Sprinter Diagnostics

[Auspoweng]

For those who have come into the local forum recently....about 9 months back I picked up 2002 413 CDI cab chassis for $5k here in Perth, with 230,000km on the clock but with a stuffed engine. It has been off the road and unlicensed since Jan 2010. The story went that a local second hand machinery and truck dealer (ahem) picked it up from an auction and set their diesel mechanic onto it.

Originally, it was known to have 'spun a main bearing'. So, they put new bearings and rings, re-did the head, new clutch and heat exchanged. They ran it up but something went pear-shaped and it stopped going round and round.

So, I expected a dead engine and was told that an exchange engine would be about another '5 grand' or so. I didn't want to test this fact too early due to need for plausible deniability, I was on shaky ground with my wife...." but darling they told me it would only cost 5 thousand more...it isn't my fault."

So I bought it, then went to get an exchange engine and found out it would cost quite a bit more than 5 grand. After pulling it out the original, I found that the valve cap had been gouged by the cam. Perhaps they cranked it to death without good oil flow? I looked into a new head, but not knowing what else was done by the dealership mechanic and after getting some budgets for the head overhaul (somewhere between $3.5k and $7k I think) I looked around for a Plan C.

Eventually I decided on the somewhat risky move to import an engine from the UK, which I did and it arrived safely by boat in January. I also bought 4 refurbished injectors, because at 100 pounds each, it seemed like a good idea to eliminate that from the outset. My customs agent made the final delivery from the Perth container yard to my storage unit (5 km) and literally lost the box of injectors off the back of the truck...'Have you got marine insurance they said!'....another story grrr.

Aside from that setback, the engine itself looks okay but time will tell. 6 weeks later, with about 6-8 hours a week, I have the new engine back in the Sprinter will all the fruit connected back in their original spots...thanks to some help from the forum.

The starter motor turns the engine around nicely but that is all. I am trying to get hold of a Sprinter Mech locally to light up my rocket...another story.

This thread is about engine diagnostics. I figured back in October, after reading various posts on this forum, that DIY Sprinter owners need access to either
1) a Merc mate either from the dealer or around the traps or,
2) their own diagnostic unit.

I initially tried to get a 'DAD unit' out the states via Andy Bittenbinder but they had all been sold. So I bought a sprinter premium software package and interface out of Belgium from Carsoft. It was 575 Euro, I think.

I only activated the software today, so will let everyone know how this goes, but again I have the feeling I am in way over my head here.

[Type2Teach]

You probably are in over your head, BUT.... You've got this forum and the members to help you out!
Seriously, I bought a Sprinter in non-running condition and with the help of this list she's now my daily driver and kid hauler. Before this I had never even worked on a diesel engine, but had lots of shade-tree mechanic experience with gasoline engines.
If you need help (which it looks like you do) you've come to the right place.

Read, Post and ask lots of questions!

[Auspoweng]

Well .. Day 1 with Sprinter diagnostics did not go well.

Software would not connect to the diagnostic port and I must admit when it comes to serial comms, I am an expert, due to my day job.

I have reassigned the inbuilt USB-serial port but no go. Perhaps Carsoft is no good on Windows 7 64-bit?

Have asked their tech support...let's see...

[jdcaples]

I don't have version 10 running yet.

Version 10 reports that I must "upgrade the security Dongle."

Version 8 still launches fine; it just can't reliably communicate with all the modules in my Sprinter.

I've emailed the WiBU activation info to Carsoft and am waiting to hear back.

The back of the program CD packaging lists very modest system requirements:

• Pentium III 500 mhz
• 128 MB RAM
• 500 MB hard disk space
• 1024x768 screen resolution
• CD-ROM or DVD-ROM drive
• 1 USB 2.0 Port to connect the vehicle interface cable
• 1 USB 1.1/2.0 Port to connect security dongle
• Microsoft Windows 2000 or Windows XP or Vista or Windows 7

Given these requirements, your musing about the product needing a 32 bit system has some merit.

While you're waiting to hear back from Belgium, you might want to try logging in as Administrator and running it.

You also may want to try running it in some compatibility mode (XP compatibility? - I'm not a Windows expert).

-Jon

PS: Under version 3 and up to version 8, I could run this software with the wibu key in any USB port, but the vehicle cable needed to be assigned a USB port assigned COM1 or COM3 in at least one version on at least one of three laptops I've owned since first running Carsoft. Seasoned geeks will remember the special relationship between COM1 & COM3 as well as COM2's relationship with COM4 under the IBM PC & Compatible hardware platforms. There may have been some assumptions coded in at least one version of Carsoft.... or the USB hardware driver I was using at the time.

[Auspoweng]

Folks,

Okay this will be long post, as I finally got CarSoft to talk to the Sprinter. I have a legitimate version of Carsoft up to date to Version 10.

The only module I can communicate with at the moment is the CDI.

Full list follows below but summary of error codes are:
1) P1481 Glow plug failure
2) P1630 WSP Immobilizer Signal Error
3) P0600 CAN-Bus Fault
4) P2006 Pre-Delivery Pressure Sensor (Low Pressure) (OM611/612 Only)
5) P1330 Starter Relay Control (OM611/612 Only)
6) P1354 Synchronization Error: CMP and CKP (OM611/612 Only)
7) P1615 CDI Control Unit: Voltage Supply Error
8) P0110 Intake (Charge) air temperature sensor G14
9) P0105 Boost Pressure sensor

Apart from this it seems there are no other problems

Status: Fout

Module Information:

Part Number : 611 153 09 91
Software Date : 38/03
Hardware Date : 14/00
Diagnosis Recognition : 16/131
Supllier : Bosch

---------------------------------------------------------------------------------------------------------------------------------

Stored Fault Code and Current Fault Code :

Fault Code : P1481

P1481 Glow plug failure

--> The error will be stored within a few seconds.
--> The Check Engine (MIL)light does not light

--> Conditions listed in Freeze Frame Data:
- 001 Glow plug failure: Cylinder 1
- 002 Glow plug failure: Cylinder 2
- 004 Glow plug failure: Cylinder 3
- 008 Glow plug failure: Cylinder 4
- 016 Glow plug failure: Cylinder 5


--> Glow Plug indicator light may be on or flashing

Stored Falt Code :

Fault Code : P1630

P1630 WSP Immobilizer Signal Error

--> Start enable commmand not issued
--> Engine does not start
--> START ERROR may be displayed in Instrument Cluster multifunction display

--> Conditions listed in Freeze Frame Data:
- 001 WSP Control Unit faulty
- 002 WSP Control Unit does not answer or time exceeded
- 004 Authentication value expended
- 008 Key use inhibited or transponder blocked
- 016 WSP Control Unit does not answer or answer unrecognized
- 032 Authentication value incorrect
- 064 CDI Control Unit checksum fault: EEPROM test 1
- 128 CDI Control Unit checksum fault: EEPROM test 2


--> Possible causes :

- WSP Control Unit A62 does not respond, or has an internal fault
- Starting attempt with locked WSP from another vehicle
- WSP error: incorrect code generated
- Transponder key has not been synchronized
- WSP Coding is not correct for vehicle



Stored Falt Code :

Fault Code : P0600

P0600 CAN-Bus Fault

--> Open Circuit, Short to Ground, or Short to Positive

--> Conditions listed in Freeze Frame Data:
- 001 CAN-Bus open circuit, short to ground, or short to positive
- 004 CAN-Databus faulty or damaged
- 008 Transmission of message unsucessful
- 016 Transmission of message unsucessful
- 032 Hardware Fault
- 064 Hardware Fault
- 128 Signal Plausibility

--> Inspect wiring harness for damage or faults. Test CAN-Bus







Stored Fault Code and Current Fault Code :

Fault Code : P2006

P2006 Pre-Delivery Pressure Sensor (Low Pressure) (OM611/612 Only)

--> Low pressure sensor on fuel filter water separator signal fault

--> Conditions listed in Freeze Frame Data
- 001 Signal too low
- 002 Signal too high
- 004 Plausibility

--> Inspect fuel filter and water in fuel sensor
Verify no wiring faults exist and connections are secure





Stored Falt Code :

Fault Code : P1330

P1330 Starter Relay Control (OM611/612 Only)

--> Engine does not start, starter does not rotate.

--> Conditions from Freeze Frame Data:
- 004 Starter Relay Short circuit
- 008 Starter Relay Open circuit
- 016 Attempt to start without Circuit 50 signal


--> Possible causes :
- Verify wiring and connections between CDI control unit and
starter relay. Inspect Starter Relay and replace if necessary







Stored Falt Code :

Fault Code : P1354

P1354 Synchronization Error: CMP and CKP (OM611/612 Only)

--> The error will be stored within a few seconds.
--> The EPC control light does not light.
--> It is impossible to start the engine.

--> Conditions from Freeze Frame Data:
- 001 Flow limiter activated
- 002 Camshaft frequency signal too high
- 004 No Camshaft frequency signal
- 008 Crankshaft frequency signal too high
- 016 No Crankshaft frequency signal
- 032 Signal Error Plausibility
- 064 Signal Error Plausibility no camshaft signal
- 128 Signal Error Plausibility: Injection correction is faulty

--> Pin Setup crankshaft: 1: Sensor Ground; 2: Signal
--> Pin Setup camshaft: 1: Sensor Ground ; 2: Signal ; 3: +12 V

--> Possible causes :

- Camshaft frequency to high
- RPM not plausible
- Camshaft Signal missing







Stored Falt Code :

Fault Code : P1615

P1615 CDI Control Unit: Voltage Supply Error

--> The voltage supply is out of optimum range
Minimum voltage or maximum voltage thresholds
exceeded.

--> Conditions listed in Freeze Frame Data:
- 001 Voltage supply too high, or; too low
- 002 Voltage supply too low, or; too high

--> Minimum : 8 V - Maximum : 16 V
Voltage supply out of range. Verify condition of charging
system, batteries, and voltage regulation.







Stored Falt Code :

Fault Code : P0110

P0110 Intake (Charge) air temperature sensor G14

--> The error will be stored within a few minutes.
--> The Check Engine (MIL)light does not light.

--> Conditions listed in Freeze Frame Data:
- 001 Signal voltage too low or open circuit
- 002 Signal voltage too high or short circuit
- 004 Supply voltage too high or too low, or CAN-Bus signal faulty
- 008 Plausibility of signal
- 016 Plausibility of signal
- 032 Plausibility of signal
- 064 Plausibility of signal
- 128 Plausibility of signal

--> Pin Setup : 1: Ground Sensor; 2: Signal

--> Possible causes :

- Signal to low : < 0,22 V
- Signal to high : > 4,71 V
- Open Circuit (Condition 001 Freeze Frame Data)
- Short Circuit (Condition 002 Freeze Frame Data)







Stored Falt Code :

Fault Code : P0105

P0105 Boost Pressure sensor

--> OM611/612: B112 Boost Pressure Sensor
--> OM647: B141 Boost Pressure Sensor
--> The error will be stored within a few seconds.
--> The Check Engine Light (MIL)does not light.
--> Atmospheric pressure is used as a substitute value.
The EGR is switched off.

--> Conditions listed in Freeze Frame Data:
- 001 Signal voltage too low
- 002 Signal voltage too high
- 004 Supply voltage too high or too low, or CAN-Bus signal faulty
- 008 Plausibility of signal
- 016 Plausibility of signal
- 032 Plausibility of signal
- 064 Plausibility of signal
- 128 Plausibility of signal

--> Pin Setup : 1: Signal; 2: Sensor Ground; 3 : +5V

--> Possible causes :

- Signal to low : < 0,25 V (Condition 002 Freeze Frame Data)
- Signal to high : > 4,6 V (Condition 001 Freeze Frame Data)
- Power supply to low : < 4,6 V
- Power supply to high: > 5,1 V
- Plausibility of Signal (Condition 008 Freeze Frame Data)
- CAN Signal Fault (Condition 004 Freeze Frame Data)

[Auspoweng]

I though I would break this post up a bit....

Next, I reset the fault codes. After another start attempt, they have all gone, except for the for the glow plug P1481.

So, I have measured the resistance off the removable plug behind the passenger (left) headlight. 3 are 1.0-1.2Ohm and one is open circuit. I will remove the intake manifold and check that connection, but given all 5 glow plug faults come up, then I think I have bigger problems.

Is it normal that the diagnositics does not recognise I have 4 cyclinders but reporting a glow plug 5 problem also?

The original CAN bus fault might be the reason I have no other module communications, but I thought this fault should reappear after the reset?

Also, during the full diagnosis, and error was reported on the Instrument Panel (KI as attached), indicating error codes to reset, however the scan of that module under single diagnosis could not comminicate to restrieve those codes.

[Aqua Puttana]

Originally Posted by Auspoweng

I though I would break this post up a bit....

...
Is is normal that the diagnositics does not recognise I have 4 cyclinders but reporting a glow plug 5 problem also?...

I know that the earlier NAFTA T1N Sprinters (2001 - 2006) are known for inaccurate glow plug postion fault codes. It is always recommended to verify the glow plug as actually bad with additional tests and to not just change any out based only upon the malfunction code indication. That may figure in to your situation. (NAFTA NCV3 2007 - current model fault position indications are said to be more accurate.)

This is for what it is worth as I'm not certain if it translates directly over to EURO models, but I expect that it does.

Thanks for the Carsoft lessons. Very interesting stuff. vic

[Oldfartt]

Peter,

In your climate, the glow plugs are not necessary for starting. The glow plug controller has a fuse for each plug inside the box. One may have blown, indicating that plug has shorted. Search this site for glow plug info in T1N sprinters. I would concentrate your search elsewhere at this stage. Good info on Carsoft.

Cheers

Ross

[owner]

Your carsoft is newer than mine (any yours is not hacked lol). Mine is V7.4

I can talk to several modules in my sprinter, but thinking about it, they probably aren't on your model anyway. Controllers like ESP, Airbag, Tranny, and of course CDI all show in my carsoft. Mines a 316 ex ambo.

So of those 4 you probably only have CDI. I can't talk to anything else on my sprinter other than those IIRC.

So you might be ok, and it could just be the glowplugs that are preventing starting, although it should still technically start. Did you try cranking it and then re-read the codes? some of those stored codes you had would only show up again after cranking. Also if the main CAN bus is really down then it won't even engage the starter, so I'm thinking that CAN fault code was stored when the ECU was powered up without everything else connected at some point.

[Auspoweng]

Thanks Ross....I was starting to go down the path of modding the glow plug controller as per the other T1N threads Re: Internal fuses blowing. I'll avoid that path for now.

So I'll continue with CarSoft diagnostics over the next few days and try to get some more data out the instrument cluster and CDI controller.

It might immobilizer also? Not sure if the key I got was ever paired to this vehicle. Do you know if 2002 sprinter key's are RFID coded?