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Mercedes-Benz Sprinter / Dodge Sprinter. Manual - part 413

(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

14 - 11

INSTALLATION - HIGH PRESSURE LINES

(1) Loosen the fuel rail mounting bolts to install

lines free of stress.

CAUTION: Inspect sealing cone at lines. Replace if
compression points exist. Ensure lines are exactly
located.

(2) Position and install fuel lines (Fig. 3). Tighten

to 22N·m (195 lbs. in.) using a wrench to counterhold
at threaded connection.

(3) Tighten fuel rail to 14N·m (124 lbs. in.).
(4) Connect negative battery cable.

CAUTION: Care must be taken when installing the
engine cover. Assure the proper routing of the fuel
injector return fuel hose to the banjo bolt fitting in
the left rear corner of the cover. Failure to do so
may pinch or damage the hose causing fuel leakage
or a driveability concern.

(5) Start engine, run for a few minutes, turn

engine off and inspect for leaks (Refer to 14 - FUEL
SYSTEM - WARNING), (Refer to 14 - FUEL SYS-
TEM - DIAGNOSIS AND TESTING).

FUEL RAIL PRESSURE SEN-
SOR

DESCRIPTION

The fuel rail pressure sensor is attached to the

front of the fuel rail. The sensor supplies the current
fuel rail pressure to the ECM.

OPERATION

Non-constant fuel system pressure influences the

position of a diaphragm inside the sensor. This
results in a variation in the electrical resistance. The
fuel rail pressure sensor supplies the appropriate
voltage signal to the ECM.

REMOVAL

(1) Disconnect the negative battery cable.
(2) Disconnect the sensor wiring harness connector

(Fig. 4).

NOTE: Place a shop towel underneath the sensor to
capture any fuel spillage.

(3) Unscrew the sensor and discard the seal.

Fig. 3 FUEL RAIL

1 - CAMSHAFT POSITION SENSOR
2 - FUEL INJECTOR
3 - FUEL INJECTOR VALLEY DRAIN
4 - FUEL RAIL PRESSURE CONTROL VALVE
5 - BANJO BOLT
6 - FUEL RAIL
7 - HIGH PRESSURE FUEL LINE

Fig. 4 FUEL RAIL PRESSURE SENSOR

1 - FUEL RAIL PRESSURE SENSOR
2 - FUEL RAIL
3 - COOLANT TEMPERATURE SENSOR

14 - 12

FUEL DELIVERY

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