2006 MERCEDES-BENZ SPRINTER sensor

INSTALLATION
(1) Install the sealing ring onto the sensor and
screw the fuel pressure sensor into the fuel rail.
(2) Tighten the senor to 60 N´m (44 ft. lbs.), back
it off 90 degrees and retighten to 80 N´m (59 ft. lbs.)
(Fig. 4).
(3) Connect the sensor wiring harness connector.
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.
(4) (Refer to 14 - FUEL SYSTEM - WARNING).
Start engine, allow to run for a few minutes, turn the
engine off and inspect for leaks.
FUEL PUMP
DESCRIPTION
DESCRIPTION - HIGH PRESSURE PUMP
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
The high pressure pump is a fuel regulated radial
piston pump with three pistons arranged at an angle
of 120É. The regulation being carried out by the fuel
quantity valve. The high pressure pump is driven at
about 1.3 times the speed of the camshaft. Specific
moving parts inside the pump are graphite coated to
assist with the lubrication process during operation.
The high pressure pump is mounted to the front of
the cylinder head and must be replaced as an assem-
bly should a failure occur (Fig. 5).
DESCRIPTION - LOW PRESSURE PUMP
The electric fuel pump is located in the fuel tank.
The pump draws warm or hot fuel from the fuel tank
module bowl and also draws cool fuel out of the tank.
The cool fuel is drawn in and is mixed with the fuel
already in the bowl in a 50±50 mix ratio. Refer to
fuel pump module for servicing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TANK MODULE
- REMOVAL).
OPERATION
OPERATION
LOW PRESSURE SIDE
The fuel supplied by the low pressure pump flows
through the fuel supply (5) at the high pressure
pump and is passed to the fuel quantity valve (11)
and the fuel pressure relief valve (9). Any air
entrained by the fuel is directed through the restric-
tor (10) through the bleed port (7) to the return flow
(6). The quantity control valve (11) controls the
amount of fuel that flows along the ring passage (4)
through the supply ports to the three high pressure
pump elements. To lubricate the plunger and barrel
assemblies when the quantity control valve is closed
Fig. 5 HIGH PRESSURE FUEL PUMP
1 - HIGH PRESSURE PUMP
2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
8 - VACUUM PUMP
VAFUEL DELIVERY 14 - 13

HIGH PRESSURE SIDE
A. Filling the piston:The piston (6) is moved
down as a result of the piston spring (7). The fuel
supplied by the fuel delivery pump flows along the
ring passage (10), the valve disk and the valve spring
(3) into the cylinder. The check ball (4) prevents the
fuel from being able to flow back from the high pres-
sure passage (5) (Fig. 7).
B. Producing high pressure:The piston (6) is
moved up by the rising eccentric shaft (9) and the
fuel is compressed. The valve (2) disk shuts off the
delivery volume to the fuel supply. Once the fuel
pressure in the cylinder rises beyond the pressure
which exists in the high pressure circuit (5), the
check ball (4) opens and the fuel is pumped into the
high pressure circuit (5) (Fig. 7).
Fig. 6 LOW PRESSURE SIDE
1 - HIGH PRESSURE PUMP 7 - FUEL BLEED PORT
2 - FUEL TEMPERATURE SENSOR 8 - SHAFT LUBRACATION PORT
3 - FUEL SUPPLY TO PUMP ELEMENTS 9 - FUEL PRESSURE RELIEF VALVE
4 - FUEL ANNULAR PORT 10 - ZERO DELIVERY RESTRICTOR
5 - FUEL SUPPLY 11- FUEL QUANTITY VALVE
6 - FUEL RETURN
VAFUEL DELIVERY 14 - 15

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

(5) Pull module assembly up just a few inches to
gain access to float support arm/rod (3) (Fig. 12). Be
careful not to bend float support rod while removing
pump module.
(6) Rotate clip (2) (Fig. 13) to release float rod (3)
from fuel level sensor (1).(7) Twist rod (3) slightly (Fig. 14) to remove from
fuel level sensor. Do not allow float assembly to fall
into fuel tank.
(8) While holding float rod, remove fuel pump
module from fuel tank.
(9) Remove float assembly from fuel tank.
(10) Remove and discard rubber gasket (seal) from
pump module.
Fig. 11 FUEL PUMP MODULE R/I
1 - LOCKNUT (LOCKRING)
2 - SPECIAL TOOL #6856
3 - TOP OF PUMP MODULE
Fig. 12 FLOAT ROD CLIP
1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
Fig. 13 FLOAT ROD CLIP REMOVAL
1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
Fig. 14 FLOAT ROD CLIP REMOVED
1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
VAFUEL DELIVERY 14 - 19

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 QUANTITY CONTROL
VA LV E
DESCRIPTION
The fuel quantity control valve mounts to front of
the high pressure pump and is controlled by the
ECM. The quantity control valve assists in maintain-
ing proper fuel quantity injected under all operating
conditions. Fuel tank heat protection is also provided
by the quantity control valve. The valve meters the
exact amount of fuel to prevent excess heated fuel
from returning to the tank.
OPERATION
The ECM monitors the fuel system and measures
for pressure vibrations. The ECM will then send a
pulse width signal to the quantity control valve to
regulate the amount of fuel to the high pressure
pump plunger and barrel assemblies. The valve then
adjusts the injection correction quantity for each
individual cylinder in line with the firing order, there
by eliminating the pressure resonance in the fuel rail
and improving each independent injectors operation.
The fuel quantity valve also interrupts the fuel sup-
ply to the high pressure pump plunger and barrel
assemblies when the engine is switched off.
The ECM detects the operating state which exists
at the engine by means of the sensors. In order to
adapt the quantity injected, either the rail pressure
can be adjusted by way of the pressure regulator
valve and the quantity control valve, or the actuationtime of the solenoid valves in the fuel injectors can
be extended or shortened.
Fuel quantity control is performed under the fol-
lowing operating conditions:
²Approximately 30 seconds after the engine has
started
²Fuel temperature > 20ÉC (68ÉF)
²Engine not in deceleration mode
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the control valve wiring harness
connector (Fig. 18).
(3) Remove the valve fasteners and remove the
control valve (Fig. 18).
INSTALLATION
(1) Clean sealing surfaces.
(2) Install new seal on sensor.
(3) Position the control valve on to the high pres-
sure pump and install fasteners (Fig. 19).
(4) Connect wiring harness connector to control
valve (Fig. 19).
(5) Connect negative battery cable.
(6) Start the engine, allow to run, turn engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION - WARNING).
Fig. 17 ALIGN PUMP MODULE
1 - LOCKNUT
2 - ALIGNMENT ARROW (POSITION TOWARDS RIGHT SIDE OF
VEHICLE)
Fig. 18 HIGH PRESSURE FUEL PUMP
1 - HIGH PRESSURE PUMP
2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
8 - VACUUM PUMP
VAFUEL DELIVERY 14 - 21

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