t h e dr iver wa n t s t o br a ke. It m on it or s
t h e br a ke pr essu r e via a pr essu r e sen sor. Th e
pa ssen ger ca r br a ke a ssist syst em u ses a va cu u m
boost er solen oid. Th e Spr in t er u ses t h e h ydr a u lic
con t r ol u n it t o develop t h e br a ke pr essu r e.
3.4 TCS (ASR)
Th e pr im a r y fu n ct ion of t h e Tr a ct ion Con t r ol Syst em
is t o r edu ce wh eel slip a n d m a in t a in t r a ct ion a t t h e
dr iven wh eels wh en t h e r oa d su r fa ces a r e slipper y. Th e
Tr a ct ion Con t r ol Syst em r edu ces wh eel slip by a pplyin g
t h e br a ke t h a t h a s lost t r a ct ion . Th e syst em is design ed
t o oper a t e a t speeds below 50 km /h (30 m ph ). Th e
en gin e’s t or qu e ca n be r edu ced by t h e E CM via t h e CAN
C Bu s, if n ecessa r y. Th e TCS ca n be dea ct iva t ed wit h
swit ch on t h e da sh . Th e Tr a ct ion Con t r ol Syst em u ses
t h e ABS t o in dica t e spin n in g t ir es t o en a ble t h e t r a ct ion
con t r ol fu n ct ion . Th e TCS soft wa r e is in t h e CAB.
Th e TCS (ASR) per for m s t h e followin g fu n ct ion s:
1. E n gin e power der a t e
2. E n gin e deceler a t ion r egu la t ion . If t h e veh icle is
on a pa t ch of ice, t h e sim ple a ct ion of r elea sin g
t h e t h r ot t le is en ou gh t o ca u se t h e r ea r wh eels t o
slip. To a void t h is, t h e t h r ot t le in pu t is r egu la t ed
so power dr ops slowly in st ea d of a br u pt ly. Th e
en gin e power is r edu ced (deceler a t ed) a s n eces-
sa r y.
3.5 ELECTRONIC BRAKE DISTRIBUTION
(EBD)
Th e syst em wa s en h a n ced a n d elim in a t es t h e
n eed for t h e ALB syst em (loa d sen sin g va lve). All
E SP equ ipped m odels will n ot h a ve ALB. Th e E BV
syst em self-a da pt s t o oper a t in g con dit ion s. It de-
t ect s t h e veh icle’s pa yloa d wh en t h e veh icle st a r t s
a n d pu lls a wa y. Ba sed on t h e a cceler a t ion r a t e
wh en t h e veh icle fir st pu lls a wa y fr om a st a n dst ill,
t h e syst em is a ble t o ca lcu la t e t h e a ct u a l pa yloa d.
Th is is a r ou gh est im a t e wh ich is u sed in it ia lly.
La t er on , t h e syst em ga t h er s m or e pr ecise in for m a -
t ion by m on it or in g t h e br a ke pr essu r e a n d wh eel
speed a n d n ega t ive slip wh en t h e dr iver a pplies t h e
br a kes. Th e syst em will t h en pr odu ce a m or e a ccu -
r a t e ca lcu la t ion of pa yloa d depen din g on br a ke
r et a r da t ion . Th e a da pt a t ion is er a sed wh en t h e
ign it ion is swit ch ed off. A n ew a da pt a t ion will occu r
on t h e n ext dr ivin g cycle. By defa u lt , t h e syst em
a ct s u pon t h e veh icle a s if in a n u n loa ded con dit ion
(sa fe m ode).
On ce a n ew dr ivin g cycle begin s wit h t h e veh icle
in a fu lly loa ded con dit ion (wit h ou t h a vin g ga t h er ed
m or e pr ecise in for m a t ion ) t h e syst em will det ect
ABS a ct u a t ion in t h e fr on t wh eels a n d will a llow
en ou gh pr essu r e t o be a pplied t o t h e r ea r a xle, t o a n
ext en t wh er e t h e wh eels a r e ju st a bou t t o lock u p
(m a xim u m br a kin g possible).
Th e syst em ca lcu la t es t h e br a kin g for ce a t t h e
fr on t a n d r ea r a xles. If t h e dr iver a pplies t h e br a kes
gen t ly a n d t h en r ea lizes h e n eeds t o a pply t h e
br a kes fu r t h er, t h e E BV a llows t h e pr oper pr essu r e
t o be a pplied t o t h e fr on t a n d r ea r br a kes.
Th e E BV a lso con t a in s a fea t u r e ca lled “cor n er
br a ke syst em ” (CBS) wh ich oper a t es wh en t h e ve-
h icle is br a ked wh ile cor n er in g t o a void a possible
over st eer in g con dit ion . Th e E BV m on it or s t h e
wh eel speed of bot h r ea r wh eels t o det ect wh en t h e
veh icle is cor n er in g a n d a llows pr ecise br a ke pr es-
su r e a pplica t ion t o t h e fr on t a n d r ea r br a kes. Also
wh en t h e br a kes a r e a pplied du r in g cor n er in g, t h e
ou t er wh eels get m or e of t h e veh icle’s weigh t wh ile
t h e in n er wh eels get less weigh t a n d cou ld lose
t r a ct ion (wh eel lock u p). Th e E BV syst em split s t h e
pr essu r e bet ween left a n d r igh t sides in a ddit ion t o
fr on t a n d r ea r br a kes.
3.6 VEHICLE CONTROLLING (FZR)
Ve h ic le c o n tro llin g (F ZR)
r equ ir es a ddit ion a l
sen sor s t o oper a t e. Th e t er m E SP r efer s t o t h e
soft wa r e of t h e syst em . Th e t er m F ZR r efer s t o t h e
syst em con t r oller. Th e TCS (ASR) syst em r equ ir es
wh eel speed sen sor s t o m on it or wh eel slip a n d CAN
bu s com m u n ica t ion s t o r egu la t e en gin e power. In
a ddit ion t o t h ese in pu t s, t h e veh icle con t r ollin g
(F ZR) r equ ir es a st eer in g a n gle sen sor, a n d a la t er a l
a cceler a t ion /ya w r a t e sen sor.
Th e E SP syst em does n ot t a ke t h e veh icle loa d
in t o a ccou n t . In st ea d, t h e coefficien t of fr ict ion is
ca lcu la t ed in a 20 m illisecon d per iod, wh er e t h e
con t r oller m ea su r es t h e r a t e a t wh ich t h e wh eel
speed is deceler a t ed, a s br a ke pr essu r e is a pplied t o
t h e wh eel.
3.7 SYSTEM COMPONENTS
•
Con t r oller An t ilock Br a ke (CAB)
•
H ydr a u lic Con t r ol Un it (H CU)
•
P u m p Mot or
2
GEN ERAL I N FORM AT I ON
Summary of Contents for 2006 Sprinter
Page 22: ...NOTES 14...
Page 23: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 15...
Page 256: ...NOTES 248...
Page 263: ...8 9 3 SWITCHES 8 9 4 SIREN C O M P O N E N T L O C A T I O N S 255 COMPONENT LOCATIONS...
Page 264: ...NOTES 256...
Page 278: ...C O N N E C T O R P I N O U T S 270 CONNECTOR PINOUTS...
Page 281: ...C O N N E C T O R P I N O U T S 273 CONNECTOR PINOUTS...
Page 283: ...C O N N E C T O R P I N O U T S 275 CONNECTOR PINOUTS...
Page 285: ...C O N N E C T O R P I N O U T S 277 CONNECTOR PINOUTS...
Page 291: ...C O N N E C T O R P I N O U T S 283 CONNECTOR PINOUTS...
Page 299: ...10 2 2 CAN BUS NETWORK S C H E M A T I C D I A G R A M S 291 SCHEMATIC DIAGRAMS...
Page 301: ...10 3 2 CABIN HEA TER MODULE CHM S C H E M A T I C D I A G R A M S 293 SCHEMATIC DIAGRAMS...
Page 303: ...10 4 INSTRUMENT CLUSTER S C H E M A T I C D I A G R A M S 295 SCHEMATIC DIAGRAMS...
Page 305: ...10 5 2 SLIDING AND REAR DOORS S C H E M A T I C D I A G R A M S 297 SCHEMATIC DIAGRAMS...
Page 307: ...10 6 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 299 SCHEMATIC DIAGRAMS...
Page 308: ...10 7 RAIN SENSOR SYSTEM S C H E M A T I C D I A G R A M S 300 SCHEMATIC DIAGRAMS...
Page 312: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...
Page 316: ...NOTES iv...
Page 324: ...NOTES 8...
Page 325: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...
Page 398: ...8 2 CAB WSS C O M P O N E N T L O C A T I O N S 82 COMPONENT LOCATIONS...
Page 404: ...NOTES 88...
Page 406: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...
Page 418: ...NOTES xii...
Page 429: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 11...
Page 666: ...NOTES 248...
Page 669: ...8 4 SENSORS C O M P O N E N T L O C A T I O N S 251 COMPONENT LOCATIONS...
Page 670: ...C O M P O N E N T L O C A T I O N S 252 COMPONENT LOCATIONS 8 4 SENSORS Continued...
Page 671: ...8 5 SWITCHES C O M P O N E N T L O C A T I O N S 253 COMPONENT LOCATIONS...
Page 672: ...NOTES 254...
Page 682: ...C O N N E C T O R P I N O U T S 264 CONNECTOR PINOUTS...
Page 684: ...C O N N E C T O R P I N O U T S 266 CONNECTOR PINOUTS...
Page 686: ...C O N N E C T O R P I N O U T S 268 CONNECTOR PINOUTS...
Page 690: ...C O N N E C T O R P I N O U T S 272 CONNECTOR PINOUTS...
Page 692: ...NOTES 274...
Page 694: ...10 2 ENGINE CONTROL MODULE S C H E M A T I C D I A G R A M S 276 SCHEMATIC DIAGRAMS...
Page 695: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 277 CHARTS AND GRAPHS...
Page 696: ...NOTES 278...
Page 698: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...
Page 700: ......
Page 704: ...Fig 2 FASTENER IDENTIFICATION 4 INTRODUCTION VA...
Page 705: ...Fig 3 FASTENER STRENGTH VA INTRODUCTION 5...
Page 708: ...Fig 4 METRIC CONVERSION CHART 8 INTRODUCTION VA...
Page 710: ...Fig 5 TORQUE SPECIFICATIONS 10 INTRODUCTION VA...
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Page 1078: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMA TION VA...
Page 1079: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 VA 8W 01 WIRING DIAGRAM INFORMA TION 8W 01 3...
Page 1080: ...Fig 3 Wiring Diagram Symbols 8W 01 4 8W 01 WIRING DIAGRAM INFORMA TION VA...
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Page 1512: ...Fig 1 ENGINE COMPARTMENT LEFT FRONT 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1514: ...Fig 3 FRONT COMPONENTS 1 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1515: ...Fig 4 FRONT COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 17...
Page 1516: ...Fig 5 FRONT COMPONENTS 3 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1517: ...Fig 6 FRONT COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 19...
Page 1518: ...Fig 7 ENGINE COMPARTMENT LEFT 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1519: ...Fig 8 ENGINE COMPARTMENT REAR VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 21...
Page 1520: ...Fig 9 INTERIOR LAMP SPLICES 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1521: ...Fig 10 ENGINE COMPARTMENT OVERVIEW VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 23...
Page 1522: ...Fig 11 FUEL AND AIR COMPONENTS 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1523: ...Fig 12 ENGINE AND INJECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 25...
Page 1524: ...Fig 13 ENGINE SENSORS AND INJECTORS 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1525: ...Fig 14 ENGINE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 27...
Page 1526: ...Fig 15 GLOW PLUGS AND FRONT ENGINE 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1527: ...Fig 16 TRANSMISSION VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 29...
Page 1528: ...Fig 17 FRONT CABIN 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1529: ...Fig 18 BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 31...
Page 1530: ...Fig 19 INSTRUMENT PANEL 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1531: ...Fig 20 CENTER STACK SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 33...
Page 1532: ...Fig 21 INSTRUMENT PANEL SPLICES 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1533: ...Fig 22 INSTRUMENT PANEL AND SHIFTER VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 35...
Page 1534: ...Fig 23 INTERIOR COMPONENTS 1 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1535: ...Fig 24 INTERIOR COMPONENTS 2 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 37...
Page 1536: ...Fig 25 INTERIOR COMPONENTS 3 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1537: ...Fig 26 INTERIOR COMPONENTS 4 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 39...
Page 1538: ...Fig 27 MIRRORS AND INTERIOR 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1539: ...Fig 28 FUSE BLOCK NO 1 VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 41...
Page 1540: ...Fig 29 DASH INLINE CONNECTORS 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1541: ...Fig 30 AJAR SWITHES LIGHTER ROOF FAN VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 43...
Page 1542: ...Fig 31 STEERING COLUMN AND PEDALS 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1543: ...Fig 32 STEERING SYSTEM VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 45...
Page 1544: ...Fig 33 HVAC ASSEMBLY 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1545: ...Fig 34 RESTRAINTS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 47...
Page 1546: ...Fig 35 FUSE AND RELAY BLOCKS 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1547: ...Fig 36 UNDER DRIVER SEAT VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 49...
Page 1548: ...Fig 37 INTRUSION SENSORS 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1549: ...Fig 38 ROOF INLINE CONNECTORS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 51...
Page 1550: ...Fig 39 ROOF A C UNIT 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1551: ...Fig 40 ROOF A C RELAYS AND MODULE VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 53...
Page 1552: ...Fig 41 ROOF A C FUSES 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1553: ...Fig 42 INTERIOR LAMPS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 55...
Page 1554: ...Fig 43 POWER DOOR LOCKS 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1555: ...Fig 44 WINDOW MOTORS AND SPEAKERS VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 57...
Page 1556: ...Fig 45 DOORS AND TURN SIGNALS 8W 91 58 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1557: ...Fig 46 DOOR LOCK MOTOR AJAR SWITCH VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 59...
Page 1558: ...Fig 47 UNDERBODY SPLICES 8W 91 60 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1559: ...Fig 48 INTERIOR LAMPS ANTENNA VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 61...
Page 1560: ...Fig 49 BRAKE SENSORS 8W 91 62 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1561: ...Fig 50 INTERIOR BODY SPLICES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 63...
Page 1562: ...Fig 51 UNDERBODY 8W 91 64 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
Page 1563: ...Fig 52 BODY GROUNDS AND AJAR SWITCHES VA 8W 91 CONNECTOR GROUND SPLICE LOCA TION 8W 91 65...
Page 1564: ...Fig 53 REAR LIGHTING 8W 91 66 8W 91 CONNECTOR GROUND SPLICE LOCA TION VA...
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Page 1667: ...Fig 5 05 FRAME DIMENSIONS 1 VA FRAME BUMPERS 13 5...
Page 1668: ...Fig 6 05 FRAME DIMENSIONS 2 13 6 FRAME BUMPERS VA...
Page 1669: ...Fig 7 FRAME DIMENSIONS VA FRAME BUMPERS 13 7...
Page 1676: ......
Page 1804: ...HYDRAULIC FLOW IN REVERSE FAILSAFE 21 66 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1805: ...HYDRAULIC FLOW IN REVERSE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 67...
Page 1806: ...HYDRAULIC FLOW IN NEUTRAL DEFAULT 21 68 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1807: ...HYDRAULIC FLOW IN NEUTRAL VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 69...
Page 1809: ...HYDRAULIC FLOW IN DRIVE FAILSAFE VA AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION 21 71...
Page 1810: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 72 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1812: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 74 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1814: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR 21 76 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1816: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR 21 78 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1818: ...HYDRAULIC FLOW IN DRIVE FIFTH GEAR 21 80 AUTOMA TIC TRANSMISSION NAG1 SERVICE INFORMA TION VA...
Page 1933: ...Fig 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART VA TIRES WHEELS 22 11...
Page 1938: ......
Page 2032: ......
Page 2152: ......
Page 2156: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...
Page 2160: ...NOTES iv...
Page 2169: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9...
Page 2288: ...NOTES 128...
Page 2290: ...NOTES 130...
Page 2294: ...NOTES 134...
Page 2295: ...10 0 SCHEMATIC DIAGRAMS S C H E M A T I C D I A G R A M S 135 SCHEMATIC DIAGRAMS...
Page 2296: ...NOTES 136...
Page 2298: ...11 2 TRANSMISSION TEMP SENSOR C H A R T S A N D G R A P H S 138 CHARTS AND GRAPHS...
Page 2300: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...