2006 MERCEDES-BENZ SPRINTER torque

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.
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.
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
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. 3).
Fig. 2 FUEL FILTER
1 - FUEL SUPPLY LINE TO HIGH PRESSURE PUMP
2 - FUEL FILTER
3 - WIF SENSOR
4 - FUEL FILTER DRAIN
VAFUEL DELIVERY 14 - 11

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).
(3) Unplug electrical connectors 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 nut. DO NOT EXCEED tightening torque.
CAUTION: DO NOT crimp or bend fuel line. Capture
all fluids that flow out of connections.
(4) Disconnect the high pressure line at high pres-
sure pump (Fig. 8).
(5) Detach fuel supply and return flow line at high
pressure pump using special tool #9539 (Fig. 8).
NOTE: Care must be taken not to drop the high
pressure pump drive when removing pump. Inspect
the pump drive for wear. If wear is present replace
the drive and gear.(6) Remove bolts attaching high pressure pump
and remove pump (Fig. 8).
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
drive if pump is being replaced. If wear is present at
drive, replace drive and gear.
(1) Position and secure the high pressure pump to
cylinder head (Fig. 9). 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.
Fig. 8 HIGH PRESSURE FUEL PUMP
1 - INTERMEDIATE GEAR
2 - HIGH PRESSURE PUMP
3 - SEALING RING
4 - DRIVER
5 - HIGH PRESSURE LINE
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
8 - BOLTS
9 - FUEL QUANTITY CONTROL VALVE
10 - FUEL TEMPERATURE SENSOR
Fig. 9 HIGH PRESSURE FUEL PUMP
1 - INTERMEDIATE GEAR
2 - HIGH PRESSURE PUMP
3 - SEALING RING
4 - DRIVER
5 - HIGH PRESSURE LINE
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
8 - BOLTS
9 - FUEL QUANTITY CONTROL VALVE
10 - FUEL TEMPERATURE SENSOR
VAFUEL DELIVERY 14 - 17

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,
recrimping clamps using special tool #9539 (Fig. 9).
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.
(3) Attach high pressure fuel line to pump.
Tighten to 22N´m (194 lbs.in.) (Fig. 9).
(4) Install the viscous fan.
(5) Connect negative battery cable.
(6) Start engine, allow to run, turn engine off and
inspect for leaks (Refer to 14 - FUEL SYSTEM -
WARNING), (Refer to 14 - FUEL SYSTEM - DIAG-
NOSIS AND TESTING).
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module is installed in the top of the
fuel tank (Fig. 10). The pump module contains the
following components:
²Electric fuel pump (transfer, or lift pump)
²Fuel reservoir
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connectionFuel is supplied to the high-pressure fuel injection
pump by the low-pressure fuel transfer (lift) pump.
This electric fuel pump is attached to the fuel pump
module and supplies approximately 165 liters/hour
(43.6 gallons/hour). A low-pressure fuel pump is not
attached to the engine.
REMOVAL
CAUTION: To prevent damage to the float rod, the
float and float rod must be removed from the pump
module. This step must be done before the pump
module is removed from the fuel tank.
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around pump module at
top of tank.
(3) Disconnect all fuel lines from pump module fit-
tings.
(4) The plastic fuel pump module locknut (lock-
ring) is threaded onto fuel tank. Install Special Tool
#6856 to locknut and remove locknut (Fig. 11). The
fuel pump module will spring up slightly after lock-
nut is removed.
Fig. 10 TOP OF FUEL TANK
1 - Cooler Lines
2-TopofTank
3 - Expansion Tank
4 - Check Valves
5 - Check Valve
6 - Module Lock Ring
7 - Fuel Pump Module
14 - 18 FUEL DELIVERYVA

INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber gasket must be replaced.
(1) Thoroughly clean locknut (lockring) and lock-
nut threads at top of tank.
(2) Position new gasket (seal) to fuel tank opening.
(3) Position float rod assembly partially into fuel
tank.
(4) Position fuel pump module partially into fuel
tank.
(5) Twist rod (3) (Fig. 15) into clip (2) on fuel level
sensor (1).
(6) Rotate clip (2) (Fig. 16) to attach rod (3) to
clip.(7) After attaching float assembly to fuel level sen-
sor, carefully position fuel pump module into opening
in fuel tank.
(8) Position locknut over top of fuel pump module.
Install locknut finger tight.
(9) The fuel line fittings should be pointed to the
right side of the vehicle. Rotate and position align-
ment arrow (Fig. 17) towards right side of vehicle (if
necessary) before tightening locknut.This step
must be performed to prevent the module's
float from contacting the side of fuel tank.
(10) Tighten locknut using Special Tool #6856.
Refer to Torque Specifications.
(11) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
Fig. 15 FLOAT ROD CLIP INSTALLATION
1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
Fig. 16 FLOAT ROD CLIP INSTALLATION
1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
14 - 20 FUEL DELIVERYVA

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 high pressure injection
pump. The rail pressure sensor, rail pressure control
valve, high pressure line, and the return flow line
are attached to the fuel rail.
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) Remove the engine cover.
(3) Disconnect the intake manifold air inlet duct
and position aside.
(4) Disconnect the fuel rail pressure and control
valve wiring harness connectors.
(5) Remove engine harness retaining bolts and
unclip the engine harness from the fuel rail.
(6) Remove injector high pressure lines (Fig. 19)
(7) Remove fuel rail retaining bolts (Fig. 19).
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.(8) Detach fuel return flow line to high pressure
pump at rail
(9) Detach fuel return flow line at banjo bolt (Fig.
19)
(10) Remove fuel rail.
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.
(1) Loosely position fuel rail into proper position
on the cylinder head and hand tighten the fasteners.
(2) Connect the fuel pressure control valve harness
connector (Fig. 19).
(3) Connect the fuel return lines at the banjo bolt
(Fig. 19).
CAUTION: Inspect sealing cones at the lines.
Replace as necessary. Ensure that all fuel pressure
lines are exactly located in original position.
(4) Install the high pressure fuel lines and hand
tighten.
Fig. 19 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
14 - 22 FUEL DELIVERYVA

(5) Tighten fuel rail bolts to 14 N´m (124 in. lbs.)
(Fig. 19)
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.
(6) Tighten the pressure line to the fuel rail to 20
N´m (177 in. lbs.).
(7) Tighten the high pressure fuel lines at the fuel
rail to 22 N´m (195 in. lbs.).
(8) Reconnect engine harness electrical connectors.
(9) Connect the intake manifold air inlet duct.
(10) 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.
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.
(11) Start engine, run for a few minutes, turn the
engine off and inspect for leaks (Refer to 14 - FUEL
SYSTEM - WARNING).
FUEL TANK
DESCRIPTION
The plastic fuel tank (Fig. 20) is mounted to the
frame rails under the left/center side of the vehicle.
The fuel tank contains a serviceable fuel pump mod-
ule with an electric fuel pump, and a fuel level send-
ing unit. The tank is also equipped with 2 fuel lines:
a fuel supply line to the fuel pump, and a separate
fuel return line.
Fuel Temperature Control:A section of the fuel
return line is coiled at the rear section of the tank
(Fig. 21). This coiled section is used to help drop the
temperature of fuel returning to the tank. A thermo-
stat (preheating valve) (3) (Fig. 21) is used to keep
fuel temperature below 167 degrees F. If fuel temper-
ature is above 167 degrees F, fuel passes first
through the coiled cooler lines, and then into the fuel
tank. If fuel temperature is below 150 degrees F, fuel
bypasses the coiled cooler lines, and is returned
directly into the fuel tank.
An electric fuel pump (more commonly referred to
in diesel applications as a fuel transfer pump or fuel
lift pump) is attached to the fuel pump module. Thismodule (Fig. 22) is located in the fuel tank. Refer to
Fuel Pump Module for additional information.
VAFUEL DELIVERY 14 - 23

(5) Connect fuel pump module electrical connector
at top of tank.
(6) Connect fuel supply and return lines.
(7) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(8) Install and position both fuel tank support
straps (7) (Fig. 26) to mounting bolts (1).
(9) Install 2 fuel tank strap nuts (8). Refer to
Torque Specifications.
(10) Remove hydraulic jack.
(11) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(12) Lower vehicle.
(13) Fill fuel tank with fuel.
(14) Start engine and check for fuel leaks near top
of module.
VAFUEL DELIVERY 14 - 27

ACCELERATOR PEDAL POSI-
TION SENSOR
DESCRIPTION
The accelerator pedal position sensor (Fig. 1) is
located on the accelerator pedal assembly. The driver
supplies the torque requirements for the engine by
operating the accelerator pedal in accordance with
the desired speed or acceleration. The pedal sensor
converts the mechanical operation of the pedal into
an electrical signal and sends the information to the
ECM. The ECM adjusts the quantity of the fuel that
is injected into the engine.
The accelerator pedal position sensor is serviced as
an assembly with the accelerator pedal assembly.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the APP sensor electrical connec-
tors.
(3) Remove the APP sensor fasteners and the sen-
sor (Fig. 2).
INSTALLATION
(1) Connect the accelerator pedal position sensor
wiring harness connector.
Fig. 1 ACCELERATOR PEDAL POSITION SENSOR
1 - APP SENSOR
2 - ACCELERATOR PEDAL
3 - BRAKE PEDAL
Fig. 2 ACCELERATOR PEDAL POSITION SENSOR
1 - APP SENSOR
2 - ACCELERATOR PEDAL
3 - BRAKE PEDAL
Fig. 3 ACCELERATOR PEDAL POSITION SENSOR
1 - APP SENSOR
2 - ACCELERATOR PEDAL
3 - BRAKE PEDAL
14 - 32 FUEL INJECTIONVA