2005 MERCEDES-BENZ SPRINTER fuel system

(24) Remove camshaft sprocket to timing chain tie
straps.
(25) Install guide rail and tighten low pressure
fuel pump drive to 50N´m (37 lbs. ft.).
(26) Install low pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(27) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(28) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).
(29) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(30) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(31) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(32) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
TIMING CHAIN TENSIONER
REMOVAL
(1) Disconnect negative battery cable.
CAUTION: Rotate engine at crankshaft only. DO
NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine counter clock-
wise.
NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(2) Position piston of number 1 cylinder to ignition
TDC.
(3) Remove intake air scoop.
(4) Remove accessory drive belt and idler pulley
above generator (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
(5) Remove timing chain tensioner (Fig. 85).
Fig. 84 RIVET INSPECTION
Fig. 85 TIMING CHAIN TENSIONER
1 - TIMING CHAIN TENSIONER
2 - TIMING CHAIN TENSIONER SEAL
9 - 70 ENGINEVA
TIMING BELT/CHAIN AND SPROCKETS (Continued)

CATALYTIC CONVERTER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
rear clamp. (Fig. 1)
(3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front clamp.
(4) Remove the cataylic converter and muffler
assembly from the isolators.
(5) Seperat the cataylic converter and muffler
assembly from the tailpipe and the exhaust pipe.
(6) Remove the cataylic converter and muffler
assembly and isolators from the vehicle.
(7) Remove the bolt, nut and front isolator from
the cataylic converter and muffler assembly.
(8) Remove the rear isolator from the cataylic con-
verter and muffler assembly.
(9)
INSTALLATION
(1) Install bolt, front isolator and nut (Fig. 1).
(2) Install rear insulator onto the cataylic con-
verter and muffler assembly
(3) Position the cataylic conveter and muffler
assembly into the exhaust pipe and tailpipe until
alignment tab is inserted into the alignment slot.
(4) Install the front and rear insulators.
(5) Install the real clamp.
(6) Install the front clamp.
(7) Lower vehicle.
(8) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(9) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
EXHAUST PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the
front and rear clamp (Fig. 1).
(3) Remove the mounting bracket nuts.
(4) Remove the exhaust pipe.
INSTALLATION
(1) Position the exhaust pipe into the exhaust pipe
into the cataylic converter and muffler assembly
until alignment tab is inserted into the alignment
slot.
(2) Install mounting bracket and nuts (Fig. 1).(3) Install clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TAILPIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration (Fig. 1).
(3) Remove the clamp.
(4) Remove the tailpipe and insulator form the
vehicle
(5) Remove the insulator from the tailpipe.
INSTALLATION
(1) Position the tail pipe into the cataylic converter
and muffler assembly until alignment tab is inserted
into the alignment slot.
(2) Install the insulator.
(3) Install the clamp.
(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make necessary adjustments, if neces-
sary.
TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The boost pressure
bracket is an integral part of the turbocharger. Tam-
pering with the boost pressure components can
reduce durability by increasing cylinder pressure
and thermal loading due to incorrect inlet and
exhaust manifold pressure. Poor fuel economy and
failure to meet regulatory emissions laws may
result. Increasing the turbocharger boost WILL NOT
increase engine power.
The turbocharger used on this vehicle is of the
variable turbine type. These turbochargers use the
entire exhaust energy to boost efficiency of the turbo-
charger and the engine.
The advantages of a turbocharger with variable
turbine geometry are:
²Higher charge pressure already in the lower and
in upper engine speed ranges.
VAEXHAUST SYSTEM 11 - 3

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM
PRESSURE...........................1
WARNING............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES.................1
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS............2STANDARD PROCEDURE -
DISCONNECTING AND CONNECTING
FUEL LINES..........................2
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER..............2
STANDARD PROCEDURE - LOW
PRESSURE FUEL PUMP TEST............3
FUEL DELIVERY..........................4
FUEL INJECTION........................17
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE INJECTORS. THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
WARNING
WARNING: UNDER NO CIRCUMSTANCES SHOULD
GASOLINE BE MIXED WITH DIESEL FUEL (NOT
EVEN DURING WINTER). THE HIGH PRESSURE
PUMP IS LUBRICATED BY DIESEL FUEL. IMMEDI-
ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS-
ING REPLACEMENT AND FLUSHING OF THE
COMPLETE DIESEL FUEL SYSTEM. HIGH PRES-
SURE PUMP SEIZURE WILL CAUSE METAL PARTI-
CLES TO SPREAD THROUGH OUT THE FUEL
CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
BE EXCHANGED AND THE LINES FLUSHED.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
(Refer to 14 - FUEL SYSTEM - WARNING). High-
pressure fuel line leaks can cause starting problems
and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES,
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR
HAND NEAR A SUSPECTED LEAK. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 1). If a high-pressure line connec-
tion is leaking, tighten the connection and perform
the Fuel System Air Purge procedure (Refer to 14 -
FUEL SYSTEM - STANDARD PROCEDURE).
Replace damaged, restricted or leaking high-pressure
fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
VAFUEL SYSTEM 14 - 1

DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM
Air will enter the fuel system whenever fuel supply
lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start-
ing, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock.
Inspect the fuel system from the fuel tank to the
injectors for loose connections (Refer to 14 - FUEL
SYSTEM - WARNING). Leaking fuel is an indicator
of loose connections or defective seals. Air can also
enter the fuel system between the fuel tank and the
fuel pump. Inspect the fuel tank and fuel lines for
damage that might allow air into the system.
With the DRBIIItconnected to the vehicle, select
Engine and the select Sensor Display. Page down to
view Fuel Pressure Set Point and Actual Fuel Pres-
sure. Start the engine and observe the Fuel Pressure
Set Point and the Actual Fuel Pressure. If the Actual
Fuel Pressure Oscillates above and below the Fuel
Pressure Set Point in a regular cycle, perform the
Fuel System Air Purge procedure (Refer to 14 -
FUEL SYSTEM - STANDARD PROCEDURE).
If the Actual Fuel Pressure gradually drops below
the Fuel Pressure Set Point then spikes well above
the Fuel Pressure Set Point, replace the fuel pres-
sure solenoid (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL PRESSURE SOLENOID -
REMOVAL), then perform the Fuel System Air Purgeprocedure (Refer to 14 - FUEL SYSTEM - STAN-
DARD PROCEDURE).
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM COMPONENTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines, fuel rail, and fuel injection
pump. Very tight tolerances are used with these
parts. Dirt contamination could cause rapid part
wear and possible plugging of fuel injector nozzle
tip holes. This in turn could lead to possible engine
misfire. Always wash/clean any fuel system compo-
nent thoroughly before disassembly and then air
dry. DO NOT wire brush injector nozzles when
cleaning. Cap or cover any open part after disas-
sembly. Before assembly, examine each part for
dirt, grease or other contaminants and clean if nec-
essary. When installing new parts, lubricate them
with clean engine oil or clean diesel fuel only.
STANDARD PROCEDURE - DISCONNECTING
AND CONNECTING FUEL LINES
NOTE: Capture and store any fuel spillage in appro-
priately marked containers.
(1) Disconnect negative battery cable.
(2) Push release arm to release position A, as far
as the stop (arrow) (Fig. 2).
(3) Disconnect fuel line.
(4) Immediately return the release arm back to the
assembly position, as far as the stop (Fig. 2).
The release arm must not be left in the release
position for a long time. Connectors left in the
release position for lengthy periods may leak and
must be replaced.
(5) Insert connector into connection in assembly
position (B) (Fig. 2).
(6) Ensure that the connectors are firmly seated
and free of leaks (Fig. 2).
STANDARD PROCEDURES - DRAINING WATER
FROM FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL FILTER / WATER
SEPARATOR - REMOVAL).
Fig. 1 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14 - 2 FUEL SYSTEMVA
FUEL SYSTEM (Continued)

STANDARD PROCEDURE - LOW PRESSURE
FUEL PUMP TEST
NOTE: Assure fuel tank quantity and proper fuel
gauge operation. Capture any fuel spillage and
store in appropriately marked containers.
(1) Disconnect the negative battery cable.
(2) Connect fuel gauge # 5069±2 with adaptor
#9068 to the low pressure fuel pump output line
junction at the fuel pressure sensor and assure that
the line locking tabs are secured in the lock position
(pulled back after hose is fitted properly). (Fig. 3).
(3) Connect negative battery cable.
(4) Crank or start the engine and observe the fuel
gauge reading.The low pressure pump draws fuel out of the fuel
tank through the fuel filter. If the pressure reading is
below specification, look for damaged or leaking fuel
lines, replace the fuel filter and repeat this test. If
the fuel pressure reading is below specification again,
replace the low pressure fuel pump.
FUEL PRESSURE SPECIFICATIONS
STARTER SPEED 6-22 PSI (0.4-1.5 bar)
IDLING SPEED RANGE 29-36 PSI (2.0-2.5 bar)
MAXIMUM FUEL
PRESSURE51   7 PSI (3.5 0.5 bar)
Fig. 2 FUEL LINE CONNECTOR
1 - RELEASE ARM
Fig. 3 FUEL PRESSURE TEST
1 - INTAKE RUNNER #1
2 - INTAKE RUNNER #2
3 - FUEL RETURN HOSE
4 - FUEL PRESSURE GAUGE ADAPTOR HOSE
5 - FUEL PRESSURE GAUGE ADAPTOR #9068
VAFUEL SYSTEM 14 - 3
FUEL SYSTEM (Continued)

FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
SPECIFICATIONS
TORQUE.............................4
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL DRAIN TUBES
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS........................5
FUEL FILTER
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
FUEL LINES
REMOVAL - HIGH PRESSURE LINES.........6
INSTALLATION - HIGH PRESSURE LINES.....7
FUEL PUMP
DESCRIPTION
DESCRIPTION - HIGH PRESSURE PUMP....7
DESCRIPTION - LOW PRESSURE PUMP....7
OPERATION
OPERATION..........................7
OPERATION - LOW PRESSURE PUMP......8
REMOVAL
REMOVAL - HIGH PRESSURE PUMP.......8
REMOVAL - LOW PRESSURE PUMP.......9INSTALLATION
INSTALLATION - HIGH PRESSURE PUMP . . 10
INSTALLATION - LOW PRESSURE PUMP . . . 11
FUEL RAIL
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
FUEL TANK
DESCRIPTION.........................12
REMOVAL.............................12
INSTALLATION.........................13
FUEL TANK MODULE
DESCRIPTION.........................13
REMOVAL.............................13
INSTALLATION.........................14
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION.........................15
REMOVAL.............................15
INSTALLATION.........................15
HI PRESSURE FUEL SHUTOFF SOL
DESCRIPTION.........................16
OPERATION...........................16
WATER IN FUEL SENSOR
DESCRIPTION.........................16
OPERATION...........................16
FUEL DELIVERY
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FUEL TANK MOUNTING NUTS 15 - 17 11 - 13 -
FUEL TANK MODULE LOCKRING
(LOCKNUT)45-55 33-41 -
14 - 4 FUEL DELIVERYVA

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)

(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).
INSTALLATION
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: 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) (Fig. 1).
(2) Position fuel filter in bracket and tighten
retaining bolt to 53 lbs. in. (6 N´m) (Fig. 1).
(3) Seat preheating valve and tighten bolt to 13
lbs. in. (1.5 N´m) (Fig. 1).
(4) Install fuel lines and tighten clamps (Fig. 1).(5) Properly seat fuel line plug connection and
properly set release arm (Refer to 14 - FUEL SYS-
TEM - STANDARD PROCEDURE)
(6) Connect negative battery cable.
(7) Start engine and inspect for leaks.
FUEL LINES
REMOVAL - 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 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
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.
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. 2).
Fig. 1 FUEL FILTER AND BRACKET
1 - FUEL LINE PLUG CONNECTION
2 - FUEL LINE INLET
3 - FUEL FILTER
4 - BOLT OF PREHEATING VALVE
5 - PREHEATING VALVE
14 - 6 FUEL DELIVERYVA
FUEL FILTER (Continued)