2005 MERCEDES-BENZ SPRINTER Service Repair Manual

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual SPECIAL TOOLS
FUEL SYSTEM
SPECIAL TOOL CROSS REFERENCE CHART
MB
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
FUEL

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual (4) Unscrew the mounting bolt on the preheating
valve, turn preheating valve out of locking arm and
pull off (Fig. 1).
(5) Remove fuel filter retaining bracket bolt and
remove fuel filter (Fig. 1).
IN

Page 835 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual INSTALLATION - HIGH PRESSURE LINES
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PS

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual HIGH PRESSURE SIDE
A. Filling the piston:The piston is moved down
as a result of the piston spring. The fuel supplied by
the fuel delivery pump flows along the ring passage,
the valve disk and the val

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual (3) Unplug electrical connector at high pressure
pump.
CAUTION: DO NOT slacken the threaded connec-
tion. Use a wrench to counterhold at the threaded
connection when loosening and tightening the
union

Page 838 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual (3) Detach fuel lines at low pressure pump (Fig. 6).
(4) Remove low pressure pump (Fig. 6).
INSTALLATION
INSTALLATION - HIGH PRESSURE PUMP
(Refer to 14 - FUEL SYSTEM - WARNING)
CAUTION: Clean sealing

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual INSTALLATION - LOW PRESSURE PUMP
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 O

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MERCEDES-BENZ SPRINTER 2005  Service Repair Manual (1) Loosely position fuel rail into position on cylin-
der head.
(2) Position and loosely install fuel return line
from fuel filter, with new seals to rail (Fig. 7).
(3) Position fuel rail to cylinder