2005 MERCEDES-BENZ SPRINTER Cool

²Higher torque as a result of improved cylinder
charge.
²Reduction in exhaust emissions as a result of an
improvement in the air supply of the engine.
²Increased power output as a result of the higher
charge pressure combined with a reduced exhaust
backpressure and thus improved charge cycle.
OPERATION
The exhaust gases of the engine are directed
through the exhaust manifold into the turbine hous-
ing onto the turbine wheel (Fig. 2). The flow energy
of the exhaust gases cause the turbine wheel to
rotate. Consequently, the compressor wheel, which is
connected through the turbine shaft with the turbine
wheel, is driven at the same speed. The fresh air
inducted by the compressor wheel is compressed and
passed to the engine (Fig. 2).
The charge pressure is controlled by varying the
position of the guide vanes (Fig. 2). The guide stud of
the control linkage of the boost pressure actuator
turns the adjusting ring in the turbine housing (Fig.
2). As a result, all the guide vanes whose guide studs
likewise mesh into the adjusting ring, are also
turned (Fig. 2).
At low speeds, the flow cross-section is reduced by
closing the guide vanes (Fig. 2). Consequently the
speed at which the exhaust gas impacts on the tur-
bine wheel is increased, as a result of which the
speed of the turbocharger and thus the charge pres-
sure rises.
At high engine speeds the guide vanes are increas-
ingly opened and the flow cross-section is thus
enlarged, as a result of which the speed of the turbo-
charger reduces and the charge pressure drops.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge air system consists of the charge air
cooler and charge air cooler piping.
The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi-
ciency and power.
OPERATION
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-
ized air from the turbocharger then flows forward
through the charge air cooler located in front of theradiator. From the charge air cooler the air flows
back into the intake manifold.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
NOTE: Slight engine oil pooling in the charge air
inlet hose IS NOT premature turbocharger failure.
Slight pooling is the normal result of the breather
system. Test the air breather tube for normal oper-
ation by referring to the appropriate diagnostic
manual.
Fig. 2 TURBOCHARGER COMPONENTS
1 - COMPRESSOR HOUSING
2 - GUIDE VANE
3 - GUIDE STUD OF GUIDE VANE
4 - GUIDE STUD OF CONTROL LINKAGE
5 - CONTROL LINKAGE
6 - ADJUSTING RING
7 - TURBINE HOUSING
8 - BOOST PRESSURE CONTROL UNIT
1A - EXHAUST GASES TO TURBINE WHEEL
2A - TURBO INLET (FRESH AIR)
3A - TURBO OUTLET (COMPRESSED AIR)
4A - EXHAUST OUTLET
11 - 4 EXHAUST SYSTEMVA
TURBOCHARGER SYSTEM (Continued)

Low turbocharger boost pressure and low engine
performance can be caused by leaks in the charge air
cooler or it's plumbing. The following procedure out-
lines how to check for leaks in the charge air cooler
system.
(1) Loosen clamp and remove turbocharger to air
inlet duct rubber sleeve from turbocharger.
(2) Insert Special Tool 8442 Adapter into the rub-
ber sleeve. Tighten existing clamp to 8 N´m (72
in.lbs.).
CAUTION: Do not apply more than 138 kpa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect regulated air supply to air fitting on
Special Tool 8442 Adapter. Set air pressure to a Max-
imum of 138 kpa (20 psi).
(4) Using soapy water check the air inlet ducts,
rubber sleeves, charge air cooler and intake manifold
for leaks.
REMOVAL
(1) Remove front bumper.
(2) Remove headlamp assemblies.
(3) Remove front cross member together with front
grille.
(4) Remove left and right radiator trim (Fig. 3).
(5) Disconnect charge air hoses at charge air cooler
(Fig. 3).
(6) Disconnect power steering cooler loop from
charge air cooler (Fig. 3).
(7) Remove charge air cooler from radiator assem-
bly (Fig. 3).
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit.
INSTALLATION
(1) Install charge air cooler to radiator (Fig. 3).
(2) Connect power steering cooler loop to charge
air cooler (Fig. 3).
(3) Connect charge air hoses (Fig. 3).
(4) Install both radiator trim pieces (Fig. 3).
(5) Install front grille with front cross member.
(6) Install headlamp assemblies.
(7) Install front bumper.
Fig. 3 CHARGE AIR COOLER
1 - POWER STEERING COOLER LOOP
2 - CHARGE AIR HOSE
3 - CHARGE AIR COOLER HOSE
4 - CHARGE AIR COOLER
5 - LEFT RADIATOR TRIM PANEL
6 - RIGHT RADIATOR TRIM PANEL
VAEXHAUST SYSTEM 11 - 5
CHARGE AIR COOLER AND PLUMBING (Continued)

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 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
In order to assure trouble free operation with win-
ter grade diesel fuel, a preheater valve is located
with in the fuel filter. Depending on the temperature
of the heated return flow fuel, fuel flows back
through the preheating valve into the fuel filter to
heat up or flows through the cooling coils directly
back into the fuel tank.
OPERATION
PRE - HEATING Up to 30ÉC (86ÉF), the thermo
bimetal plate of the preheater, shuts off the return
fuel flow port to the fuel tank. The fuel from the rail
flows into the fuel filter to be warmed. If there is air
in the system, a ball seals off a port and the air is
directed to the fuel tank.
NON PRE - HEATING From above 30ÉC (86ÉF) the
thermo bimetal plate of the preheater, shuts off the
port to the fuel filter and fuel from the rail flows
directly into the return flow line to the fuel tank.
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.
(1) Disconnect negative battery cable.
(2) Separate the fuel outlet line connector on the
fuel filter (Refer to 14 - FUEL SYSTEM - STAN-
DARD PROCEDURE). (Fig. 1)
(3) Slacken the hose clamp on the fuel inlet line
and detach fuel line (Fig. 1).
SPANNER WRENCH-6856
FUEL LINE WRENCH-9285
VAFUEL DELIVERY 14 - 5
FUEL DELIVERY (Continued)

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 valve spring into the cylinder.
The ball valve prevents the fuel from being able to
flow back from the high pressure passage.
B. Producing high pressure:The piston is
moved up by the rising eccentric shaft and the fuel is
thus compressed. The valve disk shuts off the deliv-
ery volume to the fuel feed. Once the fuel pressure in
the cylinder rises beyond the pressure which exists
in the high pressure circuit, the ball valve opens and
the fuel is pumped into the high pressure circuit.
C. Fuel Temperature RegulationThe ECM can
Interrupt the fuel high pressure delivery of one of the
pump elements in the particle load range in order to
reduce the power required for driving the high pres-
sure pump so as to reduce the fuel temperature. The
pump element is switched off if the fuel temperature
is excessively high (above 278É, 120 bar).
OPERATION - LOW PRESSURE PUMP
The low pressure pump draws fuel from tank
through fuel filter and supplies the high pressure
pump. Fuel pressure at starter speed is 0.4 to 1.5 bar
(6 to 22 psi.). A fuel pressure of 2.0 to 2.5 bar (29 to
36 psi.) is reached at idle speed. Fuel pressure is lim-
ited to 3.5 bar   .5 bar (51 psi.   7 psi) by the valve
in the fuel delivery pump. This valve opens by over
coming a spring force and allows excessive fuel to
flow to the intake side of the low pressure pump.
This diverted fuel flows into the return flow pipe
through the fuel cooler back to the tank. As a result
of this circulation, the fuel always remains relatively
cool.
REMOVAL
REMOVAL - HIGH PRESSURE PUMP
(Refer to 14 - FUEL SYSTEM - WARNING)
(1) Disconnect negative battery cable.
(2) Remove viscous fan clutch (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
Fig. 3 HIGH PRESSURE PUMP
1 - FUEL RETURN LINE
2 - FUEL LINE BRACKET
3 - HIGH PRESSURE PUMP
4 - O-RING
5 - PUMP DRIVE
6 - FUEL LINE BRACKET
7 - HIGH PRESSURE FUEL LINE FROM PUMP TO FUEL RAIL
Fig. 4 VACUUM PUMP AND LOW PRESSURE FUEL
PUMP ASSEMBLIES
1 - VACUUM LINE
2 - FUEL OUTLET LINE
3 - FUEL FEED LINE
4 - LOW PRESSURE FUEL PUMP
5 - VACUUM PUMP
14 - 8 FUEL DELIVERYVA
FUEL PUMP (Continued)

(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 surfaces with appropriate
solvents and replace all seals.
NOTE: Inspect then attach high pressure pump
driver and intermediate piece if pump is being
replaced. If wear is present at driver, replace the
intermediate gear.
(1) Position and secure the high pressure pump to
cylinder head (Fig. 5). Tighten bolts to 14 N´m (124
lbs. in.).CAUTION: NEVER slacken the thread connection.
Use a wrench to counterhold at threaded connec-
tion when slackening and tightening torque in order
to avoid also slackening the threaded connection
the next time.
CAUTION: DO NOT crimp or bend fuel line. Inspect
sealing cone at line; replace line if compression
exists.
NOTE: Care must be taken not to cross the fuel
return and supply lines during installation.
(2) Attach fuel flow supply and return lines (Fig.
5).
(3) Install bracket to high pressure pump (Fig. 5).
Tighten nut to 9N´m (80 lbs. in.).
CAUTION: NEVER slacken the thread connection.
Use a wrench to counterhold at threaded connec-
tion when slackening and tightening torque in order
to avoid also slackening the threaded connection
the next time.
CAUTION: DO NOT crimp or bend fuel line. Inspect
sealing cone at line; replace line if compression
exists.
NOTE: Care must be taken not to cross the fuel
return and supply lines during installation.
(4) Attach high pressure fuel line to pump (Fig. 5).
Tighten to 22N´m (194 lbs.in.).
(5) Install viscous fan clutch (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
(6) Connect negative battery cable.
(7) Refill coolant system with proper mixture to
correct level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOU
HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT
WEAR LOOSE CLOTHES.
(8) Start engine and inspect for leaks (Refer to 14 -
FUEL SYSTEM - WARNING)
Fig. 6 VACUUM PUMP AND LOW PRESSURE FUEL
PUMP ASSEMBLIES
1 - VACUUM LINE
2 - FUEL OUTLET LINE
3 - FUEL FEED LINE
4 - LOW PRESSURE FUEL PUMP
5 - VACUUM PUMP
14 - 10 FUEL DELIVERYVA
FUEL PUMP (Continued)

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 ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
NOTE: Clean sealing surfaces, replace seal if nec-
essary.
(1) Prime the low pressure pump with the appro-
priate fuel.
(2) Attach low pressure fuel pump to cylinder head
front cover. Tighten bolt to 9N´m (80 lbs. in.).
(3) Attach fuel lines to low pressure pump.
(4) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).
(5) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT
WEAR LOOSE CLOTHING.
(6) Start engine and inspect for leaks.
FUEL RAIL
DESCRIPTION
The fuel rail acts like a high pressure store. It is
available to all injectors for drawing fuel which has
been compressed by the injection pump. The rail
pressure sensor, rail pressure solenoid, high pressure
line, and the return flow line are attached to the fuel
rail (Fig. 7).
OPERATION
The stored fuel volume inside the rail acts as a
damper for pressure fluctuations which result
because of pulsating supply and brief large extrac-
tions of fuel during injector firing. The rail primarily
influences the atomization of fuel at the injector noz-
zle, and the accuracy of injected quantity during
injection.
REMOVAL
(Refer to 14 - FUEL SYSTEM - WARNING).
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.
(1) Disconnect negative battery cable.
(2) Partially drain cooling system from radiator
only.
(3) Remove thermostat housing.
(4) Disconnect engine wiring electrical connectors
from sensors restricting harness movement.
(5) Remove engine harness retaining bolts.
(6) Remove fuel temperature sensor from fuel rail.
(7) Remove fuel rail retaining bolts and disconnect
glow plug connectors.
(8) Remove front engine lift support.
CAUTION: When slackening and tightening fuel
injection line union nuts, counter hold with wrench
at threaded connection. ON NO ACCOUNT exceed
the tightening torque at any time. Do NOT crimp or
bend lines.
NOTE: After removing lines, seal connections and
ensure cleanliness.
(9) Remove injector high pressure lines (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL) (Fig. 7).
(10) Remove pressure line of high pressure pump
(Fig. 7).
(11) Detach fuel return flow line to high pressure
pump at rail (Fig. 7).
(12) Detach fuel return flow line to fuel filter at
fuel filter (Fig. 7).
(13) Remove fuel rail (Fig. 7).
INSTALLATION
(Refer to 14 - FUEL SYSTEM - WARNING)
WARNING: NO FIRE, FLAMES OR SMOKING. RISK
OF POISONING FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. POUR FUELS ONLY INTO
SUITABLE AND APPROPRIATELY MARKED CON-
TAINERS. WEAR PROTECTIVE CLOTHING.
VAFUEL DELIVERY 14 - 11
FUEL PUMP (Continued)

(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 head, feed in high
pressure line with new seals (Fig. 7).
CAUTION: Inspect sealing cones at the lines.
Replace as necessary. Ensure that all fuel pressure
lines are exactly located in original position.
(4) Hand start all injector lines (Fig. 7).
CAUTION: When tightening fuel injection line union
nuts, counter hold with a wrench at the thread con-
nection. ON NO ACCOUNT exceed the tightening
torque at any time.
(5) Tighten fuel rail bolts to 14 N´m (124 lbs.in.)
(Fig. 7).
(6) Tighten nut of pressure line to rail/injector to
22N´m (194 lbs.in.).
(7) Tighten nut of pressure line to high pressure
pump/rail to 22N´m (194 lbs.in.).(8) Tighten banjo bolt of fuel return line to fuel
rail to 20N´m (177 lbs.in.).
(9) Install fuel temperature sensor.
(10) Install front engine support lift.
(11) Install thermostat housing.
(12) Reconnect engine harness electrical connec-
tors (Fig. 7).
(13) Refill cooling system.
(14) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT
WEAR LOOSE CLOTHING.
(15) Start engine and inspect for leaks (Refer to 14
- FUEL SYSTEM - WARNING).
FUEL TANK
DESCRIPTION
The plastic fuel tank is mounted to the frame rails
under the left/center side of the vehicle. The fuel
tank contains a serviceable fuel tank module (Fig. 8)
and fuel level sending unit. The tank is also
equipped with 2 fuel lines: a fuel supply line to the
fuel pump, and a separate fuel return line. A section
of the fuel return line is coiled (Fig. 8) at the rear
section of the tank. This coiled section is used to help
drop the temperature of fuel returning to the tank.
A fuel tank mounted, electric fuel pump is not used
with diesel powered models. Refer to Fuel Tank Mod-
ule for additional information.
REMOVAL
(1) Drain diesel fuel from tank using an approved
diesel fuel draining station.
(2) Disconnect fuel fill and vent lines (Fig. 8) from
body.
(3) Raise and support vehicle.
(4) Support tank with a hydraulic jack.
(5) Remove 2 fuel tank strap nuts and position
straps towards left side of vehicle.
(6) Carefully lower tank a few inches and discon-
nect electrical connector at top of fuel tank module.
(7) Disconnect fuel supply line at tank.
(8) Disconnect fuel return line at tank.
(9) Continue to carefully lower tank for removal.
(10) If fuel tank module is to be removed, thor-
oughly clean area at top of fuel tank around module.
(11) If fuel tank is to be replaced, remove fuel tank
module from tank. Refer to Fuel Tank Module
Removal/Installation procedures.
Fig. 7 FUEL PRESSURE SOLENOID
1 - INJECTION LINES
2 - FUEL RAIL
3 - FUEL RETURN LINE
4 - FUEL PRESSURE SOLENOID
5 - OIL LINE
6 - SEALS
7 - FUEL RETURN LINE AT COOLER
8 - HIGH PRESSURE FUEL LINE TO FUEL RAIL
9 - FUEL LINE BRACKET
10 - FUEL PRESSURE SENSOR
14 - 12 FUEL DELIVERYVA
FUEL RAIL (Continued)

INSTALLATION
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Remov-
al/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines.
(6) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(7) Install and position both fuel tank support
straps to mounting studs.
(8) Install 2 fuel tank strap nuts. Refer to Torque
Specifications.
(9) Remove hydraulic jack.
(10) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump isnot usedin the fuel tank
module for diesel powered engines. Fuel is supplied
to the fuel injection pump by the fuel transfer (lift)
pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 9). The fuel tank module contains the
following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connection
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
(3) Disconnect both fuel lines from tank module
fittings.
Fig. 8 FUEL TANK ASSEMBLY
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
Fig. 9 FUEL TANK MODULE
1 - COOLER LINES
2 - CHECK VALVE
3 - TOP OF FUEL TANK
4 - LOCK RING
5 - FUEL TANK MODULE
6 - FUEL FILL LINE
7 - FUEL VENT LINE
8 - CHECK VALVE
VAFUEL DELIVERY 14 - 13
FUEL TANK (Continued)