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Dodge Sprinter. Manual - part 244

Switching Off Main Injection

Main injection is switched off when:
• Engine speed is too high >4700 - 4800 rpm

• Main injection quantity too low

• Low fuel pressure in fuel rail

• Engine off

• External quantity control

• Deceleration mode

Calculating Main Injection

The quantity of main injection is calculated by:
• Engine speed

• Atmospheric pressure

• Coolant temperature

• Boost air temperature

• Fuel rail pressure

• Boost pressure

Period of Actuation

For calculating the period of actuation of the main

injection it is necessary to know whether a pre-injec-
tion has occurred or not.

The coolant temperature, charge air temperature

and the atmospheric pressure are used for correcting
the main injection quantity. If main injection quan-
tity is less than a minimum quantity which is depen-
dent on fuel rail pressure, no preinjection takes
place. In this case, only main injection is performed.
If the quantity is then still below the minimum
quantity, neither main injection or pre-injection takes
place (deceleration mode).

Deceleration Mode

The purpose of the deceleration mode is to inter-

rupt the operation of the injectors. The ECM deter-
mines the accelerator pedal position from a supplied
signal and it determines the engine speed by the
crank sensor. In the overrun and with the engine
speed above 1600, with the accelerator pedal no
pressed, the injectors are no longer actuated and the
fuel rail pressure is lowered by the pressure regula-
tor valve.

Full Load Injected Quantity

The purpose of the full load injected quantity is to

minimize the formation of smoke. The ECM limits
the fuel rail pressure when the engine is operating at
full load by way of the quantity control valve, and
quantity of fuel injected by the injectors. this mini-
mizes the formation of smoke when accelerating and
driving at constant speeds. If a fault occurs at the
boost pressure control, full load injected quantity is
reduced.

Limiting Maximum Engine Speed

The ECM determines the engine speed based on

the signal supplied by the crankshaft sensor and lim-

its this by interrupting the operation of the fuel
injectors.

Fuel Quantity Control

The fuel quantity is controlled separately for each

cylinder by the ECM inline with the firing order.The
ECM detects the operating state which exists at the
engine by means of the sensors. In order adapt the
quantity injected, either the fuel rail pressure can be
adjusted by the fuel solenoid and quantity control
valve or the actuation time of the solenoid valves in
the injectors

Boiling Protection

In order to protect against thermal overload and

along with criteria programmed in the ECM, the
injection quantity is reduced as a function of the cool-
ant temperature and vehicle speed. If the coolant
temperature sensor fails the oil temperature signal
from the oil sensor is used as a suitable value.

Fuel Tank Protection

The fuel rail pressure is lowered in order to protect

the fuel tank from overheating. The fuel temperature
sensor measures the temperature of the fuel being
supplied from the tank, in the high pressure flange.
If the fuel is too warm the fuel rail pressure is fur-
ther reduced by the quantity control valve.

STANDARD PROCEDURE

STANDARD PROCEDURE - DRAINING FUEL
TANK - DIESEL

(1) Position a drain hose into the fuel fill opening.
(2) Drain fuel tank using an approved diesel fuel

draining station.

FUEL CONTAMINATION

If a diesel engine’s fuel supply has been contami-

nated with gasoline, the following procedure must be
followed:

(1) Remove all fuel from the fuel tank. (Refer to 14

- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE-DRAINING FUEL TANK) Use an
appropriate fuel container. Dispose of the contami-
nated fuel using the proper procedures.

CAUTION: Dispose of petroleum based products in
a manner consistent with all applicable Local, State,
Federal, and Provincial regulations.

(2) Remove and clean fuel tank. (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY/FUEL TANK -
REMOVAL)

(3) Install the fuel tank. (Refer to 14 - FUEL SYS-

TEM/FUEL DELIVERY/FUEL TANK - INSTALLA-
TION)

14 - 8

FUEL DELIVERY

(4) Fill fuel tank with fresh diesel fuel.
(5) Drain and remove the fuel filter. (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER /
WATER SEPARATOR - REMOVAL)

(6) Install a new fuel filter. (Refer to 14 - FUEL

SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER
SEPARATOR - INSTALLATION)

(7) Check the engine control module for any diag-

nostic trouble codes (DTCs). Record and clear any
DTCs that are present.

(8) Start and run the engine. Run the engine for

up to 15 minutes to allow time for any DTCs to reset
and shut off the engine.

(9) Check the engine control module for any diag-

nostic trouble codes (DTCs). Record any DTCs that
are present. Refer to the appropriate engine electrical
diagnostics to diagnose any DTCs that were set.

CAUTION: With the high pressure fuel system in
this vehicle, any residual contaminated fuel will be
removed very quickly. Shut off the engine immedi-
ately if signs of engine damage are noted.

The engine should then be evaluated to determine

if the contaminated fuel has caused any damage to
the fuel system and/or engine. Indicators that the
fuel system has been damaged include the following:

• Unstable fuel rail pressure. This can manifest

itself as instability of idle speeds, excessive under-
shoot/overshoot

engine

start-up,

excessive

undershoot/overshoot when the engine operating con-
ditions change. A typical engine response to a large
rail pressure undershoot would be a decrease in
engine speed or engine stall.

• Excessive noise from the engine. This could indi-

cate poor rail pressure control or the inability of the
injection system to inject the proper amount of fuel.

• Excessive smoke (black or white). This could

indicate the inability of the fuel system to inject the
proper amount of fuel.

NOTE: If any of these conditions are exhibited after
cleaning the fuel system, proceed to the appropri-
ate engine electrical diagnostic information. Repair
the fuel system and/or engine as necessary.

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

FUEL TANK MOUNTING NUTS

15 - 17

11 - 13

FUEL TANK MODULE LOCKRING (LOCK-

NUT)

PRESSURE CONTROL VALVE NUT TO

FUEL RAIL (2 STAGES)

60, loosen 90°, re-

tighten to 80

44, loosen 90°, re-

tighten to 59

SPECIAL TOOLS

FUEL SYSTEM

SPECIAL TOOL CROSS REFERENCE CHART

TOOL #

MILLER
TOOL #

DESCRIPTION

N/A

5069-2

FUEL GAUGE

N/A

6856

SPANNER WRENCH

N/A

9068

FUEL GAUGE ADAPTER

N/A

9285

FUEL LINE WRENCH

SPANNER WRENCH-6856

FUEL DELIVERY

14 - 9

FUEL DRAIN TUBES

DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS

LOW - PRESSURE LINES

Fuel supply line restrictions can cause starting

problems and prevent engine from accelerating. The
starting problems include; low power and/or white
fog like exhaust.

Test all fuel supply lines for restrictions or block-

age. Flush or replace as necessary.

HIGH - PRESSURE LINES

CAUTION: High pressure lines cannot contact each
other or other components. Do not attempt to weld
high-pressure fuel lines or to repair lines that are
damaged. High pressure lines must be replaced at
each disassembly. Use only recommended lines
when replacement of high-pressure fuel line is nec-
essary.

Restricted (kinked or bent) high-pressure lines can

cause starting problems, poor engine performance,

engine mis-fire and white smoke from exhaust (Refer
to 14 - FUEL SYSTEM - WARNING).

FUEL FILTER

DESCRIPTION

The fuel filter was designed for improved high alti-

tude operation and for better re-start after the fuel
tank has been completely emptied. The water drain
plug and water in fuel (WIF) sensor are located on
the top of the filter. Water is drained by using the in-
tank electric fuel pump to generate flow (attach a
hose to the drain plug). The filter has a pressure dif-
ferential of 200–300 mbar (2.9 psi.) when new. When
dirty, the pressure differential rises to 800 mbar (11.6
psi.) (Fig. 2).

REMOVAL

WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.

CAUTION: DO NOT bend, twist or cut the fuel hose
clamps. The fuel hose clamps through out the fuel
system are reusable when using special tool #9539.
Orginal clamps must be used when servicing the
fuel system.

(1) Disconnect negative battery cable.
(2) Disconnect the water in fuel (WIF) sensor har-

ness connector (Fig. 2).

(3) Release the fuel inlet and outlet hose clamps

using special tool #9539 at the fuel filter (Fig. 2).

(4) Remove fuel filter retaining bracket bolt and

remove fuel filter (Fig. 2).

(5) Separate the WIF sensor from the fuel filter

(Fig. 2)

FUEL LINE WRENCH-9285

FUEL LINE PLIERS-9539

14 - 10

FUEL DELIVERY

INSTALLATION

NOTE: Capture any fuel spillage and dispose of in
appropriately marked container.

(1) Fill new fuel filter with the new diesel fuel

(approximately 0.4 liters)

(2) Carefully seat WIF sensor and tighten bolt to

13 lbs. in. (1.5 N·m) (Fig. 2)

(3) Position fuel filter in bracket and tighten

retaining bolt to 53 lbs. in. (6 N·m) (Fig. 2)

(4)

Install fuel lines and re-crimp clamps using

special tool #9539 (Fig. 2).

(5) Connect the WIF wiring harness connector

(Fig. 2).

(6) Connect negative battery cable.

(7) Cycle ignition several times to build pressure.
(8) Start engine and inspect for leaks.

FUEL LINES

REMOVAL - HIGH PRESSURE LINES

(1) Disconnect negative battery cable.

CAUTION: Counterhold with wrench at threaded
connections of injectors. DO NOT EXCEED the
tightening torque in order to avoid also slackings
the threaded connection.

CAUTION: DO NOT crimp or bend lines.

NOTE: After removing injection lines, seal connec-
tions and ensure cleanliness.

(2) Unscrew union nuts of injection lines.
(3) Remove injection lines (Fig. 3).

Fig. 2 FUEL FILTER

1 - FUEL SUPPLY LINE TO HIGH PRESSURE PUMP
2 - FUEL FILTER
3 - WIF SENSOR
4 - FUEL FILTER DRAIN

FUEL DELIVERY

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