2005 MERCEDES-BENZ SPRINTER warning

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Page 851 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual NOTE: Always replace the seals that seal off the
injectors at the cylinder head to the combustion
chamber and replace the retaining screws.
REMOVAL
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUE

Page 852 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual 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-
A

Page 853 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual (15) Install battery tray(Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(16) Connect PDC to battery tray.
(17) Install battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTA

Page 854 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual REMOVAL
REMOVAL
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 23,000PSI (1600)BAR.
USE EXTREME CAUT

Page 855 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual INSTALLATION
(1) (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION - WARNING) Install the sealing ring on to the
sensor (Fig. 13).
(2) Screw the sensor in to the fuel rail. Counter-
hold the threaded connec

Page 856 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual REMOVAL
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 PSI).
USE EXTREME CAUTION WHE

Page 857 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT PUT YOUR HANDS NEAR
PULLEYS, BELTS, OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(4) Start engine and inspect for leaks (Refer to 14 -
FUEL SYSTEM -

Page 872 of 1232

MERCEDES-BENZ SPRINTER 2005  Service Repair Manual PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 12
STANDARD PROCEDURE
STANDARD PROCEDURE - PO